PMC PHDX-2, PHD-2 Service Manual

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PHDX-2 Proportioner

Service Manual

Ref. # 202266

Revision 1.1

FOR PROFESSIONAL USE ONLY

Not approved for use in European explosive atmosphere locations

1 Komo Dr. Lakewood, NJ 08701 Phone: 732-415-4400

URL: http://www.polymacusa.com

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

TABLE OF CONTENTS

Table of Contents

1 WARRANTY 5

2 SAFETY AND HANDLING 7

3 CHARACTERISTICS 9

3.1 PRINCIPAL HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 9

3.2 HOSE HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 DOUBLE ACTING OPPOSED PISTON METERING PUMPS . . . . . . 10

3.4 PRESSURE BALANCE CONTROL SYSTEM . . . . . . . . . . . . . . . 10

4 TECHNICAL SPECIFICATIONS 11

4.1 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.2 MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 DESCRIPTION 13

5.1 OPERATION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.2 OPTIONS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.3 ALARMS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.4 CHEMICAL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.5 PROCESS DATA MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.6 SETUP MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.7 BUTTON APPEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6 INSTALLATION 24

6.1 HEATED HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 26

6.2 HOSE HEAT TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . 29

7 PROPORTIONER PURGING 30

8 PRESSURE BALANCE CONTROL 32

8.1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

9 TEMPERATURE CONTROLS 33

9.1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

10 START-UP 34

11 SHUT-DOWN 36

11.1 SHORT-TERM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

11.2 LONG-TERM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

12 TROUBLESHOOTING 37

12.1 HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

12.2 HYDRAULIC DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 42

12.3 METERING PUMP-LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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TABLE OF CONTENTS

12.4 HOSE HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

13 MAINTENANCE 51

13.1 INLET MATERIAL SCREENS . . . . . . . . . . . . . . . . . . . . . . . . 53

13.2 ISO LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 54

13.3 HYDRAULIC DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 55

13.4 METERING PUMP-LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

13.5 PUMP SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 56

13.6 MATERIAL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

14 HYDRAULIC OIL SPECIFICATIONS 59

14.1 MANUFACTURERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

15 PARTS IDENTIFICATION 60

15.1 FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

15.2 PROX SENSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 62

15.3 HYDRAULIC MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . 63

15.4 EXIT MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 64

15.5 HYDRAULIC SEAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 65

15.6 HYDRAULIC PISTON ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 66

15.7 HYDRAULIC CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . 67

15.7.1 HYDRAULIC CYLINDER REBUILD KIT . . . . . . . . . . . . . . 68

15.8 A & R SINGLE PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 69

15.9 PUMP-LINE SEAL ORIENTATION . . . . . . . . . . . . . . . . . . . . . 71

15.10 PUMP-LINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

15.10.1 PUMP REBUILD KIT . . . . . . . . . . . . . . . . . . . . . . . . . 73

15.11 ”A” INLET MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . 74

15.12 ”R” INLET MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . 75

15.13 HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

15.14 MOTOR-LINE ASSEMBLY (1 PHASE) . . . . . . . . . . . . . . . . . . . 80

15.15 MOTOR-LINE ASSEMBLY (3 PHASE) . . . . . . . . . . . . . . . . . . . 82

15.16 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

15.17 PHDX-2 HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

15.17.1 HALF INCH HOSE KIT . . . . . . . . . . . . . . . . . . . . . . . . 90

15.18 LUBE BOTTLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 91

15.19 EXIT MANIFOLD ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . 92

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LIST OF FIGURES

List of Figures

1 Pressure Balance Control Logic Diagram . . . . . . . . . . . . . . . . . . . . 10

2 Proportioner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 Component Identiﬁcation - Front . . . . . . . . . . . . . . . . . . . . . . . . 13

4 Component Identiﬁcation - Back . . . . . . . . . . . . . . . . . . . . . . . . . 14

5 Y-Strainer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6 Front Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7 HMI Operation Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8 HMI Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

9 HMI Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

10 HMI Chemical Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

11 HMI Process Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

12 HMI Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

13 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

14 Component Identiﬁcation - Misc . . . . . . . . . . . . . . . . . . . . . . . . . 25

15 Temperature Sensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

16 Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

17 Metering Pump-Line (PL-10) . . . . . . . . . . . . . . . . . . . . . . . . . . 44

18 PHDX-2 Console - Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . 45

19 Frame Assembly (FR-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

20 Prox Sensor Assembly (RM-243) . . . . . . . . . . . . . . . . . . . . . . . . . 62

21 Hydraulic Manifold Assembly (HI-05335) . . . . . . . . . . . . . . . . . . . . 63

22 Exit Manifold Assembly (HI-05343) . . . . . . . . . . . . . . . . . . . . . . . 64

23 Hydraulic Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

24 Hydraulic Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

25 Hydraulic Cylinder Assembly (HI-05336) . . . . . . . . . . . . . . . . . . . . 67

26 A & R Single Pump Assembly (202192) . . . . . . . . . . . . . . . . . . . . . 69

27 A & R Single Pump Cross Section . . . . . . . . . . . . . . . . . . . . . . . . 70

28 A & R Single Pump Assembly Detail A . . . . . . . . . . . . . . . . . . . . . 71

29 A & R Single Pump Assembly Detail B . . . . . . . . . . . . . . . . . . . . . 71

30 Pump-Line Assembly (PL-10) . . . . . . . . . . . . . . . . . . . . . . . . . . 72

31 ”A” Inlet Manifold Assembly (YS-6-PHX) . . . . . . . . . . . . . . . . . . . 74

32 ”R” Inlet Manifold Assembly (YS-7-PHX) . . . . . . . . . . . . . . . . . . . 75

33 Heater Assembly, 6 Rod - A . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

34 Heater Assembly, 6 Rod - B . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

35 Heater Assembly, 8 Rod - A . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

36 Heater Assembly, 8 Rod - B . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

37 Motor-Line Assembly - 1 Phase . . . . . . . . . . . . . . . . . . . . . . . . . 80

38 Motor-Line Assembly - 3 Phase . . . . . . . . . . . . . . . . . . . . . . . . . 82

39 PHDX-2 Final Assembly - A . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

40 PHDX-2 Final Assembly - B . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

41 PHDX-2 Final Assembly - C . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

42 PHDX-2 Final Assembly - D . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

43 Proportioner Hoses - Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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LIST OF FIGURES

44 Proportioner Hoses - Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

45 Lube Bottle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

46 In-Plant Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

47 In-Trailer Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

48 Exit Manifold Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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PHDX-2 SERVICE MANUAL

1. WARRANTY

1 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:

1. 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.

2. 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.

3. 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.

4. 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 modiﬁ-

cation 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.

REVISION 1.1 5

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1. WARRANTY

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.

REVISION 1.1 6

POLYURETHANE MACHINERY CORPORATION

2 SAFETY AND HANDLING

This chapter contains important information on the safety, handling, and use of your

PHD Series Proportioner.

Before installing the PHD 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 PHD Series Proportioner. All of the information is aimed at improving user safety and avoiding possible breakdowns from the incorrect use of the PHD Series Proportioner.

PHDX-2 SERVICE MANUAL

2. SAFETY AND HANDLING

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 issues.

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 PHD 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 PHD 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.polymacusa.com).

The PHD Series Proportioner has been designed and built for the application of polyurea chemical systems, polyurethane foam chemical systems, and some two-component epoxy systems

REVISION 1.1 7

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PHDX-2 SERVICE MANUAL

2. SAFETY AND HANDLING

WARNING! The design and conﬁguration of the PHD 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 PHD 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 PHD 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 PHD 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 (SDS) 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.

REVISION 1.1 8

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PHDX-2 SERVICE MANUAL

3. CHARACTERISTICS

3 CHARACTERISTICS

The PHD Series Proportioner has been designed and built for the application of polyurea chemical systems, polyurethane foam chemical systems, and some speciﬁc twocomponent epoxy systems.

3.1 PRINCIPAL HEATING SYSTEM

The Proportioner consists of one (1) Material Heater without internal seals. The Low Pressure 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. The High Pressure Heater has four (4) Heating Elements per ﬂuid side rated at 1750 watts, each giving the Proportioner a total heat output of 14,000 watts. Every heating system provides the necessary control and safety components for their precise operation. The Material Heater design allows for a controlled and precise temperature diﬀerential (∆T) and material application temperatures of up to 190oF under ambient temperatures.

3.2 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 tinnedcopper 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.

REVISION 1.1 9

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PHDX-2 SERVICE MANUAL

3. CHARACTERISTICS

3.3 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.

3.4 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.

Figure 1: Pressure Balance Control Logic Diagram

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POLYURETHANE MACHINERY CORPORATION

4. TECHNICAL SPECIFICATIONS

PHDX-2 SERVICE MANUAL

4 TECHNICAL SPECIFICATIONS

4.1 ELECTRICAL

PHDX-2, Single Phase, 208-240V

Pressure Heater Size Electrical Consumption

9.0kW(4.5kW/side) 83A

3,000PSI

10.5kW(5.25kW/side) 90A

14.0kW(7.0kW/side) 105A

PHDX-2, Three Phase, 208-240V

Pressure Heater Size Electrical Consumption

9.0kW(4.5kW/side) 50A

3,000PSI

10.5kW(5.25kW/side) 53A

14.0kW(7.0kW/side) 62A

PHDX-2, Three Phase, 400V

Pressure Heater Size Electrical Consumption

9.0kW(4.5kW/side) 34A

3,000PSI

Material Heater Power Power Consumption

4.50kW/side(3x1500W/side) 9.0kW

5.25kW/side(3x1750W/side) 10.5kW

7.0kW/side(4x1750W/side) 14.0kW

Hose Transformer Power Consumption

Electrical Motor Power Consumption

CAUTION! Inside the console is a Terminal Strip for connecting the

main power (wire not supplied) to the PHD Series Proportioner. This electrical connection must be made only by a qualiﬁed electrician.

10.5kW(5.25kW/side) 36A

14.0kW(7.0kW/side) 41A

70V 2kVA 90V 3kVA

120V 5kVA

PHDX-2 3hp

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4.2 MECHANICAL

Maximum Working Pressure 2,000PSI(14MPa, 138bar)

Maximum Production 31lb/min(14kg/min)

Minimum Production 2lb/min(1kg/min)

Gallons per Stroke 0.01859gal/stroke(0.07037L)

Strokes per 55gal(200L) Drum 2,958strokes

2kVA Transformer 210ft(64m) 3kVA Transformer 310ft(95m) 5kVA Transformer 410ft(125m)

Hydraulic Tank Empty 415lbs(166kg)

Hydraulic Tank Full (12gal) 450lbs(197kg)

PHDX-2 SERVICE MANUAL

4. TECHNICAL SPECIFICATIONS

123 Pumps

Maximum Hose Length

Approximate Weight

Overall Dimensions(W x D x H)

42in x 25in x 55in (106cm x 63cm x 139cm)

Figure 2: Proportioner Dimensions

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5 DESCRIPTION

PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Figure 3: Component Identiﬁcation - Front

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PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Figure 4: Component Identiﬁcation - Back

REVISION 1.1 14

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PHDX-2 SERVICE MANUAL

5. DESCRIPTION

A. Control Panel - Controls and regulates the operation of the PHD 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 pres-

sure 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. Flow Meters (Optional) - Monitor the ﬂow rate of both materials exiting the Propor-

tioner.

