PMC PHDX-2, PHD-2 Service Manual
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
REVISION 1.1 1
POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
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
REVISION 1.1 2
POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
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
REVISION 1.1 3
POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
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
REVISION 1.1 4
POLYURETHANE
MACHINERY
CORPORATION
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
POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
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
POLYURETHANE
MACHINERY
CORPORATION
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
POLYURETHANE
MACHINERY
CORPORATION
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
POLYURETHANE
MACHINERY
CORPORATION
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
REVISION 1.1 10
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
REVISION 1.1 11
POLYURETHANE
MACHINERY
CORPORATION
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
REVISION 1.1 12
POLYURETHANE
MACHINERY
CORPORATION
5 DESCRIPTION
PHDX-2 SERVICE MANUAL
5. DESCRIPTION
Figure 3: Component Identification - Front
REVISION 1.1 13
POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
5. DESCRIPTION
Figure 4: Component Identification - Back
REVISION 1.1 14
POLYURETHANE
MACHINERY
CORPORATION
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
9)
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.
(c) Securely tighten the Socket Head Set Screw.
(d) Install electrical tape around Connector Body.
NOTE! A good practice is to add some dielectric grease
(Permatex 67VR or equivalent) to the outside of the
Terminal, where the electrical connection is made, prior
to insertion.
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
Loading...