J. Hydraulic Manifold Assembly - Provides pressure reading of hydraulic ﬂuid and

controls direction of ﬂow.

K. Hydraulic Pressure Control - Allows the pressure of the hydraulic system to be in-

creased 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.

L. Motor - Provides power for hydraulic pump.

M. Hose Heating Transformer - Right side (inside of hydraulic tank) - Supplies

the required voltage for material Heated Hoses.

Figure 5: Y-Strainer Components

REVISION 1.1 15

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Figure 6: Front Panel Description

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. Human-Machine Interface (HMI) - The HMI unit on this PHD Series Proportioner

is a 10.1” touch screen. This screen is used to operate the PHD Series Proportioner and allows users to enable/disable optional functions of the Proportioner.

P. Emergency Stop - Interrupts the PHD Series control power circuit to stop all motion

and heating.

Q. USB Port - The USB Port is used to update the software of the PHD Series Proportioner

as well as to retrieve data collected during usage.

REVISION 1.1 16

POLYURETHANE MACHINERY CORPORATION

5.1 OPERATION MENU

PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Figure 7: HMI Operation Menu

1 - A SIDE HEATER ON/OFF

2 - INPUT A SIDE HEATER TEMPERATURE

3 - R SIDE HEATER ON/OFF

4 - INPUT R SIDE HEATER TEMPERATURE

5 - HOSE HEAT ON/OFF

6 - INPUT HOSE HEAT TEMPERATURE

7 - PUMP TO RETRACT POSITION ON/OFF

8 - PUMP POWER ON/OFF

9 - MOTOR POWER ON/OFF

10 - CYCLE COUNTER RESET

11 - SCREEN NAVIGATION

REVISION 1.1 17

POLYURETHANE MACHINERY CORPORATION

5.2 OPTIONS MENU

PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Figure 8: HMI Options Menu

12 - PRESSURE BALANCE CONTROL ON/OFF

13 - PRESSURE BALANCE ALARM RESET

14 - INPUT PRESSURE BALANCE CONTROL VALUE

15 - INPUT COUNTDOWN COUNTER

16 - SET COUNTDOWN COUNTER

17 - COUNTDOWN COUNTER RESET

18 - COUNTDOWN COUNTER ON/OFF

REVISION 1.1 18

POLYURETHANE MACHINERY CORPORATION

5.3 ALARMS MENU

PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Figure 9: HMI Alarms Menu

19 - REPLACE PUMP LUBE ALARM RESET

20 - REPLACE HYDRAULIC OIL ALARM RESET

21 - SERVICE Y-STRAINER ALARM RESET

22 - PUMP REBUILD ALARM RESET

23 - MANUAL HOSE HEAT ON/OFF

24 - INPUT HOSE HEAT

REVISION 1.1 19

POLYURETHANE MACHINERY CORPORATION

5.4 CHEMICAL MENU

PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Figure 10: HMI Chemical Menu

25 - CHEMICAL COUNTDOWN COUNTER ON/OFF

26A - RATIO ALARM ON/OFF

26B - INPUT CHEMICAL RATIO HIGH LIMIT

26C - INPUT CHEMICAL RATIO LOW LIMIT

27A - INPUT LOW LIMIT FOR CHEMICAL A ALARM

27B - INPUT STARTING AMOUNT OF CHEMICAL A

27C - DISPLAYS AMOUNT OF CHEMICAL A USED

28A - INPUT LOW LIMIT FOR CHEMICAL R ALARM

28B - INPUT STARTING AMOUNT OF CHEMICAL R

28C - DISPLAYS AMOUNT OF CHEMICAL R USED

REVISION 1.1 20

POLYURETHANE MACHINERY CORPORATION

5.5 PROCESS DATA MENU

PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Figure 11: HMI Process Menu

29 - INPUT JOB NUMBER

30 - INPUT DATE OF JOB

31 - DATA DISPLAY

32 - ALARM DISPLAY

33 - USB EJECT

REVISION 1.1 21

POLYURETHANE MACHINERY CORPORATION

5.6 SETUP MENU

PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Figure 12: HMI Setup Menu

34 - INPUT USER NAME

35 - INPUT PASSWORD

36 - LOGIN

37 - LOGOUT

38 - INPUT LEVEL PASSWORD

REVISION 1.1 22

POLYURETHANE MACHINERY CORPORATION

5.7 BUTTON APPEARANCE

CONTROL ON OFF

Heater A (Figure 7,

Item 1)

Heater R (Figure 7,

Item 3)

Hose Heat (Figure 7,

Item 5)

PHDX-2 SERVICE MANUAL

5. DESCRIPTION

Motor (Figure 7, Item

Standard Button #1

Standard Button #2

REVISION 1.1 23

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

6. INSTALLATION

6 INSTALLATION

WARNING! Use suitable protection and follow the recommenda-

tions in the Safety Information enclosed and provided by material suppliers when installing or working with the Proportioner.

CAUTION! Make sure the power cable is disconnected from the

main power source before connecting to the Terminal Strip in the Console.

NOTE! To ensure the PHD Series Proportioner works correctly,

the electrical supply must meet the speciﬁcations indicated on the Serial Number Placard aﬃxed to the Electrical Console.

Figure 13: Electrical Installation

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 59 for hydraulic 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 tanks maximum capacity.

3. To check the level of the hydraulic ﬂuid in the Hydraulic Pump Case, disconnect the Hydraulic Hose from the 90 degree 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.

REVISION 1.1 24

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

6. INSTALLATION

Figure 14: Component Identiﬁcation - Misc

CAUTION! 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 in-

coming 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.

REVISION 1.1 25

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

6. INSTALLATION

6.1 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 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 these tapered seat Coupling Connections.

2. Connect the material Heated Hoses to the outlets of the respective Exit Manifold Assembly. Iso (A) Heated Hose to the JIC ﬁtting on the left side of the Exit Manifold Assembly and the Poly (R) Heated Hose to the JIC ﬁtting on the left side of the Exit Manifold Assembly. Ensure the 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.

(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.

5. Repeat the above steps to connect the “Fast-Lock” Connectors that you will ﬁnd on all Heated Hose power wire.

REVISION 1.1 26

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

6. INSTALLATION

CAUTION! Ensure the proper mechanical and electri-

cal connections of the Heated Hoses are made to avoid possible material leakage and Hose heat problems.

6. 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).

Figure 15: Temperature Sensing Unit

(TSU) Part# EL-51A-4

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.

REVISION 1.1 27

POLYURETHANE MACHINERY CORPORATION

7. Ensure the Manual Valves are CLOSED and connect the Coupling Block to the Heated Gun Whip.

PHDX-2 SERVICE MANUAL

6. INSTALLATION

CAUTION! Excessive force closing or opening the Man-

ual Valves may result in damage to the Manual Valves and/or Coupling Block.

8. Connect the Transfer Pump/ Heated Hose Assemblies/Air Supply and Air Dryer systems as required. Review the Installation Instructions for each to ensure proper set-up and operation.

9. 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 Mate-

rial 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 (3/4” 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 (1/2” 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 con-

nections of the Iso (A) and Poly (R) Material Delivery Hoses are diﬀerent sizes, making it diﬃcult to swap connections.

10. 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.

11. Connect air to the air line coming oﬀ the ﬁrst section of hose (90-110 psi, 6-8 bar)

REVISION 1.1 28

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

6. INSTALLATION

6.2 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 listed in the table below.

RECOMMENDED TAP SETTINGS

Tap Hose Length (Feet) Hose Length (Meters)

120V 410 125.0 105V 360 109.7

90V 310 94.5 75V 260 79.5 60V 210 64.0 45V 160 48.8 30V 110 33.5 18V 60 18.3

Figure 16: Transformers

*90V transformers (shown above) allow for a maximum hose length of 310 ft (94.5 m). 120V transformers allow for a maximum hose length of 410 ft (125 m).

REVISION 1.1 29

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

7. PROPORTIONER PURGING

7 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 accor-

dance with all applicable local, state and federal codes. DO NOT turn on the Auto Countdown Switch or the Pressure Balance Control Switch.

REVISION 1.1 30

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

7. PROPORTIONER PURGING

6. Turn Hydrualic Pressure Control (Item K, Figure 4) fully COUNTERCLOCKWISE.

7. Turn ON Main Power (Item N, Figure 6).

8. Turn ON Motor Power (Item 9, Figure 7). Button will turn green when activated.

9. Activate Pump Power (Item 8, Figure 7). The button will turn green and the pump will activate. Turn Hydraulic Pressure Control CLOCKWISE increasing material pressure to 400 psi (28 bar). Both Material Pressure Gauges on the Exit Manifold Assembly (Item G, Figure 3) should approximately read the same. Check all Heated Hose Coupling connections for leakage.

10. Check all TSU and ”Fast-Lock” connections for leaks.

11. 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.

REVISION 1.1 31

POLYURETHANE MACHINERY CORPORATION

8. PRESSURE BALANCE CONTROL

PHDX-2 SERVICE MANUAL

8 PRESSURE BALANCE CONTROL

The PHD 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.

8.1 OPERATION

The Pressure Balance Control menu is located in the Options tab. This screen is detailed in Section 5.2 on page 18.

• Input Pressure (Item 14, Figure 8) - Press and a pop up will appear contain- ing a standard number pad. This is where the desired value for the Pressure Balance Control is input.

• Pressure Balance Control ON/OFF (Item 12, Figure 8) - Press to acti- vate the Pressure Balance Control option. Once activated the button will turn GREEN and read ON. Press to deactivate the Pressure Balance Control option.

• Pressure Balance Control Alarm Reset (Item 13, Figure 8) - Once a value is input and the option is activated, the PLC 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, an alarm will trigger and the Proportioner will stop pumping. Once the issue is resolved and is pushed, the alarm will reset and allow the Proportioner to pump again.

REVISION 1.1 32

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

9. TEMPERATURE CONTROLS

9 TEMPERATURE CONTROLS

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.

9.1 OPERATION

The Temperature Controller menu is located in the ”Operation” tab. This screen is detailed in Section 5.1 on page 17.

• Input Heater A Temperature (Item 2, Figure 7) - Press and a pop up will appear containing a standard number pad. This is where the desired value for the A side Heater is input.

• A side Heater ON/OFF (Item 1, Figure 7) - Press to activate the A side

Heater. While the A side Heater is active the button will appear as .

• Input Heater R Temperature (Item 4, Figure 7) - Press and a pop up will appear containing a standard number pad. This is where the desired value for the R side Heater is input.

• R side Heater ON/OFF (Item 3, Figure 7) - Press to activate the R side

Heater. While the R side Heater is active the button will appear as .

• Input Hose Heat Temperature (Item 6, Figure 7) - Press and a pop up will appear containing a standard number pad. This is where the desired value for the Hose Heater is input.

• Hose Heat ON/OFF (Item 5, Figure 7) - Press to activate the Hose Heater. While the Hose Heater is active the button will appear as .

REVISION 1.1 33

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

10. START-UP

10 START-UP

NOTE! Follow the recommended procedure in the order shown.

CAUTION! The Start-up procedures assume that all steps in Pro-

portioner purging (Section 7) have been performed and no problems were found.

1. Check the hydraulic ﬂuid level and service as required.

2. Make sure the materials have been stored at the manufacturer’s recommended temperature. Ask your material supplier for information (Safety Data Sheet) on the minimum storage temperature.

3. Y-Strainer screens should be checked routinely.

4. Connect air supply to the two Transfer Pumps and ensure Air Valves are in the full OPEN position. OPEN both Proportioner Material Inlet Ball Valves.

CAUTION! Remove all Heated Hose sections from coiled storage

and lay ﬂat to eliminate heat build-up and possible Heated Hose failure.

5. Turn ON Main Power (Item N, Figure 6).

6. Turn ON Hose Heater (Item 5, Figure 7) and conﬁrm material set-point temperature as recommended by the material supplier or application conditions.

CAUTION! To avoid excessive pressure in the Proportioner, wait

for the Hose Heater to reach its set-point temperature before continuing.

7. Turn ON each Primary Heater and conﬁrm material set-point temperature as required by the material supplier or application conditions has been reached.

8. Turn ON Motor Power (Item 9, Figure 7).

9. Turn ON Pump to NORMAL (Item 8, Figure 7).

NOTE! The Material Pressure Gauges should be approximately

equal and remain constant throughout the Metering Pump cycle. If not, refer to the Troubleshooting section (Section 12).

REVISION 1.1 34

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

10. START-UP

10. Using the Hydraulic Pressure Control (Item K, Figure 4), adjust to the required stall pressure and check each Material Pressure Gauge.

11. Countdown Counter - Follow the steps below to set the Auto Shut Down Counter:

a. Press and input desired number of cycles.

b. Press to submit the value to the counter.

c. When the counter counts down to zero the machine will stop and the pump direc-

tional light will be oﬀ.

d. To reset the counter press and the Proportioner will continue to pump.

12. Proceed with Installation and Start-up of the Spray Gun as per the Gun manual.

Model Pump Size Cycles per Gallon Cycles per Liter

PHDX-2 (2,000PSI) 123 27 Cycles 7.1 Cycles

Stall pressure: When materials are at recommended application temperature and Metering Pumps are pressurized but not moving. This pressure is normally 100–200 psi (7-14 Bar) greater than the developed spray pressure as recommended by the material supplier.

REVISION 1.1 35

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

11. SHUT-DOWN

11 SHUT-DOWN

11.1 SHORT-TERM

Follow the procedure below for temporary shut-downs, such as lunch breaks:

1. Turn OFF pump RETRACT. The button should appear as when inactive.

2. Turn OFF pump NORMAL. The button should appear as when inactive.

3. Turn OFF MOTOR POWER. The button should appear as when inactive.

4. Turn OFF both “A” and “R” Heaters. The buttons should appear as and when inactive. Hose Heater should remain ON. Never leave Proportioner ON if unattended.

5. CLOSE Spray Gun Manual Valves.

11.2 LONG-TERM

Follow the procedure below for shut-downs when work is stopped for the day:

1. Turn ON the pump NORMAL and RETRACT. The buttons should appear as when active.

2. Spray oﬀ the application surface until Material Pressure Gauge (Item G, Figure 3) readings begin to fall.

CAUTION! To avoid possible Proportioning Pump Seal weepage,

and moisture vapor drive into the Heated Hoses, the system pressure should not be reduced to zero. It is recommended to lower the system pressure to a minimum of 400 psi (28 bar).

3. CLOSE the Spray Gun Coupling Block Manual Valves.

4. Turn OFF MOTOR POWER. The button should appear as when inactive.

5. Turn OFF both “A” and “R” Heaters. The buttons should appear as and when inactive.

6. Turn OFF the Main Power (Item N, Figure 6).

7. Disconnect the air supply to the two Transfer Pumps and CLOSE the Proportioner Material Inlet Valves.

CAUTION! Excessive force opening or closing the Manual Valves

may result in damage to the Manual Valves and/or Coupling Block.

REVISION 1.1 36

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

12. TROUBLESHOOTING

12 TROUBLESHOOTING

This PHD Series Proportioner has been designed and built to withstand severe working conditions with a high degree of reliability, provided that it is used in a suitable application by a properly trained operator. This chapter contains information on possible faults that may interrupt the operation of the PHD Series Proportioner. The information provided will serve as a guideline to detect and resolve problems. In any case, feel free to contact your authorized PMC distributor, where a qualiﬁed technician will advise you.

WARNING! Only qualiﬁed personnel should perform troubleshoot-

ing; unqualiﬁed personnel may cause damage to the unit and put the operator at risk.

To prevent possible injury caused by incorrect handling of the raw materials and solvents used in the process, carefully read the Safety Data Sheet (SDS) provided by your supplier. Deal with the waste caused according to current regulations.

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.

REVISION 1.1 37

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

12. TROUBLESHOOTING

When the proportioner experiences an error an alarm will ﬂash on the current menu in use. This alarm is shown below. Upon activation of this alarm the machine will cease to function. The proportioner will only allow further usage once the parameter that is causing the fault has been ﬁxed. To troubleshoot the fault go into the alarms menu.

The alarms menu below shows the current alarms triggered with a description of the components aﬀected. When an alarm is triggered the red circle that says FAULT will be ﬂashing.

REVISION 1.1 38

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

12. TROUBLESHOOTING

12.1 HEATERS

WARNING! Only qualiﬁed personnel should perform troubleshoot-

ing; unqualiﬁed personnel may cause damage to the unit, personnel, or property and put the operator at risk. The Heaters are components that reach high temperatures; you must wait until they cool before handling.

NOTE! The Thermal Limit Switch is a safety switch in contact with

the Heater Body. If the surface temperature exceeds 220◦F (109◦C) the Limit Switch will shut oﬀ the Heater power. The Limit Switch will not reset until the temperature in the Heater is below 190◦F (88◦C). The system is designed that in case of an over temperature, a contactor located in the console will open and disable power to both Heaters and the Hose.

Frequent Heater Problems

Primary heater does not heat and the display on the HMI shows ambient temperature. Primary heater does not heat and the display on the HMI shows an error. Page 41 Primary heater shows excessive temperature and the circuit has turned oﬀ. Page 41 Primary heater temperature drops excessively while spraying. Page 41

Follow the recommended procedure in the indicated order to solve the problem and avoid unnecessary repairs. Make sure all features are in the correct setting before determining the existence of a fault.

Page 40

REVISION 1.1 39

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

12. TROUBLESHOOTING

• Problem: Primary heater does not heat and the display on the HMI shows ambient temperature.

Solutions:

1. Check the heater breaker in the main console and reset the breaker. If it continues to trip, wrap an Amp Clamp around one of the wires coming oﬀ the breaker. If the Amperage reading does not exceed the rating of the breaker, the breaker needs to be replaced. If the breaker draws more than its rating the most likely cause is that one or more of the ﬁre rods located in the heater are shorted.

If the breaker is not tripped, move on to the next step.

2. Open the console top and locate the solid state relays for the heaters, looking over the console top from the front of the machine. There are two relays to the left bottom of the console, the one to the far left is for the “A” heater and the one to the right is for the “R” heater. With the heater on, look to see if an LED light is lit on the relay.

If there is no LED light on the solid state relay, move to the next step.

3. Using a DC volt meter, read across position A1 and A2 on the solid state relay (smaller wires) if you have a reading of 4-6 volts DC and the AC reading across L1 and L2 (heavy wires) reads 208-230 volts AC replace the solid state relay. With 4-6 volts DC at A1 and A2 the proper reading should be 1 volt AC across L1 and L2. A defective over temperature switch will open a contactor disabling both Heaters and the Hose.

If there is no DC voltage to the relay, move to the next step.

4. Check the M1 contactor to ensure it is activated. If not, inspect the contactor for possible causes of failure.

If the M1 contactor is activated, call your distributor for further assistance.

REVISION 1.1 40

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

12. TROUBLESHOOTING

• Problem: Primary heater does not heat and the display on the HMI shows #### for ambient temperature.

Solutions:

1. Open the console and check PLC slice TS3101. Make sure that the wires in spots 5A, 5B, 7A, and 7B are securely fastened.

If the wires are tight, move to the next step.

2. Remove the heater cover and check that the thermocouple wires are secure to the harness going up to the controller.

If there are no loose connections replace the heater thermocouple.

• Problem: Primary heater controller shows excessive temperature and the circuit has turned oﬀ.

CAUTION! The heater must be allowed to cool down before

continuing.

Solutions:

1. Set the controller set point at least 20 degrees lower than the temperature shown on the controller. Brieﬂy turn on the heater and look for the LED light on the solid state relay to be on.

If the light is on, replace the controller. If the light is oﬀ, replace the solid state relay.

• Problem: Primary heater temperature drops excessively while spraying. Solutions:

1. Temperature of the chemical in the containers is too cold.

2. Exceeding the ﬂow rate speciﬁcation of the machine. Use a smaller mixing chamber to reduce ﬂow.

3. Disconnect power to the machine. One or more of the ﬁre rods in the heater have malfunctioned. Remove the heater cover and disconnect the wires to measure the resistance across each rod. Installing a smaller mixing chamber in the gun may allow you to spray until a new rod(s) is installed.

CAUTION! If the rod that is used in conjunction with the

thermocouple is defective, do not operate the heater until the rod is replaced.

Individual Ohm Measurement 1250 WATT 37 OHMS 1500 WATT 31 OHMS 1750 WATT 27 OHMS

REVISION 1.1 41

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

12. TROUBLESHOOTING

12.2 HYDRAULIC DRIVE SYSTEM

Frequent Hydraulic Drive System Problems

Hydraulic Pump does not develop pressure and the electric motor is not running. Low or zero hydraulic pressure with unusual Hydraulic Pump noises. Page 43

Page 43

WARNING! Only qualiﬁed personnel should perform trou-

bleshooting; unqualiﬁed personnel may cause damage to the unit, personnel, or property and put the operator at risk. The Heaters are components that reach high temperatures; you must wait until they cool before handling.

NOTE! Hydraulic pressure is not generated if the Motor Power

(Item 9, Figure 7) is OFF.

Motor Contactor Safety or Motor Breaker - The

Electric Motor is protected from excessive current by an Overload Safety Switch. After allowing the Motor to cool, open the Control Panel and reset Motor Contactor Safety.

REVISION 1.1 42

POLYURETHANE MACHINERY CORPORATION

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12. TROUBLESHOOTING

• Problem: Hydraulic Pump does not develop pressure and the electric motor is not running.

Solutions:

Hydraulic Power Package - With the Pump in the NORMAL position, the failure of

the Hydraulic Pump to develop pressure is loss of pump suction (this is called ”prime”). To ensure positive prime, check the following:

a. Motor Rotation.

b. Hydraulic Reservoir is ﬁlled to the correct level.

c. Hydraulic Pump Case is ﬁlled with the proper hydraulic ﬂuid.

d. Loose Inlet Plumbing: Check that all inlet plumbing to Hydraulic Pump is tight

ensuring no air leakage into the hydraulic system.

• Problem: Low or zero hydraulic pressure with unusual Hydraulic Pump noises. Solutions:

1. The use of an incorrect hydraulic ﬂuid can result is unusual noises from the pump, excessive wear, and moisture absorption. Ensure the hydraulic oil used is from the list on page 59. In addition, continuous excessive hydraulic oil temperature as well as failure to change the hydraulic oil on a yearly basis will cause the oil to fail and result in excessive Hydraulic Pump wear and unusual noises.

2. Loose Inlet Plumbing: Check that all inlet plumbing to Hydraulic Pump is tight, ensuring no air leakage into the hydraulic system.

CAUTION! Excessive force opening or closing the Manual Valves

may result in damage to the Manual Valves and/or Coupling Block.

REVISION 1.1 43

POLYURETHANE MACHINERY CORPORATION

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12. TROUBLESHOOTING

12.3 METERING PUMP-LINE

Figure 17: Metering Pump-Line (PL-10)

Frequent Pump-Line Problems

Metering pumps do not change direction and the pressures on both of chemical gauges are lower than normal. Pump Cavitation. Page 47 Pressure Loss: Discharge/Inlet Ball. Page 47

Page 44

• Problem: Metering pumps do not change direction and the pressures on both of chemical gauges are lower than normal.

Solutions:

1. The Metering Pump Line has Reversing Plates which actuates two Proximity Switches (EL-153), one at each end of the stroke. The Prox Switches in turn actuate the appropriate Directional Valve Solenoid (HI-05003). Failure to make contact with either Prox Switch may be caused by:

a. Deformation of the Reversing Plate.

b. Foreign material preventing the Reversing Plate from contacting the Prox

Switches.

2. Passing of the Reversing Plate beyond the Prox Switch may be caused by:

a. Failure of the Prox Switch and related components on the side of the over-run.

b. Failure of a component of the Directional Valve.

c. Mounting Plate (PU-07006) and/or Prox Switch is out of adjustment.

REVISION 1.1 44

POLYURETHANE MACHINERY CORPORATION

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12. TROUBLESHOOTING

NOTE! If the directional indicator light (arrows for RETRACT and

NORMAL, Page 17) is ON check the reversing valve coil on the side that the light is on. If you have 24 volts dc at the plug check the ohm’s resistance of the coil, it should read approximately 19 ohm’s, if not replace the coil or reversing valve. If the directional light is oﬀ proceed below.

NOTE! Before troubleshooting, the reversing plate must be moved

away from the switch.

d. Bleed down the chemical pressures.

e. Ensure Pump (Item 8, Figure 7) is OFF.

f. Turn on the Motor (Item 9, Figure 7).

g. Go to the Directional Valve and locate the Actuation Coils. Located in the

middle of each coil is a small round tab that can be pushed in to manually shift the spool to move the pumps. If the Reversing plate is all the way to the left push in on the right side coil. If it’s all the way to the right side, push in on the left side coil.

WARNING! The motor must be oﬀ and the pump switch in the

normal position.

h. Take a small screw driver or a thin piece of metal and move it across the front

of each Prox switch. A red light on the back of the switch should illuminate. If not, replace the switch that does not light.

i. If the Prox switches light up, turn oﬀ all power and check for continuity on

both over pressure switches, pin 1 and 2. If the pressure switches are good, go to the two solid state relays inside the console and interchange them, they can be pulled from their housing. Power up the unit with the pump in the normal position and the motor OFF. If the directional light comes on replace the defective solid state relay. If not replace the Latching relay.

Figure 18: PHDX-2 Console - Bottom Plate

REVISION 1.1 45

POLYURETHANE MACHINERY CORPORATION

3. Safety Pressure Switch - Each Metering Pump has a Safety Pressure Switch set to 2,200 psi for #123 pumps, 3,200 psi for #61 pumps. When the material system reaches this pressure, the Safety Pressure Switch will remove power from the Directional Valve and Direction Indicator Lights (arrows for RETRACT and NORMAL, Figure 7). Lack of Direction Indicator Lights along with high pressure indicated on one or both of the material Pressure Gauges (Items E & F, Section

5) is an indication of an over-pressure condition. The Safety Pressure Switches are a momentary design; when the pressure bleeds oﬀ the Metering Pump Line will resume normal operation. However, the cause of the over-pressure should be determined and corrected. The most common causes are:

a. Cavitations of the Metering Pump on the low pressure side causing high

b. A restriction in the Spray Gun on the high pressure side.

4. Pressure/Material Imbalance - Troubleshooting this problem requires the applicator to:

PHDX-2 SERVICE MANUAL

12. TROUBLESHOOTING

pressure on the opposite side.

a. Know what the NORMAL spray pressures are for the application in progress.

b. Determine what material is NOT exiting the Mixing Chamber.

c. Read the Pressure Gauge on the problem side and interpret the reading.

Material Condition ”A” GAUGE ”R” GAUGE

NORMAL

LACK OF ISO (A)

LACK OF POLY (R)

RESTRICTION OF ISO

(A)

RESTRICTION OF POLY

(R)

REVISION 1.1 46

POLYURETHANE MACHINERY CORPORATION

• Problem: Cavitation. Solutions:

1. Cavitation occurs when the Metering Pump requires a larger volume of material than the supply system (Transfer Pump) can furnish. This creates a ”void” of material in the Metering Pump. The most common causes of cavitations are:

a. Material temperature too low causing increased material viscosity resulting

in the inability of the Transfer Pump to maintain suﬃcient supply to the Metering Pump. This is most common with today’s blowing agents. Ensure the material temperature in the drums is no lower than the material suppliers’ recommendation.

b. Failure to vent the material drum while drawing material out with the Trans-

fer Pump causes a vacuum and cavitations in the Transfer Pump. Ensure the drum is vented to the atmosphere or a Desiccated Air Dyer Kit is installed as recommended by the material supplier.

c. Insuﬃcient air volume for Transfer Pump or a partially closed Transfer Pump

Air Valve will limit the ability of the Transfer Pump to operate at its maximum capability.

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12. TROUBLESHOOTING

d. Inlet Material Screen obstructed (See Section 13.1 on page 53).

e. Metering Pump Inlet Ball does not seat properly allowing material to ﬂow

back into the Material Delivery Hose when the Metering Pump is on the ”Discharge” stroke. This causes the volume of material on that Metering Pump to be less on the discharge stroke resulting in intermittent oﬀ-ratio material and Pressure Gauge ﬂuctuation.

• Problem: Pressure Loss: Discharge/Inlet Ball. Solutions:

1. Simultaneous observation of the material Pressure Gauge (Items E & F, Section

5) and Direction Indicator Light (arrows for RETRACT and NORMAL, Figure

7) is necessary to determine which direction the Metering Pump fails to maintain pressure. Refer to the chart to determine problem:

Iso Pressure Gauge

FALLS

Poly Pressure Gauge

FALLS

Left Arrow Directional

Indicator Light ON

Iso Inlet Ball does not seat

properly

Poly Discharge Ball does

not seat properly

Right Arrow Directional

Indicator Light ON

Iso Discharge Ball does not

seat properly

Poly Inlet Ball does not

seat properly

In most cases the cause of a leaking Inlet/Discharge Ball is foreign material preventing the Ball from seating properly. If the above steps do not resolve the problem, replace the appropriate Ball. For service see Section 13.4 on page 56.

REVISION 1.1 47

POLYURETHANE MACHINERY CORPORATION

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12. TROUBLESHOOTING

12.4 HOSE HEATING

WARNING! Before correcting any kind of defect, make sure the

Main Power Switch is OFF and incoming power is locked OFF. NEVER access the inside of the Control Panel with the Proportioner power supply ON. The Heated Hose are components which reach high temperatures; you must wait until they have cooled before handling.

CAUTION! Excessive force opening or closing the Manual Valves

may result in damage to the Manual Valves and/or Coupling Block.

Hose Heating Problems

Hose heater does not heat and the HMI displays ambient temperature. Page 48 Hose heater does not heat and the HMI shows an error. Page 49 Hose heater shows excessive temperature. Page 50 Hose will heat but not up to set temperature. Page 50 Hose does not heat and the HMI shows an error message. Page 50

• Problem: Hose heater does not heat and the HMI displays ambient temperature. Solutions:

1. Check that the light on the on/oﬀ switch is lit when the heater is turned on, if not replace the switch.

If the light is on, move on to the next step.

2. Check the Hose Heat breaker in the main console and reset the breaker. If it continues to trip, wrap an Amp Clamp around one of the wires coming oﬀ the breaker. If it does not draw more than the rated value of the breaker, the breaker needs to be replaced.

If the breaker is not tripped, move on to the next step.

3. Check the circuit breaker mounted on the transformer and reset the breaker. If it continues to trip, wrap an Amp Clamp around one of the wires from the transformer going to the heated hose. If it does not draw more than the rated value of the breaker, the breaker needs to be replaced.

If the Amp Draw is less than the rated value, move on to the next step.

4. Check that the tap setting on the transformer is set for the proper hose length.

If it is set correctly, move to the next step.

REVISION 1.1 48

POLYURETHANE MACHINERY CORPORATION

5. To check the secondary side of the transformer, you must take an AC volt reading across the two leads coming out of the transformer that are connected to the “A” and “R” hose leads. If you are reading voltage (your volt reading will vary depending on what tap setting is used), most likely the problem is in the heated hose. Either a connector has come loose or there is a broken wire.

6. Because the gun whip takes the most abuse, it is most likely the whip that has failed. Disconnect the crossover wires on the machine end of the whip hose and connect the two wires together coming oﬀ the 50’ section. Turn on the hose heat and see if the hose heat circuit is operating; if so replace the whip. To take a continuity reading through the heated hose, one of the leads from the transformer to the “A” or “R” heated hose must be disconnected.

If no voltage is coming out of the transformer to the heated hose, move on to the next step.

7. Open the right side of the tank (where the transformer is located) and locate the solid state relay for the hose circuit (EL-35). With the hose turned on and the LED light illuminated on the relay, take a volt meter (set on DC) and measure across position A1 and A2; your reading should be 24 volts. Then take an AC volts measurement across position L1 and L2 (heavy wires). With the relay functioning properly you should have a 1 volt Reading. If the Reading is 18 to 90 volts AC, the relay has malfunctioned and needs to be replaced. If the AC Reading across L1 and L2 is .025 volts check the over temperature switches in the heaters. A defective over temperature switch will open a contactor disabling both Heaters and the Hose.

If there is no light on the solid state relay, move to the next step.

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12. TROUBLESHOOTING

8. Using a DC volt meter, measure across position C7 and D7 on the back of the TS3101. This is the output that sends power to the solid state relay. Your reading will be 4-6 volts DC. If there is no voltage, check to make sure that the set temperature of the HMI is above ambient temperature. If there is no DC

voltage to the relay, contact your local distributor for further assistance.

• Problem: Hose does not heat and the HMI shows an error. Solutions:

1. Check position C7 and D7 on the PLC slice TS3101 for loose wires.

If the wires are tight, move to the next step.

2. Remove the transformer cover and check that the thermocouple wires are secure to the harness going up to the controller. If there are no loose connections, disconnect the wire from the TSU and connect it directly to the thermocouple harness coming out of the hose transformer.

If the controller still shows the error code, replace the hose thermocouple. If the error code goes away and temperature is now shown on the display, then all the TSU harnesses from the TSU to the transformer need to be checked for loose connectors or one or more of the harnesses are defective.

REVISION 1.1 49

POLYURETHANE MACHINERY CORPORATION

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12. TROUBLESHOOTING

• Problem: Hose heater shows excessive temperature. Solutions:

1. Set the temperature set point at least 20 degrees lower than the temperature shown on the controller. Brieﬂy turn on the hose and look for the led light on the solid state relay to be on.

If the light is oﬀ, replace the solid state relay. If the light is on, contact your local distributor for further assistance.

• Problem: Hose will heat but not up to set temperature. Solutions:

1. Check the tap setting on the transformer to ensure that the correct position has been selected for the length of hose being used. Depending on the machines incoming voltage, you may have to move the tap setting higher (up one).

CAUTION! Do not exceed the trip value of the transformer hose

breaker.

WARNING! Before correcting any kind of defect, make sure the

Main Power Switch is OFF and incoming power is locked OFF. NEVER access the inside of the Control Panel with the Proportioner power supply ON.

• Problem: Hose does not heat and the HMI shows an error message. Solutions:

1. Check position 5 and 7 on the PLC slice TS3101 for loose wires.

If the wires are tight, move to the next step.

2. Remove the transformer cover and check that the thermocouple wires are secure to the harness going up to the controller. If there are no loose connections disconnect the wire from the TSU and connect it directly to the thermocouple harness coming out of the hose transformer.

If the controller still shows the error code, replace the hose thermocouple. If the error code goes away and temperature is now shown on the display of the controller, then all the TSU harnesses from the TSU to the transformer need to be checked for loose connectors or one or more of the harnesses are defective.

REVISION 1.1 50

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

13. MAINTENANCE

13 MAINTENANCE

To achieve maximum output from the PHD Series Proportioner, a daily or regular maintenance schedule is required.

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.

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.

CAUTION! All repairs performed by unqualiﬁed personnel or

the use of parts other than supplied by PMC may cause damage to the unit and put the operator at risk.

REVISION 1.1 51

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13. MAINTENANCE

The ﬁrst four alarms in the alarms menu are simple maintenance warnings. These alarms will not automatically stop the proportioner from functioning. They are, however, critical features that require maintenance and, if neglected, could compromise the integrity of the proportioner. Once serviced, press and the alarm will deactivate.

The components that these warnings aﬀect are as follows:

• REPLACE PUMP LUBE (ISO LUBRICATION SYSTEM, Section 13.2)

- This alarm is triggered after a certain amount of pump strokes. The pump lube acquires dirt over time and should be monitored regularly. Dirty lube could aﬀect pump performance and compromise certain seals.

• HYD OIL REPLACEMENT (HYDRAULIC DRIVE SYSTEM, Section

13.3) - Failure to change the hydraulic oil on a yearly basis will result in unusual

noises from the pump as well as excessive wear and unwanted moisture absorption.

• Y-STRAINER SERVICE (INLET MATERIAL SCREENS, Section 13.1) - This is the main ﬁlter for chemicals entering the Proportioner. Failure to clean out the ﬁlter in the Y-strainer could cause a blockage of material, resulting in the Proportioner not functioning correctly.

• PUMP REBUILD (METERING PUMP-LINE, Section 13.4) - This alarm is triggered after a certain amount of pump strokes. When this alarm is active it is best to inspect the Pump-Line for any visible leaks or damage.

REVISION 1.1 52

POLYURETHANE MACHINERY CORPORATION

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13. MAINTENANCE

13.1 INLET MATERIAL SCREENS

CAUTION! Make sure the Main Power Switch is OFF and incom-

ing power is locked OFF.

NOTE! Inspect and clean Inlet Material Screens before Propor-

tioner start-up. They should not be cleaned after the days’ operation as the Proportioner should be purged (see page 30) immediately after inspection and cleaning. This is to reduce the risk of moisture contamination, chemical reaction with the solvent used in the cleaning operation, and cross-over in the Spray Gun due to air entrapment.

Inspection of the Inlet Material Screens on a daily basis is no longer necessary as long as the following conditions are met.

1. Material drums are stored within the recommended material storage temperature range and drums are not opened prior to installing the Proportioner Material Transfer Pumps.

2. Desiccant air dryers are used to dry replacement air as material is removed from the drums to the Proportioner.

3. Consolidation of old material into a common drum for use is minimized, especially the Iso (A).

If the above conditions are met, inspection of the Inlet Material Screens may be done on a bi-weekly basis. Instructions for a proper inspection are listed below.

1. CLOSE the Poly (R) Proportioner Inlet Valve.

2. Place a suitable container under the Material Inlet Strainer to collect the residual material. Carefully loosen the Strainer Plug to drain material into the container.

3. Completely unscrew the Strainer Plug.

4. Remove the Seal, Spring and Screen and clean them with a suitable solvent. Dry the parts and ensure the Screen is not obstructed. Replace the Screen if more than 20% of the Screen surface is obstructed by residue.

REVISION 1.1 53

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

13. MAINTENANCE

5. Reinstall the Screen, Spring and Seal. Screw on the Strainer Screw and screw in Plug.

6. OPEN the Poly (R) Proportioner Inlet Valve, pressurize the Material Transfer Pump, check for leaks and wipe Y-strainer clean.

7. Repeat above for the Iso (A) side.

8. Proceed with Proportioner Purging operation (See Section 7 on page 30).

13.2 ISO LUBRICATION SYSTEM

DAILY: Check the condition of the PMC Lube Oil in the Iso Lube Reservoir. Replace the PMC Lube Oil if you see signiﬁcant changes in the color or signs of solidiﬁcation. Ensure inside of Reservoir is wiped clean.

To replace the Lube Oil, proceed as follows:

1. Remove the Lube Reservoir from its support, unscrew the Lid and remove the Check Valve from the Suction Hose.

2. Empty the contaminated Lube Oil in a waste container and reﬁt the Check Valve in the Suction Hose.

NOTE! Valve is directional.

3. Clean the Reservoir, reﬁll with Lube Oil, and screw on the Lid and place the Reservoir in its support.

The system is auto-suction and does not need priming.

REVISION 1.1 54

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

13. MAINTENANCE

13.3 HYDRAULIC DRIVE SYSTEM

WARNING! Before performing any maintenance, make sure the

Main Power Switch is OFF and incoming power is locked OFF. The Hydraulic Unit is a component that works under pressure. Do not open any connection or carry out maintenance on components subject to pressure until all pressure has been bled to zero.

The hydraulic unit should be serviced yearly:

1. Completely drain the Tank of hydraulic ﬂuid.

2. Clean the Tank Top to prevent foreign material from falling into the Tank when the Cover is removed.

3. Unscrew the Suction Pipe from its connection with the Hydraulic Pump.

4. Remove the Cover and Suction Pipe from the Hydraulic Tank. Take care not to damage Tank Cover Gasket.

5. Inspect the bottom of the Tank for sediment and clean as required. Clean the Suction Pipe and its connections.

6. Fill the Tank with 10 gal (37 L) of approved hydraulic ﬂuid (See Section 14 on page 59 for recommendations).

7. Insert the Suction Pipe into the Tank Cover and install the Cover. Again, take care not to damage Tank Cover Gasket. Connect the Suction Pipe securely to the Hydraulic Pump.

8. Ensure the Hydraulic Pump Case is full of ﬂuid and proceed with the normal operation.

REVISION 1.1 55

POLYURETHANE MACHINERY CORPORATION

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13. MAINTENANCE

13.4 METERING PUMP-LINE

WARNING! Before performing any maintenance, make sure the

Main Power Switch is OFF and incoming power is locked OFF. Allow material temperature to cool below 80◦F and bleed all material pressure to zero.

Weekly:

small amount of Poly (R) material to appear on the Pump Shaft. This material should be wiped away so dirt does not accumulate on the Pump Shaft and the Pump Shaft Packings are not damaged.

Yearly or as required: It is not unusual for those who use the PHD Series Proportioner on a regular basis to rebuild the Proportioning Pumps on a yearly basis and service the Hydraulic Drive System at the same time, while the Proportioner is out of service.

When the Proportioning Pumps are functioning properly it is not unusual for a

13.5 PUMP SEAL REPLACEMENT

The pump rebuild kit part number for low pressure pumps is KT-PA and for high pressure pumps is KT-PAX.

NOTE!

• When Iso (A) Proportioning Pump Cylinder is disassembled for service, all parts included in the Seal Kit (KT-PA) should be replaced.

• When the Poly (R) Proportioning Pump Cylinder is disassembled for service, all parts included in the Seal Kit (KT-PA) should be replaced.

• When assembling Proportioning Pump, lubricate all Seals, Piston Rod, and Pump Cylinder with #1 Lithium Grease to assist in assembly and minimize Seal damage during re-assembly.

CAUTION! Use wooden or plastic tools or a brass brush for clean-

ing. Do not use metal or abrasive tools that can scratch the contact surfaces.

REVISION 1.1 56

POLYURETHANE MACHINERY CORPORATION

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13. MAINTENANCE

13.6 MATERIAL HEATER

WARNING! Before performing any maintenance, make sure the

Main Power Switch is OFF and incoming power is locked OFF. NEVER access the inside of the Control Panel with the Proportioner power supply ON. The Heaters are components that reach high temperatures; you must wait until they have cooled before handling and bleed all material pressure to zero.

THERMOCOUPLE REPLACEMENT

NOTE! The Thermocouple is assembled into the Connector Body

with a Ferrule and Nut. Once inserted into the Body and the Nut is tightened, the Ferrule locks to the Thermocouple and does not allow it to be relocated or moved. The location of the Thermocouple is very important and must be done correctly before tightening the Nut.

1. Unscrew the Nut that holds the defective Thermocouple and remove from the Body. Disconnect Thermocouple wiring located under the Top Cover of the Heater. Remove Body and discard.

2. Install Heating Element and Spring if also removed.

3. Install Connector Body into Heater using an open-end wrench and tighten to prevent leakage. Teﬂon Tape or appropriate Thread Sealant should be used.

4. Slide the Nut and the Ferrule over the Thermocouple and insert this assembly into the Connector Body until it comes into positive physical contact with the Heating Rod. Make sure the Spring does not prevent the Thermocouple from making contact with the Heating Rod.

5. Slowly tighten the Nut using an open-end wrench, ensuring the Thermocouple maintains positive physical contact with the Heating Rod.

6. Reinstall the Thermocouple wires.

REVISION 1.1 57

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

13. MAINTENANCE

WARNING! Before performing any maintenance, make sure the

To replace a defect Heating Rod, proceed as follows:

1. Ensure Main Power Switch is OFF and incoming power is locked OFF. Depressurize proportioner and remove the Cover on Heater.

WARNING! If the Heating Rod to be replaced is the one in

contact with the Thermocouple, it is necessary to remove the Thermocouple ﬁrst. Do not loosen or tighten Thermocouple Body.

2. Disconnect the suspect Heating Rod from the wire connections and test the Heating Rod again for proper electrical resistance.

Heating Rod Ohm Measurement per

Rod

1250 WATT 39.0 Ω 13.0 Ω 1500 WATT 32.4 Ω 10.8 Ω 1750 WATT 27.5 Ω 9.2 Ω

3. Unscrew the Heating Rod and remove from the Heater Block along with its Spring and inspect; it must be smooth and shiny in appearance. If it is blackened or has material adhered to it replace the Heating Rod, even if ohm reading is acceptable.

4. Apply Teﬂon Tape or appropriate Thread Sealant to the Heating Rod thread and assemble Heating Rod and Spring into the Heater Block. Tighten securely to 110 ft/lbs (150 Nm)

5. If necessary carefully re-install Thermocouple ensuring positive physical contact with the Heating Rod. Make sure the Spring does not prevent the Thermocouple from making contact with the Heating Rod. Tighten Nut with open-end wrench.

Measurement per Fluid

Total Ohm

Side

6. Reconnect wire connections and replace Cover.

7. Ensure Heater is full of material prior to electrical testing.

REVISION 1.1 58

POLYURETHANE MACHINERY CORPORATION

14. HYDRAULIC OIL SPECIFICATIONS

PHDX-2 SERVICE MANUAL

14 HYDRAULIC OIL SPECIFICATIONS

Recommended Hydraulic Oil Speciﬁcation:

ISO/ASTM Viscosity Grade 32

Viscosity:

28.8 – 35.2 SSU at 104◦F Rust and Oxidation Inhibited

14.1 MANUFACTURERS

• Mobil DTE24 (Recommended)

• Cook’s Albavis 8

• Ashland - Valvoline AW15

• Shell – Tellus 32(25)

• Sun Oil - Sunvis 706

• Chevron ISO32

• American Oil & Supply – PQ Iso 32

• Gulf Oil – Harmony 32AW (43AW)

• Atlantic Richﬁeld – Duro AWS-150

• BP Oil – Energol HLP-C32

• Exxon – Nuto H-32(44)

• Margolis – T.I.P.100-15-7

• Fiske Bros. – Lubriplate Hyd. #0

• SW – Alemite Hydraulic HD #0

• Texaco – Rando HD32 (HD A0)

• White & Bagley – EP Hyd. 150

REVISION 1.1 59

POLYURETHANE MACHINERY CORPORATION

15 PARTS IDENTIFICATION

15.1 FRAME ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 19: Frame Assembly (FR-10)

REVISION 1.1 60

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

FRAME ASSEMBLY (FR-10)

ITEM QTY PART NUMBER DESCRIPTION

1 1 200950 GROMMET, 1.750” GD, 0.375” GW, 1.500” ID 2 2 200951 GROMMET, 1.000” GD, 0.125” GW, 0.813” ID 3 24 201060 WASHER, LOCK, 1/4, 18-8 SS 4 2 201328 GROMMET, 2.250” GD, 0.125” GW, 2.000” ID 5 8 201560 BHCS, 1/4-20 X 0.5, 18-8 SS 6 4 201583 SHCS, 3/8-16 X 2.0, 18-8 SS 7 2 201590 BHCS, #8-32 X 0.5, 18-8 SS 8 24 201621 WASHER, FLAT, 1/4, 18-8 SS

9 4 201627 WASHER, FLAT, 3/8, 18-8 SS 10 4 201628 WASHER, LOCK, 0.375, 18-8 SS 11 4 201899 BHCS, 1/4-20 X 0.75, 18-8 SS 12 4 201902 BHCS, 1/4-20 X 1.0, 18-8 SS 13 4 201904 BHCS, 3/8-16 X 2.25, 18-8 SS 14 16 201930 HHCS, 1/4-20 X 1.0, ZP GRD8 15 2 EL-000P12 HAYCO #6 AWG SR 16 1 EL-000P7 HAYCO SR THERMOCOUPLE 17 1 HI-00001A SIGHT GAUGE 18 1 HI-00002-A-1 GROMMET MODIFIED 1” 19 1 HI-00014-03A TANK TOP GASKET 20 1 HI-00047A HYDRAULIC FILL STRAINER 21 4 HI-001 PLASTIC TUBE CAPS 22 1 HI-05306 TANK PUMP DRAIN TUBE 23 1 HI-05308 TANK DISCHARGE TUBE 24 1 HI-05317 3/8 JIC BULKHEAD UNION 25 1 HI-05319 1/2 JIC BULKHEAD UNION 26 1 MQ-01008A LUBE BOTTLE BRACKET 27 1 RM-05700-11 TANK LID 28 1 RM-05700-15 MOTOR MOUNT BARS 29 1 RM-238 TANK 30 1 RM-240 FRAME BASE ASSY 31 1 RM-241 FRAME UPRIGHT 32 1 TN-05704 4” CASTER

REVISION 1.1 61

POLYURETHANE MACHINERY CORPORATION

15.2 PROX SENSOR ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 20: Prox Sensor Assembly (RM-243)

PROX SENSOR ASSEMBLY (RM-243)

ITEM QTY PART NUMBER DESCRIPTION

1 2 201060 WASHER, LOCK, 1/4, 18-8 SS 2 2 201621 WASHER, FLAT, 1/4, 18-8 SS 3 2 201930 HHCS, 1/4-20 X 1.0, ZP GRD8 4 1 EL-153 12MM PROX SWITCH 5 2 EL-153-01 HEX JAM NUT, M10 6 1 PU-07006 PROX SWITCH MOUNT

REVISION 1.1 62

POLYURETHANE MACHINERY CORPORATION

15. PARTS IDENTIFICATION

15.3 HYDRAULIC MANIFOLD ASSEMBLY

PHDX-2 SERVICE MANUAL

Figure 21: Hydraulic Manifold Assembly (HI-05335)

HYDRAULIC MANIFOLD ASSEMBLY (HI-05335)

ITEM QTY PART NUMBER DESCRIPTION

1 1 HI-05070-3 HYDRAULIC MANIFOLD 2 2 HI-05007 6 ORB X 6 JIC 3 1 HI-05324 6 ORB X 1/2 JIC; 90 DEG 4 1 HI-05348 6 ORB EXTENTION 5 1 HI-05350 6 JIC 6 ORB ”T” 6 1 HI-05040 PRESSURE GAUGE 0-2000 PSI 7 1 HI-05006-6 1/4 NPT X 6 JIC GAUGE FITTING 8 1 HI-05349 6 JIC X 8 JIC

REVISION 1.1 63

POLYURETHANE MACHINERY CORPORATION

15.4 EXIT MANIFOLD ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 22: Exit Manifold Assembly (HI-05343)

EXIT MANIFOLD ASSEMBLY (HI-05343)

ITEM QTY PART NUMBER DESCRIPTION

1 1 HI-05307 OUTLET MANIFOLD 2 3 HI-05011 6 ORB X 6 JIC NIPPLE 3 4 HI-05036 1/4 NPT FLUSH SEAL PIPE PLUG 4 1 HI-05329 6 ORB X 5 JIC

5 2 HI-05070-4 HEX SOCKET 0-RING BOSS 6* 2 HI-05028 PRESSURE GAUGE 0-3000 PSI (HI-05331) 6* 2 HI-00035 PRESSURE GAUGE 0-5000 PSI (HI-05343)

7 2 HI-05323 10 ORB PLUG

* Indicates parts not included in HI-05343

REVISION 1.1 64

POLYURETHANE MACHINERY CORPORATION

15.5 HYDRAULIC SEAL ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 23: Hydraulic Seal Assembly

HYDRAULIC SEAL ASSEMBLY

ITEM QTY PART NUMBER DESCRIPTION

1 1 HI-05025-13 BUSHING,ROD 2 1 HI-05025-4 WIPER, ROD 3 1 HI-05025-5 SHAFT SEAL 4 1 HI-05025-6 BACK UP RING, BUSHING 5 1 OR-00039A O-RING #218 HYD CYLINDER ROD

Hydraulic Cylinder Rebuild Kit is on page 68

REVISION 1.1 65

POLYURETHANE MACHINERY CORPORATION

15.6 HYDRAULIC PISTON ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 24: Hydraulic Piston Assembly

HYDRAULIC PISTON ASSEMBLY

ITEM QTY PART NUMBER DESCRIPTION

6 1 HI-05300 HYDRAULIC PISTON 7 1 HI-05025-3 WEAR RING 8 2 HI-05025-2 BACK-UP RING, PISTON 9 2 HI-05025-1 U-CUP

REVISION 1.1 66

POLYURETHANE MACHINERY CORPORATION

15.7 HYDRAULIC CYLINDER ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 25: Hydraulic Cylinder Assembly (HI-05336)

REVISION 1.1 67

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

HYDRAULIC CYLINDER ASSEMBLY (HI-05336)

ITEM QTY PART NUMBER DESCRIPTION

1 1 - HYDRAULIC PISTON ASSEMBLY (SEE PAGE 66) 2 1 HI-05301 HYDRAULIC CYLINDER 3 2 HI-05200-3 PORT BLOCK, HYDRAULIC 4 2 - HYDRAULIC SEAL ASSEMBLY (SEE PAGE 65) 5 2 HI-05302 FEMALE CLEVIS 6 2 HI-05303 SWITCH PLATE 7 2 OR-00040A O-RING -036 HYD CYLINDER 8 1 HI-05322 FLANGE RTAINER, “A” SIDE

9 1 HI-05333 FLANGE RETAINER, “R” SIDE 10 4 201580 WASHER, FLAT, 5/16, 18-8 SS 11 4 201591 FHCS, #8-32 X 0.375, 18-8 SS 12 2 HI-05337 SPRING PIN, SLOTTED 1/8” DIA 13 4 202145 WASHER, LOCK, 5/16, 18-8 SS 14 4 202212 HHCS, 5/16-18 X 7.00, GRD5

15.7.1 HYDRAULIC CYLINDER REBUILD KIT

HYDRAULIC CYLINDER REBUILD KIT (KT-05200)

ITEM QTY PART NUMBER DESCRIPTION

1 2 HI-05025-1 U CUP 2 2 HI-05025-2 BACK-UP RING, PISTON 3 1 HI-05025-3 WEAR RING 4 2 HI-05025-4 WIPER, ROD 5 2 HI-05025-5 SHAFT SEAL 6 2 HI-05025-6 BACK-UP RING, BUSHING 7 2 OR-00039A O-RING -218 HYD CYLINDER ROD 8 2 OR-00040A O-RING -036 HYD CYLINDER

REVISION 1.1 68

POLYURETHANE MACHINERY CORPORATION

15.8 A & R SINGLE PUMP ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 26: A & R Single Pump Assembly (202192)

REVISION 1.1 69

POLYURETHANE MACHINERY CORPORATION

ITEM QTY PART NUMBER DESCRIPTION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

A & R SINGLE PUMP ASSEMBLY (202192)

1 1 200700 INLET BODY, LP 2 1 200701 INLET VALVE, LP

3 4 201625 SHCS, 3/8 X 4.0, 18-8 SS 4* 1 OR-035 O-RING, -035, VITON 5* 1 OR-916 O-RING 6* 1 OR-920 O-RING

7 1 PA-045 OUTLET BODY

8 1 PA-046 PISTON VALVE

9 1 PA-047 PISTON 10 1 PA-048 3/4” CHROME BALL 11 1 PA-049 SPRING 12 1 PA-050 SPRING RETAINER 13 1 PA-051 ROD BUSHING

14* 2 PA-052 ROD SEAL ASSEMBLY 15* 1 PA-054 PISTON SEAL ASSEMBLY

16 1 PA-055 PISTON BUSHING 17 1 PA-059 1” BALL 18 1 PA-060 BALL STOP 19 1 PA-061 SPRING, FOOT VALVE 20 1 PA-062 FLUID ROD 21 1 PA-064 PACKING NUT

22* 1 PA-065 SCRAPER SEAL

* Indicates part included in KT-PA: Low Pressure Pump Rebuild Kit (See page 73)

Figure 27: A & R Single Pump Cross Section

REVISION 1.1 70

POLYURETHANE MACHINERY CORPORATION

15.9 PUMP-LINE SEAL ORIENTATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 28: A & R Single Pump Assembly Detail A

Figure 29: A & R Single Pump Assembly Detail B

REVISION 1.1 71

POLYURETHANE MACHINERY CORPORATION

15.10 PUMP-LINE ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 30: Pump-Line Assembly (PL-10)

REVISION 1.1 72

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

PUMP LINE ASSEMBLY - HIGH PRESSURE (PL-10)

ITEM QTY PART NUMBER DESCRIPTION

1 2 PAX-044 SINGLE PL-PAX PUMP 2 1 PU-07002 BRACKET, PAX 3 16 201589 SHCS, 1/4-20 X 1.000, 18-8 SS 4 2 HI-05338 FLANGE, PAX 5 4 201584 SHCS, 3/8-16 X 3.000, 18-8 SS 6 4 PU-07009 STAND OFF, PUMP-LINE 7 1 PU-07001 MALE CLEVIS 8 1 PU-07003 SHAFT, PA LUBE

9 2 PU-05007 CLEVIS PIN 10 1 HI-05336 HYDRAULIC CYLINDER ASSY, PH(X)-2 11 2 HI-05011 9/16-18 O-RING X 9/16-18 JIC 12 4 201585 SHCS, 3/8-16 X 6.000, 18-8 SS 13 1 OR-806 O-RING #120 VITON 14 1 PU-07004 LUBE SECTION, PAX 15 1 OR-807 O-RING #137 VITON

15.10.1 PUMP REBUILD KIT

PUMP-LINE ASSEMBLY - HIGH PRESSURE (PL-10)

QTY PART NUMBER DESCRIPTION

1 KT-PAX PHX PUMP REBUILD KIT (3,000PSI)

REVISION 1.1 73

POLYURETHANE MACHINERY CORPORATION

15.11 ”A” INLET MANIFOLD ASSEMBLY

Figure 31: ”A” Inlet Manifold Assembly (YS-6-PHX)

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

”A” INLET MANIFOLD ASSEMBLY (YS-6-PHX)

ITEM QTY PART NUMBER DESCRIPTION

1 1 HI-05305 INLET MANIFOLD 2 2 HI-05036 1/4 NPT FLUSH SEAL PIPE PLUG 3 2 HI-05315 12 ORB X 12 JIC 90 DEG 4 1 HI-05316 3/4 NPTM X 12 JIC SW 5 1 HI-05055 TEMP GAUGE 0-200 F 6 1 HI-05103 PRESS GUAGE 0-600 PSI 7 1 HI-05311 TEMP GUAGE STAND-OFF 8 1 HI-05017 3/4 NPTM UNION

9 1 RA-00078 3/4 BALL VALVE SS 10 1 HI-05018 3/4 NPTM X 1/2 NPTM SW 11 1 RA-00074-00A Y-STRAINER 12 1 HI-05341 INLET MANIFOLD BRACKET 13 3 201324 FHCS, 1/4-20 X 0.500, 18-8 SS

1 RA-00074-03-30A REPLACEMENT SCREEN; 30 MESH

15 1 SP-00009A REPLACEMENT SPRING 16 1 RA-00074-02A REPLACEMENT GASKET 17 1 RA-00074-04 Y-STRAINER NUT 18 1 HI-05093 NPTM X NPTF ELBOW

1 RA-00074-03-60A REPLACEMENT SCREEN; 60 MESH 1 RA-00074-03-90A REPLACEMENT SCREEN; 90 MESH

REVISION 1.1 74

POLYURETHANE MACHINERY CORPORATION

15.12 ”R” INLET MANIFOLD ASSEMBLY

Figure 32: ”R” Inlet Manifold Assembly (YS-7-PHX)

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

”R” INLET MANIFOLD ASSEMBLY (YS-7-PHX)

ITEM QTY PART NUMBER DESCRIPTION

1 2 HI-05036 1/4 NPT FLUSH SEAL PIPE PLUG

2 1 HI-05325 12 ORB X 12 JIC

3 1 HI-05316 3/4 NPTM X 12 JIC SW

4 1 HI-05305 INLET MANIFOLD

5 1 HI-05311 TEMP GUAGE STAND-OFF

6 1 HI-05103 PRESS GUAGE 0-600 PSI

7 1 HI-05055 TEMP GUAGE 0-200 F

8 1 HI-05017 3/4 NPTM UNION

9 1 RA-00078A 3/4 BALL VALVE SS 10 1 HI-05016 3/4 NPTM X 3/4 NPTF SW 11 1 RA-00074-00A Y-STRAINER 12 1 HI-05341 INLET MANIFOLD BRACKET 13 3 201324 FHCS, 1/4-20 X 0.500, 18-8 SS

1 RA-00074-03-30A REPLACEMENT SCREEN; 30 MESH

15 1 SP-00009A REPLACEMENT SPRING 16 1 RA-00074-02A REPLACEMENT GASKET 17 1 RA-00074-04 Y-STRAINER NUT 18 1 HI-05093 NPTM X NPTF ELBOW

1 RA-00074-03-60A REPLACEMENT SCREEN; 60 MESH 1 RA-00074-03-90A REPLACEMENT SCREEN; 90 MESH

REVISION 1.1 75

POLYURETHANE MACHINERY CORPORATION

15.13 HEATER ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 33: Heater Assembly, 6 Rod - A

Figure 34: Heater Assembly, 6 Rod - B

REVISION 1.1 76

POLYURETHANE MACHINERY CORPORATION

ITEM QTY PART NUMBER DESCRIPTION

1 4 201560 BHCS, 1/4-20 X 0.500, 18-8 SS 2 4 201899 BHCS, 1/4-20 X 0.750, 18-8 SS 3 2 201561 BHCS, #6-32 X 0.375, 18-8 SS 4 1 EL-00006A OVERTEMP SWITCH

6 6 GM-05423-7 SPRING 18” 7 1 GM-07000 HEATER BLOCK 8 4 GM-07004 HEATER SPACER 9 2 GM-07005 HEATER MOUNT

10 2 HI-05011 6 ORB X 6 JIC 11* 2 HI-05020 THERMOCOUPLE NUT 12* 2 HI-05021 E TYPE THERMOCOUPLE

13 4 HI-05033 8 ORB PLUG

14 6 HI-05034 12 ORB PLUG

15 2 HI-05318 6 ORB X 6 JIC 45 DEGREE

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

PREHEATER ASSEMBLY

PH-21 (3750W) PH-22 (4500W) PH-23 (5250W)

6 GM-05423-1250 FIRE ROD, 1250W, 3/4 NPT, 17.5” 6 GM-05423-1500 FIRE ROD, 1500W, 3/4 NPT, 17.5” 6 GM-05423-1750 FIRE ROD, 1750W, 3/4 NPT, 17.5”

* Indicates part included in KT-05021: Heater Thermocouple Kit

REVISION 1.1 77

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 35: Heater Assembly, 8 Rod - A

Figure 36: Heater Assembly, 8 Rod - B

REVISION 1.1 78

POLYURETHANE MACHINERY CORPORATION

ITEM QTY PART NUMBER DESCRIPTION

1 4 201560 BHCS, 1/4-20 X 0.500, 18-8 SS 2 4 201899 BHCS, 1/4-20 X 0.750, 18-8 SS 3 4 201561 BHCS, #6-32 X 0.375, 18-8 SS 4 2 EL-00006A OVERTEMP SWITCH

6 8 GM-05423-7 SPRING 18” 7 4 GM-07004 HEATER SPACER 8 2 GM-07005 HEATER MOUNT

9 1 GM-07006 8 ROD HEATER BODY 10* 2 HI-05020 THERMOCOUPLE NUT 11* 2 HI-05021 E TYPE THERMOCOUPLE

12 6 HI-05033 8 ORB PLUG 13 8 HI-05034 12 ORB PLUG 14 2 HI-05036 1/4 NPT FLUSH SEAL PIPE PLUG 15 4 HI-05352 8 ORB X 6 JIC

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

PREHEATER ASSEMBLY

PH-33 (7000W)

8 GM-05423-1250 FIRE ROD, 1250W, 3/4 NPT, 17.5” 8 GM-05423-1500 FIRE ROD, 1500W, 3/4 NPT, 17.5” 8 GM-05423-1750 FIRE ROD, 1750W, 3/4 NPT, 17.5”

* Indicates part included in KT-05021: Heater Thermocouple Kit

REVISION 1.1 79

POLYURETHANE MACHINERY CORPORATION

15. PARTS IDENTIFICATION

15.14 MOTOR-LINE ASSEMBLY (1 PHASE)

PHDX-2 SERVICE MANUAL

Figure 37: Motor-Line Assembly - 1 Phase

REVISION 1.1 80

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

MOTOR-LINE ASSEMBLY (1 PHASE)

ML-2 (3HP, 1PH, 60HZ) ML-3 (5HP, 1PH, 60HZ)

ITEM QTY PART NUMBER DESCRIPTION

1 8 201620 SHCS, 3/8-16 X 1.500, 18-8 SS 2 10 201628 WASHER, LOCK, 3/8, 18-8 SS 3 4 201629 WASHER, FLAT, 1/2, 18-8 SS 4 4 201630 WASHER, LOCK, 1/2, 18-8 SS 5 2 202152 HHCS, 3/8-16 X 1.000, ZP GRD8 6 4 202207 HHCS, 1/2-13 X 1.25, ZP GRD8

8 1 HI-00005-03 ACCESS COVER

9 1 HI-00049A 1X16 BLACK PIPE FOR HYDRAULIC 10 1 HI-00065-01 COUPLER INSERT 11 1 HI-00065-02 COUPLER HUB, 1 1/8 12 1 HI-00065-03 COUPLER HUB, 3/4 13 1 HI-05001 BELL HOUSING 14 1 HI-05004 HYDRAULIC PUMP 15 1 HI-05004-1 CONTROL KNOB, HYD PUMP 16 1 HI-05007 6 ORB X 6 JIC 90 DEGREE 17 1 HI-05008 1-1/16-12 O-RING X 3/4 JIC 18 1 HI-05009 1-1/16-12 OUTLET FLANGE 19 1 HI-05010 1” NPT INLET FLANGE

1 EL-05221 ELECTRIC MOTOR, 3HP, 1PH, 60HZ (ML-2) 1 EL-05222 ELECTRIC MOTOR, 5HP, 1PH, 60HZ (ML-3)

REVISION 1.1 81

POLYURETHANE MACHINERY CORPORATION

15. PARTS IDENTIFICATION

15.15 MOTOR-LINE ASSEMBLY (3 PHASE)

PHDX-2 SERVICE MANUAL

Figure 38: Motor-Line Assembly - 3 Phase

REVISION 1.1 82

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

MOTOR-LINE ASSEMBLY (1 PHASE)

ML-2 (3HP, 1PH, 60HZ) ML-3 (5HP, 1PH, 60HZ)

ITEM QTY PART NUMBER DESCRIPTION

1 8 201620 SHCS, 3/8-16 X 1.500, 18-8 SS

2 10 201628 WASHER, LOCK, 3/8, 18-8 SS

3 4 201629 WASHER, FLAT, 1/2, 18-8 SS

4 4 201630 WASHER, LOCK, 1/2, 18-8 SS

5 2 202152 HHCS, 3/8-16 X 1.000, ZP GRD8

6 4 202207 HHCS, 1/2-13 X 1.25, ZP GRD8

8 1 HI-00005-03 ACCESS COVER

1 EL-05224 ELECTRIC MOTOR, 3HP, 3PH, 60HZ (ML-1) 1 EL-05223 ELECTRIC MOTOR, 5HP, 3PH, 60HZ (ML-4)

REVISION 1.1 83

POLYURETHANE MACHINERY CORPORATION

15.16 FINAL ASSEMBLY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 39: PHDX-2 Final Assembly - A

REVISION 1.1 84

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 40: PHDX-2 Final Assembly - B

Figure 41: PHDX-2 Final Assembly - C

REVISION 1.1 85

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 42: PHDX-2 Final Assembly - D

REVISION 1.1 86

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

PHDX-2 FINAL ASSEMBLY (HIGH PRESSURE)

ITEM QTY PART NUMBER DESCRIPTION

1 2 201057 NUT, HEX #8-32

2 30 201060 WASHER, LOCK, 1/4, 18-8 SS

3 1 201242 LIGHT UNIT, RED, 120VAC

4 2 201243 LIGHT UNIT, WHITE, 120VAC

5 4 201529 FHCS, 1/4-20 X 0.750, 18-8 SS

6 1 201546 CONSOLE ASSY, 1PH, 220V, PHD(X)-2

7 1 201567 FAN, DC BRUSHLESS, 24VDC

8 4 201580 WASHER, FLAT, 5/16, 18-8 SS

9 12 201581 HHCS, 1/4-20 X 0.750, 18-8 SS 10 2 201586 SHCS, #8-32 X 1.75, 18-8 SS 11 22 201621 WASHER, FLAT, 1/4, 18-8 SS 12 10 201627 WASHER, FLAT, 3/8, 18-8 SS 13 10 201628 WASHER, LOCK, 1/8, 18-8 SS 14 1 201883 INLET MONITORING KIT, FLOW METERS 15 8 201899 BHCS, 1/4-20 X 0.750, 18-8 SS 16 2 201920 COVER, FAN, 92MM 17 22 201930 HHCS, 1/4-20 X 1.000, ZP GRD8 18 4 202145 WASHER, LOCK, 5/16, 18-8 SS 19 6 202152 HHCS, 3/8-16 X 1.000, ZP GRD8 20 1 202173 CONSOLE ENCLOSURE, TOP, PHD(X)-2 21 30 202191 BHCS, #8-32 X 0.250, 18-8 SS 22 4 202201 BHCS, #8-32 X 0.875, 18-8 SS 23 4 202202 BHCS, #10-24 X 0.3125, 18-8 SS 24 4 202203 SHCS, #10-24 X 2.000, 18-8 SS 25 4 202204 HHCS, 5/16-18 X 0.875, 18-8 SS 26 4 202205 BHCS, 3/8-16 X 2.500, 18-8 SS 27 1 CL-03004 HEATER COVER TOP 28 1 CL-03005 HEATER COVER FRONT 29 2 CL-03006 HEATER COVER ENDS 30 1 CL-03007 THERMOCOUPLE COVER 31 2 CL-03009 HEATER HOLE COVER 2 32 4 EL-00052 SOLENOID VALVE CONNECTOR 33 4 EL-00053 SOLENOID VALVE GASKET 34 1 EL-00118A-00-1 HOSE BREAKER MOUNTING PLATE 35 2 EL-05220-01 CONSOLE KNOBS 36 1 EL-05225 90V TRANSFORMER 37 1 EL-05230-03 RT ANGLE CONDUIT CONNECTOR 38 1 EL-05237 THERMOCOUPLE HARNESS 39 1 EL-150 CIRCUIT BREAKER 63AMP 40 4 EL-158 MICRO CORDSET 90 DEGREE

REVISION 1.1 87

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

ITEM QTY PART NUMBER DESCRIPTION

41 1 EL-192 TERMINAL BLOCK 42 1 EL-193 INRUSH CURRENT LIMITER 43 2 EL-195 0-5000 PRESS TRANSDUCER 44 1 EL-35 HOSE HEAT RELAY 45 1 EL-35-1 HEAT SINK 46 1 EL-37 TRANSFORMER, SIGNAL 47 2 EL-42-3200 PRESSURE SWITCH 48 1 FR-10 FRAME ASSY, PH-2 49 2 HI-00035 PRESSURE GAUGE 0-5000 PSI 50 1 HI-05003 DIRECTIONAL VALVE 51 4 HI-05011 6 ORB X 6 JIC 52 2 HI-05304 HYD CYLINDER TUBE 53 1 HI-05335 HYDRAULIC MANIFOLD ASSY 54 2 HI-05342 #12 JIC X 1/2 NPTM 90 DEG 55 1 HI-05343 EXIT MANIFOLD ASSY, PH2/PHX 56 2 HI-05347 3/8 NPT X 6 JIC 90 DEGREE 57 2 HI-05351 PRESSURE MANIFOLD 58 2 HOSE HEAT WIRE HOSE HEAT WIRE 59 2 KT-00029A-1 HOSE HEAT, CONNECTOR BODY 60 1 ML-4 MOTORLINE ASSY, 5HP, 3PH, 60HZ 61 1 MQ-01009-01A LUBE BOTTLE 62 1 MQ-01009-02A LUBE BOTTLE LID 63 1 PH-33 8 ROD HEATER ASSY, PH(X)-2 64 1 PL-10 PUMP-LINE, PHX-2 65 2 PU-07000 CLEAR PUMP COVER 66 4 FEMALE SWIVEL FITTING 3/8 X 9/16-18 UNF 67 1 RA-00066A CBMB 90 DEG MALE ELBOW NPT 68 1 RA-00067A CBMB 90 DEG MALE ELBOW NPT 69 1 RA-00068A CHECK VALVE 70 1 RA-06008 CHECK VALVE, POLYTUBE, 3/8 71 1 RM-212 TRANSFORMER DOOR 72 1 RM-222 TRANSFORMER BRACKET 73 2 RM-243 PROX SENSOR MOUNTING ASSY 74 1 TN-04196 HOSE CLAMP 75 1 YS-6-PHX ”A” INLET MANIFOLD ASSY 76 1 YS-7-PHX ”R” INLET MANIFOLD ASSY

REVISION 1.1 88

POLYURETHANE MACHINERY CORPORATION

15.17 PHDX-2 HOSES

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 43: Proportioner Hoses - Front

Figure 44: Proportioner Hoses - Back

REVISION 1.1 89

POLYURETHANE MACHINERY CORPORATION

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

PROPORTIONER HOSES

ITEM QTY PART NUMBER DESCRIPTION

1 2 HI-05047-2 HOSE 9” HYD PUMP TO TANK 2 2 HI-05340-1 HOSE ASSY, PHX-2 3 2 HI-05047-6 HOSE 13” TOP PUMP CYL TO LEFT M 4 2 HI-05047-7 HOSE ASSY HYDRAULIC PUMP TO TA 5 1 HI-05047-8 HOSE ASSY 6 1 HI-05013 HYD TANK RETURN HOSE 1/2 X 2 7 1 HI-05047-4 HOSE 13” TOP PUMP CYL TO LEFT

15.17.1 HALF INCH HOSE KIT

HALF INCH HOSE KIT (200599)

PART NUMBER DESCRIPTION QTY

200600 6 ORB X 8 JIC 1 200601 6 ORB X 10 JIC 1 200602 6 ORB X 8 JIC 90 DEG 1

200603 6 ORB X 10 JIC 90 DEG 1 RA-00019 JIC REDUCER 7/8-14 X 9/16-18 1 RA-00020 JIC REDUCER 3/4-16 X 1/2-20 1

REVISION 1.1 90

POLYURETHANE MACHINERY CORPORATION

15.18 LUBE BOTTLE COMPONENTS

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 45: Lube Bottle Assembly

LUBE BOTTLE ASSEMBLY

ITEM QTY PART NUMBER DESCRIPTION

1 1 MQ-01009-01A LUBE BOTTLE 2 1 MQ-01009-02A LUBE BOTTLE LID 3 1 MA-00024A 1/2” X 3’ PLASTIC TUBING, SUPPLY 4 1 MA-00025A 3/8” X 3’ PLASTIC TUBING, RETURN 5 1 RA-00068A CHECK VALVE 6 1 RA-06008 CHECK VALVE (PHX-2 ONLY)

- 1 GP-00960-1-GAL PUMP LUBE GALLON

- 1 GP-00960-1-QRT PUMP LUBE QUART

REVISION 1.1 91

POLYURETHANE MACHINERY CORPORATION

15.19 EXIT MANIFOLD ACCESSORY

PHDX-2 SERVICE MANUAL

15. PARTS IDENTIFICATION

Figure 46: In-Plant Option

Figure 47: In-Trailer Option

Figure 48: Exit Manifold Accessory

EXIT MANIFOLD ACCESSORY

ITEM QTY PART NUMBER DESCRIPTION

1 2 HI-05011 6 ORB X 6 JIC 2 2 EL-00051A-5 1/4 NPT X 6 SWIVEL 3 2 GP-00100-2 BALL VALVE 1/4 5000 PSI 4 1 EL-00051A-4 1/4 NPT X 5 JIC 5 1 EL-00051A-6 1/4 NPT X 6 JIC 6 2 HI-05007 6 ORB X 6 JIC 90 DEG 7 1 200226 5 JIC CAP 8 1 200227 6 JIC CAP

REVISION 1.1 92

PMC PHDX-2, PHD-2 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual