PH-20/PHX-20
Proportioner
Manual
Ref. # MN-04007
JUNE 1, 2013
Polyurethane Machinery Corp.
Corporate: 1 Gusmer Drive, Lakewood, NJ 08701
Manufacturing: 2 Gusmer Drive, Lakewood, NJ 08701
Phone: 732-415-4400 Fax: 732-364-4025
http://www.polymac-usa.com
Before installing the PH Series Proportioner and start-up, carefully read all the technical
and safety documentation included in this manual. Pay special attention to the
information in order to know and understand the operation and the conditions of use of
the PH Series Proportioner. All of the information is aimed at improving user safety and
avoiding possible breakdowns from the incorrect use of the PH Series Proportioner
PH-20/PHX-20 Manual
Warranty ……………………………………………………………………………………….. 3
Safety and Handling …………………………………………………………………………. 5
Characteristics
Principal Heating System …………………………………………………………………. 7
Hose Heating System ……………………………………………………………………… 7
Double Acting Piston Metering Pumps …………………………………………………… 7
Technical Specifications
Electrical ……………………………………………………………………………………… 8
Mechanical …………………………………………………………………………………… 8
Description ……………………………………………………………………………………… 9
Installation ………………………………………………………………………………………. 14
Proportioner Purging………………………………………………………………………….. 20
Digital Temperature Controller………………………………………………………………. 22
Start-Up ……………………………………………………………………….......................... 23
Shutdown Procedures ………………………………………………………………………. 25
Troubleshooting ……………………………………………………………………………… 26
Heaters ……………………………………………………………………………………… 27
Hydraulic Drive System……………………………………………………………………. 30
Metering Pump Line………………………………………………………………………... 33
Hose Heating ……………………………………………………………………………….. 37
Maintenance …………………………………………………………………………………… 41
Inlet Material Screens ……………………………………………………………………… 42
Hydraulic Drive System ……………………………………………………………………. 43
Metering Pump Line ………………………………………………………………………… 44
Material Heater ……………………………………………………………………………… 45
Hydraulic Oil Specification …………………………………………………………………... 47
Parts Identification …………………………………………………………………..………… 46
Replacement Kits ……………..………..…………………………………………………… 48
Machine Spare Parts ………..…………………………………..………..………………… 49
Hoses ………………………………………………………………………………………… 52
PHX20, 3000 PSI Pump Line-61 …………………………..………..………………....... 54
PH-20, 2000 PSI Pump Line-123…………………………………………………………. 56
Electrical Parts………………………………………………………………………………. 58
Electrical Schematics……………………………………………………………………….. 62
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PH-20/PHX-20 Manual
WARRANTY
Polyurethane Machinery Corporation (hereinafter “PMC”) provides this LIMITED WARRANTY
(hereinafter “Warranty”) to the original purchaser (hereinafter “Customer”) covering this equipment and
the original PMC manufactured accessories delivered with the equipment (hereinafter “Product”)
against defects in material or workmanship of the Product (hereinafter “Defect” or “Defective”) for a
period of one (1) year from the date of first purchase as shown on the original PMC invoice (hereinafter
“Warranty Period”).
If during the Warranty Period under normal use, the Product is suspected by Customer to be Defective
in material or workmanship, it is Customer’s responsibility to contact PMC and return the Product to
PMC as directed by PMC, freight prepaid. If PMC determines that the Product is Defective and that
such Defect is covered by this Warranty, PMC will credit Customer for the reasonable freight charges
incurred by Customer in returning the Defective Product to PMC, and PMC (or its authorized agent)
will, at PMC’s option, repair or replace the Product, subject to the following:
Original Invoice: The original invoice must be kept as proof of the date of first sale and the Product
serial number. The Warranty does not cover any Product if the Original Invoice appears to have been
modified or altered, or when the serial number on the Product appears to have been altered or
defaced.
Product Maintenance: It is the Customer’s responsibility to maintain the Product properly. See your
maintenance schedule and owner’s manual for details. The Warranty does not cover an improperly
maintained Product.
Non-PMC Components and Accessories: Non-PMC manufactured components and accessories that
are used in the operation of the Product are not covered by this Warranty. Such components and
accessories shall be subject to the warranty offered to the Customer, if any, by the original
manufacturer of such component or accessory.
Other Warranty Exclusions: The Warranty does not cover any Product that PMC determines has been
damaged or fails to operate properly due to misuse, negligence, abuse, carelessness, neglect, or
accident. By way of example only, this includes:
Normal wear and tear.
Improper or unauthorized installation, repair, alteration, adjustment or modification of the
Product.
Use of heating devices, pumping equipment, dispensers, or other parts or accessories with the
Product that have not been approved or manufactured by PMC.
Failure to follow the operating instructions and recommendations provided by PMC.
Cosmetic damage.
Fire, flood, “acts of God,” or other contingencies beyond the control of PMC.
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PH-20/PHX-20 Manual
WARRANTY (cont’d)
THE WARRANTY DESCRIBED HEREIN IS THE EXCLUSIVE REMEDY FOR THE
CUSTOMER AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED,
STATUTORY OR OTHERWISE, AND THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER
WARRANTIES ARE HEREBY DISCLAIMED. TO THE FULLEST EXTENT PERMITTED BY
LAW, PMC SHALL NOT BE RESPONSIBLE, WHETHER BASED IN CONTRACT, TORT
(INCLUDING, WITHOUT LIMITATION, NEGLIGENCE), WARRANTY OR ANY OTHER
LEGAL OR EQUITABLE GROUNDS, FOR ANY CONSEQUENTIAL, INDIRECT,
INCIDENTAL, LOST PROFITS, SPECIAL, PUNITIVE OR EXEMPLARY DAMAGES,
WHETHER TO PERSON OR PROPERTY, ARISING FROM OR RELATING TO THE
PRODUCT, EVEN IF PMC HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH LOSSES
OR DAMAGES.
Non-Warranty Service by PMC: If PMC determines that the suspected Defect of the Product is not
covered by this Warranty, disposition of the Product will be made pursuant to the terms and conditions
of PMC’s written estimate on a time and materials basis.
Continuing Warranty for Products Repaired or Replaced under Warranty: Following the repair or
replacement of a Product covered by this Warranty, such Product will continue to be subject to the
original Warranty for the remainder of original Warranty Period or for three (3) months from the repair
or replacement date, whichever is longer.
No Rights Implied: Nothing in the sale, lease or rental of any Product by PMC shall be construed to
grant any right, interest or license in or under any patent, trademark, copyright, trade secret or other
proprietary right or material owned by anyone; nor does PMC encourage the infringement of same.
Exclusive Warranty: This writing is the final, complete, and exclusive expression of the Warranty
covering the Product. Any statements made by PMC, its employees or agents that differ from the
terms of this Warranty shall have no effect. It is expressly understood that Customer’s acceptance of
this Warranty, by performance or otherwise, is upon and subject solely to the terms and conditions
hereof, and any additional or different terms and conditions proposed or expressed by Customer or
anyone, whether in writing or otherwise, are null and void unless specifically agreed to in writing by an
Officer of PMC.
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PH-20/PHX-20 Manual
SAFETY AND HANDLING
This chapter contains important information on the safety, handling and use of your
PH Series Proportioner.
Classic
Before installing the PH Series Proportioner and start-up,
carefully read all the technical and safety documentation
included in this manual. Pay special attention to the
information to know and understand the operation and the
conditions of use of the PH Series Proportioner. All of the
information is aimed at enhancing User Safety and avoiding
possible breakdowns derived from the incorrect use of the PH
Series Proportioner.
WARNING! presents information to alert of a situation that might cause serious
injuries if the instructions are not followed.
CAUTION! presents information that indicates how to avoid damage to the
Proportioner or how to avoid a situation that could cause minor injuries.
NOTE! is relevant information of a procedure being carried out.
Careful study of this manual will enable the operator to know the characteristics of the PH
Series Proportioner and the operating procedures. By following the instructions and
recommendations contained herein, you will reduce the potential risk of accidents in the
installation, use or maintenance of the PH Series Proportioner; you will provide a better
opportunity for incident-free operation for a longer time, greater output and the possibility of
detecting and resolving problems fast and simply.
Keep this 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, directly contact PMC or
on line at our web site (www.polymac-usa.com).
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PH-20/PHX-20 Manual
SAFETY AND HANDLING (cont’d)
The PH Series Proportioner has been designed and built for the application of polyurea chemical
systems, polyurethane foam chemical systems and some two-component epoxy systems.
WARNING! The design and configuration of the PH Series Proportioner does not
allow its use in potentially explosive atmospheres or the pressure and
temperature limits described in the technical specifications of this manual to be
exceeded.
Always use liquids and solvents that are compatible with the unit. If in doubt, consult PMC Technical
Service.
When working with the PH Series Proportioner, it is recommended that the operator wear suitable
clothing and elements of personal protection, including, without limitation, gloves, protective goggles,
safety footwear and face masks. Use breathing equipment when working with the PH Series
Proportioner in enclosed spaces or in areas with insufficient ventilation. The introduction and follow-up
of safety measures must not be limited to those described in this manual. Before starting up the PH
Series Proportioner, a comprehensive analysis must be made of the risks derived from the products to
be dispensed, the type of application and the working environment.
To prevent possible injury caused by incorrect handling of the raw
materials and solvents used in the process, carefully read the Material
Safety Data Sheet (MSDS)provided by your supplier.
Deal with the waste caused according to current regulations.
To avoid damage caused by the impact of pressurized fluids, do not open
any connection or perform maintenance work on components subject to
pressure until the pressure has been completely eliminated.
Use suitable protection when operating, maintaining or being present in
the area where the equipment is functioning. This includes, but is not
limited to, the use of protective goggles, gloves, shoes and safety clothing
and breathing equipment.
The equipment includes components that reach high temperatures and can
cause burns. Hot parts of the equipment must not be handled or touched
until they have cooled completely.
To prevent serious injury through crushing or amputation, do not work
with the equipment without the safety guards installed on the moving
parts. Make sure that all the safety guards are correctly reinstalled at the
end of the repair or maintenance work of the equipment
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PH-20/PHX-20 Manual
100% circumferential coverage produces the
most uniform distribution of heat available.
CHARACTERISTICS
The PH-20/PAX-20 Proportioner has been designed and built for the application of polyurea
chemical systems, polyurethane foam chemical systems and some specific two-component
epoxy systems.
Principal Heating System
The Proportioners consists of two (2) independent Material Heaters without internal seals. The
PH-20 Heater has Three (3) Heating Elements per heater rated at 1,250 watts each giving the
Proportioner a total heat of 7500 watts. The PHX-30 heater also has 3 Heating elements per
heater rated at 1500 watts each giving the proportioner a total heat of 9000 watts. Each heater
has the necessary controls and safety components for their precise operation. The Material
Heater design allows a temperature differential (ΔT) of 58º F and material application
temperatures of up to 190º F.
Hose Heating System
The system is designed with a 2 KVA Isolation Transformer that enables effective heating of
up to a total hose length of 210 feet. The system includes an innovative hose heating concept
in which the continuous braid tinned-copper jacket is distributed evenly around the
circumference of the hose providing a uniform heating watt density and precise control of the
material application temperature. This hose heating element design is extremely resistant to
fatigue failure.
Double Acting Piston Metering Pumps
The vertical double acting Pump Line is driven by a Hydraulic Cylinder. The in-line pump
system with vertical piston pumps provides a constant volume and ratio on both the up stroke
and down stroke. .
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PH-20/PHX-20 Manual
TECHNICAL SPECIFICATIONS
Electrical
Main Voltage: ______________________________________ 3 x 208-230V, 50/60Hz
Electrical Consumption: PH-20, 2000 PSI (2 x 3.75 kW Heaters) ___ 27 A @ 3 x 230V
Electrical Consumption: PHX-20, 3000 PSI (2 x 4.5 kW Heaters) ____32 A @ 3 x 230V
Main Voltage: ________________________________________ 1 x 208-230V, 50/60Hz
Electrical Consumption: PH-20, 2000 PSI (2 x 3.75 kW Heaters) _____ 58 A @ 1 x 230V
Electrical Consumption: PHX-20, 3000 PSI (2 x 4.5 kW Heaters) _____ 65 A @ 1 x 230V
Main Voltage: ____________________________________________ 3 x 380V, 50/60Hz
Electrical Consumption: PH-20, 2000 PSI (2 x 3.75 kW Heaters) _____ 23 A @ 3 x 380V
Electrical Consumption: PHX-20, 3000 PSI (2 x 4.5 kW Heaters) _____ 27 A @ 3 x 380V
Material Heater Power: PH-20 (2 x 3.75 kW) ______________________________ 7.5 kW
Material Heater Power: PHX-20 (2 x 4.5 kW) ______________________________ 9 kW
Hose Transformer Power: ___________________________________________ 2 KVA
Electrical Motor Power: ________________________________________________ 3 hp
CAUTION! Inside the console, is a Terminal Strip for connecting
the main power (wire not supplied) to the PH Series
Proportioner. This electrical connection must be made only by
a qualified electrician.
Mechanical
Maximum working pressure PH-20 (with 123 pumps): ______________________ 2,000 psi
Maximum working pressure PHX-20 (with 61 pumps): _____________________ 3,000 psi
Maximum production ratio 1:1 PH-20 (with 123 pumps): ____________________ 20 lb/min
Maximum production ratio 1:1 PHX-20 (with 61 pumps): _____________________ 1.3 gpm
Minimum production: ________________________________________________ 2 lb/min
Maximum hose length: _________________________________________________ 210 ft
Approximate weight (Hydraulic Tank empty): ______________________________ 365 lbs
Approximate weight (Hydraulic Tank full @ 12 gal): _________________________ 435 lbs
Dimensions: __________________________________________ 30in W x 26in D x 45in H
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PH-20/PHX-20 Manual
A
B
C
D
E
H
J
K
M
O
O
DESCRIPTION
A. Control Panel
Controls and regulates the operation of the PH Series Proportioner.
B. Isocyanate (Iso, A) Metering Pump
Meters the Isocyanate material.
C. Polyol (Poly, R) Metering Pump
Meters the Polyol material.
D. Isocyanate (Iso, A) Heater
Heats the incoming Isocyanate to a temperature set by the operator.
E. Polyol (Poly, R) Heater
Heats the incoming Polyol to a temperature set by the operator.
PH-20/PHX-20 Proportioners
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PH-20/PHX-20 Manual
N
G
F
I
L
F. Hose Heating Transformer – Right side, inside of hydraulic tank
Supplies the required voltage for material Heated Hoses.
G. Hydraulic Pressure Gage
Indicates the pressure in the Hydraulic Drive System.
H. Isocyanate (Iso, A) Pressure Gage
Indicates the pressure in the Isocyanate system.
I. Isocyanate (Iso, A) Safety Pressure Switch
Turns OFF the Directional Valve in the event of excessive pressure in the Isocyanate
system.
J. Isocyanate (Iso, A) Thermocouple
Provides temperature information of the Isocyanate to its Temperature Controller.
K. Polyol (Poly, R) Pressure Gage
Indicates the pressure in the Polyol system.
L. Polyol (Poly, R) Safety Pressure Switch
Turns OFF the Directional Valve in the event of excessive pressure in the Polyol system.
M. Polyol (Poly, R) Thermocouple
Provides temperature information of the Polyol to its Temperature Controller.
N. Hydraulic Pressure Control
Allows the pressure of the hydraulic system to be increased or decreased. Turn
clockwise to increase the pressure and counterclockwise to decrease. To regulate the
pressure of the hydraulic system, the NORMAL or RETRACT Pump Switch position
must be selected.
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PH-20/PHX-20 Manual
O. Inlet Material Strainer
Screens (60 mesh) material from bulk supply.
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PH-20/PHX-20 Manual
MODEL
PUMP SIZE
CYCLES PER GALLON
PH-20, 2000 PSI
123
23
PHX-20, 3000 PSI
61
47
R
P
Q
R U W
Y
Z
S S S
T
T
T
V
DESCRIPTION (cont’d)
Figure 3
Control Panel
P. 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.
Q. Emergency Stop - Interrupts the PH- Series control power circuit to stop all motion
and heating.
R. Control Power - Turns ON and OFF the control power to the complete electrical
circuit including Heaters and Hose Heater.
S. Heater Temperature Switch - A (Iso), R (Poly), HOSE - Turns ON and OFF power
to the specific Heaters and Hose.
T. Controllers – Displays the temperature of the chemicals. See page 22 for detailed
Temperature Controller instructions.
U. Totalizer – Indicates the number of pump cycles to calculate material usage.
V. Auto Shut Down Switch - Turns ON and OFF power to the Auto Shut Down unit.
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PH-20/PHX-20 Manual
W. Auto Shut Down Counter
Used to set the amount of cycles required to prevent the chemical drums from running
dry, the machine will shut down when the preset cycles expire. There is an on/off
switch to activate this feature or deactivate and not use it, see page 24.
X. Motor Switch - Turns ON and OFF the Electric/Hydraulic Motor. When turned ON,
the pilot will light. In the event of an overload of the Motor, pilot light will turn OFF and
Motor will stop.
Y. Pump Switch
Off - Removes power from the pump circuit. The directional indicator lights will not be
lit.
Normal - Activates the normal operation of the machine. When the switch is ON, the
directional light corresponding to the stroke direction will light.
Retract - Sets the Piston Rod of the Iso (A) metering pump to the down position and
prevents the crystallization of Iso (A) on the Piston Rod. Press the RETRACT key
every time the unit is stopped by the operator (see Shut-Down, page 25).
Z. Direction Indicator Light - Indicates the movement direction of the Metering Pumps.
If excessive pressure is caused in the system, the pump circuit will be disabled and the
directional lights will be OFF.
.
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PH-20/PHX-20 Manual
L1
L2 L3
L2
L1
3 phase x 230 Volt
LLL
N
INSTALLATION
WARNING! Use suitable protection and follow the recommendations in the
Safety Information enclosed and provided by material suppliers when installing
or working with the Proportioner.
Inside the console is a Terminal Strip for connecting the incoming power cable (not
supplied). The electrical connection of the Proportioner must be carried out by a qualified
electrician.
NOTE! To ensure the PH-20 Series Proportioner works correctly, the
electrical supply must meet the specifications indicated on the Serial Number
Placard affixed to the Electrical Console.
CAUTION! Make sure the power cable is disconnected from the main power
source before connecting to the Terminal Strip in the Console.
1 phase x 230 Volt 3 phase x 380 Volts
Follow the recommended procedure in the indicated order to install the Proportioner:
1. Insert the main power cable by passing it through the wire stop at the bottom of the
Electrical Console and connect as shown in the above diagram.
2. Fill the reservoir with the recommended hydraulic oil. To fill remove the screws from
the tank cover and rotate the cover, be careful not to damage the gasket. See page
47 for oil specifications.
Tank cover
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PH-20/PHX-20 Manual
NOTE! Do not fill the tank to maximum capacity; Make sure the amount
of hydraulic fluid is not more than 12 gal or 80% of the tank maximum
capacity.
3. Check the level of the hydraulic fluid in the Hydraulic Pump Case: Disconnect the
Hydraulic Hose from the 90 fitting and remove Fitting from Hydraulic Case. Add fluid
as required. Reattach Fitting and Hydraulic Hose. Turn the hydraulic pressure control
knob counter clockwise until it stops, that is the lowest hydraulic pressure setting.
Check Fluid Level Hydraulic Pressure control Knob
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PH-20/PHX-20 Manual
INSTALLATION (cont’d)
ENSURE THAT THE EMERGENCY (E-STOP) STOP IS NOT ENERGIZED
4. Three-phase Proportioner Only: Check the Electric Motor to ensure rotation is
clockwise. Remove the inspection cover from the motor bell housing when
viewing the end of the Electric Motor. A counter clockwise rotation indicates two of the
incoming power leads need to be reversed.
CAUTION! Ensure Main Power switch is OFF and incoming power is locked
OFF before reversing power leads.
Recheck the rotation before proceeding with Installation (3 Phase only).
Heated Hose Installation
CAUTION! The material delivery Heated Hoses are color coded Red and
Blue allowing the user to recognize them. The Red corresponds to the
Isocyanate (Iso, A) and the Blue to the Polyol (Poly, R). To avoid connection
errors the Coupling Connections of the Iso (A) and Poly (R) Heated Hoses
are also different sizes, which makes it difficult to swap connections.
NOTE! The material delivery Heated Hoses are caped 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 required for this tapered
seat Coupling Connections.
2. Connect the material Heated Hoses to the outlets of the respective Heaters i.e. Iso (A)
Heated Hose to the Iso (A) Heater and the Poly (R) Heated Hose to the Poly (R)
Heater ensuring Heated Hose assemblies lay flat.
3. Connect Air Hose Coupling Connections.
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PH-20/PHX-20 Manual
Fast-Lock Connection
EL-51A
TSU Assembly
EL-51A-2
Sensor Replacement
INSTALLATION (cont’d)
Heated Hose Installation (cont’d)
4. Connect the Heated Hose power wires to the “Fast-Lock”
Connector 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 prior to insertion.
Repeat the above steps to connect the “Fast-Lock” Connectors that you will find on all
Heated Hose power wire.
CAUTION! Ensure the proper mechanical and electrical connections of the
Heated Hoses are made to avoid possible material leakage and Hose heat
problems.
5. It is recommended the TSU be installed between the last section of Heated Hose and
the Gun Whip. Carefully straighten the sensing wire, inserting it in the Iso (A) Heated
Hose and tighten fluid fittings with appropriate sized open-end wrenches.
CAUTION! To protect the TSU sensor, you must pay special attention not to
kink or excessively bend the Heated Hoses. Do not coil the Heated Hoses
with a diameter of less than 4 feet.
CAUTION! Connecting the TSU between the first and second section of
Heated Hose results in the TSU sensing the material temperature exiting the
Heater and not the inside of the Heated Hose near the Spray Gun.
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PH-20/PHX-20 Manual
Tap
Length
72v
210’
54v
160’
36v
110'
18v
60’
Hose Heater
Transformer
INSTALLATION (cont’d)
Hose Heat Transformer
The Hose Heat Transformer offers the ability of connecting to different output voltages
depending on the total length of the Heated Hose in use, maximizing the heating ability of
the Heated Hose. The factory setting is 18 volts for use with 60 feet of Heated Hose.
Before starting the Proportioner, ensure the setting matches the Heated Hose length
installed. If Heated Hose sections are added or removed, the Tap setting should be
changed to a setting which will limit the maximum amperage in the Heated Hose to 52
amps. The suggested settings are tabled below:
6. Ensure the Manual Valves are CLOSED and connect the Coupling Block to the Heated
Gun Whip.
CAUTION! Excessive force closing or opening the Manual Valves may result
in damage to the Manual Valves and/or Coupling Block.
7. Connect the Transfer Pump/ Heated Hose Assemblies/ Air Supply and Air Dryer
systems as required. Review the Installation Instructions for each to ensure proper setup and operation.
8. Install the Material Transfer Pumps as follows:
WARNING! If Transfer Pumps have been previously used, pay special
attention to connect each Pump to “its” specific material. Inadvertently
changing the Transfer Pumps will cause a chemical reaction rendering them
useless.
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PH-20/PHX-20 Manual
INSTALLATION (cont’d)
NOTE! Placing a tape of the same color as of the Material Delivery Hoses (red
for the Iso (A), blue for the Poly (R)) on each Transfer Pump would be a good
method for minimizing errors in connection.
a. Make sure that the Inlet Valves on the Proportioner are closed.
b. Connect one end of the Polyol (R) Material Delivery Hose (¾” thread)
to the Proportioner Polyol (R) Inlet Valve and the other end to the
Polyol (R) Transfer Pump.
c. Connect one end of the Iso (A) Material Delivery Hose (½” thread) to the
Proportioner Iso (A) Inlet Valve and the other end to the Iso Transfer Pump.
d. Connect the air hose to the Transfer Pumps after ensuring each Transfer Pump
Shut-Off Valve is CLOSED.
NOTE! To avoid errors in connection, the Coupling connections of the Iso (A)
and Poly (R) Material Delivery Hoses are different sizes, making it difficult to
swap connections.
e. Ground the Transfer Pump as recommend by the material supplier. The movement
of product inside the Hoses can cause static electricity and produce electrical
discharges.
f. Connect air to the air line coming off the first section of hose (90-110 psi).
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PH-20/PHX-20 Manual
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.
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.
2. Slowly OPEN the Poly (R) Transfer Pump Air Shut-Off Valve allowing Pump to cycle
slowly as it fills the Material Delivery Hose to the Proportioner. Check for leaks.
3. OPEN Poly (R) Coupling Block Manual Valve over a waste container.
4. Slowly OPEN Proportioner Poly (R) Inlet Valve allowing Transfer Pump to move material
through the system. When all spitting of air stops and all traces of mineral oil have
disappeared, CLOSE Poly (R) Coupling Block Manual Valve. Clean Coupling Block.
5. Repeat steps 2 to 4 for Iso (A) side.
CAUTION! Properly dispose of all waste chemicals in accordance with all
applicable local, state and federal codes. DO NOT turn on the Auto countdown
switch.
6. Turn Hydraulic Pressure Control [ N, page10] full COUNTERCLOCKWISE.
7. Turn ON Main Power [P, page 12]. Green pilot will light.
8. Turn ON Control Power [R, page 12]. Switch will light.
9. Turn ON Motor Power [X, page 12]. Switch will light.
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PH-20/PHX-20 Manual
10. Set Pump Switch [Y, page 12] to NORMAL. Turn Hydraulic Pressure Control
CLOCKWISE increasing material pressure to 400 psi. Both Material Pressure Gauges
[H, K, page 9] should read the same. Check all Heated Hose Coupling connections for
leakage.
11. Check all TSU and “Fast-Lock” connections for leaks.
12. Bundle all Heated Hose Connections ensuring that there are NO kinks in the TSU
Cable or Air Hose. Wrap with Electrical Tape to securely hold all components in place
and minimize places for bundle to snag onto job site protrusions.
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PH-20/PHX-20 Manual
DIGITAL TEMPERATURE CONTROLLER
The PH-20/PHX-20 Series has three (3) Digital Temperature Controllers to manage the temperatures for the
Primary Heaters and the Heated Hose. The Hose Heater Controller is programmed different from the
heater Controllers and therefore not interchangeable with them.
WARNING! Do not turn the Temperature Controllers ON until the Proportioner Purging procedure
is complete and the Primary Heaters and Heated Hoses are filled with material.
1. Ensure Main Power [P, page 12] and Control Power [R, page 12] is ON.
2. Press and release or button. The display will flash and indicate its current set point.
3. Press and hold the or to increase or decrease the material temperature set-point to the
desired value as determined by the material supplier or application conditions.
4. Once the set point is entered the controller will go back to ambient temperature on its own.(5-8 seconds)
WARNING! The Controllers are factory programmed and are not field re-
programmable. If a problem is encountered, contact PMC Technical Service.
Do not attempt to change any of the programmed parameters. Do not
substitute a Controller from an alternate supplier as its use may result in
equipment damage and/or bodily injury.
NOTE! The Temperature Controller normally displays the actual material
temperature. When lit, the red “OUT” display in the upper left indicates power
is being sent to the Heater. The “OUT” display goes out when the material
temperature has reached its set-point. The “OUT” display will continue to
cycle on and off indicating the Controller is maintaining the material
temperature set-point.
22
PH-20/PHX-20 Manual
START-UP
NOTE! Follow the recommended procedure in the order shown.
CAUTION! The Start-up procedures assume that all of steps in Proportioner
purging have been performed and no problems 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 (Material 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 [P page 12].
6. Turn ON Control Power [R, page 12].
7. Turn ON Hose [S, page 12]. Heater 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.
8. Turn ON each Primary Heater and confirm material set-point temperature as required by
the material supplier or application conditions has been reached.
9. Turn ON Motor Power [X, page 12].
10. Set Pump Switch [Y, page 12] to NORMAL. One of the Directional Indicator Lights [Z,
page 12] will light indicating Metering Pump direction and the Metering Pump Shafts will
begin to move.
NOTE!
a. The Material Pressure Gauges [H, K, page 9] should be approximately equal and
remain constant throughout Metering Pump cycle. If not, refer to Trouble Shooting
section.
b. Directional Indicator Lights must indicate Metering Pump direction when Pump
Switch is in the NORMAL position. If not, refer to Trouble Shooting section.
11. Using the Hydraulic Pressure Control, adjust to the required stall pressure and check
each Material Pressure Gauge.
. Stall pressure: When materials are at recommend application temperature and Metering
Pumps are pressurized but not moving. This pressure is normally 100 – 200 psi greater than
the developed spray pressure as recommended by the material supplier.
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PH-20/PHX-20 Manual
MODEL
CYCLES PER GALLON
PH-20, 2000 PSI
123 pumps 23 cycles = 1 gallon
PHX-20, 3000 PSI
61 pumps 47 cycles = 1 gallon
12. AUTO SHUT DOWN COUNTER
If this function is not needed leave it in the off position.
To set the Auto Shut Down Counter:
a. Turn the switch to the on position, the green light will illuminate.
b. Insert the number of cycles desired to disable the PH machine by pushing in on the
white triangles to set the cycle count. Push in on the red button until the data is
replicated on the top row, the top row will count down. Figure B
c. When the counter counts down to zero the machine will stop and the pump
directional light will be off, push in on the red button to reset. Figure C
PR 2 Gray Red Countdown Red machine stops
Figure A Figure B Figure C
13. Proceed with Installation and Start-up of the Spray Gun as per the Gun manual.
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PH-20/PHX-20 Manual
SHUT-DOWN
Follow the recommended procedure in the indicated order for Proportioner temporary shutdown such as lunch breaks.
1. Set Pump Switch [Y, page 12] to OFF position.
2. Turn each Heater OFF. Hose Heater should remain ON. Never leave Proportioner
ON if unattended.
3. CLOSE Spray Gun Manual Valves.
CAUTION! Excessive force opening or closing the Manual Valves may result
in damage to the Manual Valves and/or Coupling Block.
Follow the recommended procedure in the indicated order for Proportioner shut-down when
work is stopped for the day.
1. Set the Pump Switch [Y, page 12] to RETRACT.
2. Spray off the application surface until Material Pressure Gauges [H, K, page 9]
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.
3. CLOSE the Spray Gun Coupling Block Manual Valves.
CAUTION! Excessive force opening or closing the Manual Valves may result
in damage to the Manual Valves and/or Coupling Block.
4. Turn OFF Motor Power [P, page 12].
4. Turn OFF the A and R Heaters and Hose Heater [S, page 12].
5. Turn OFF the Control Power [R, page 12].
6. Turn OFF the Auto Shut down switch [V, page 12].
7. Turn OFF the Main Power [P, page 12].
8. Apply grease to the “A” side grease fitting located on the pumps packing retainer.
9. Disconnect the air supply to the two Transfer Pumps and CLOSE the Proportioner
Material Inlet Valves.
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PH-20/PHX-20 Manual
TROUBLESHOOTING
The PH 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 PH Series Proportioner. The information provided will serve as a
guideline to detect and resolve problems. In any case, feel free to contact the Technical
Service group of PMC, where a qualified technician will advise you.
WARNING: Only qualified personnel should perform troubleshooting,
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 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.
26
PH-20/PHX-20 Manual
Material Heater
TROUBLESHOOTING
Heaters
WARNING! Only qualified personnel should perform troubleshooting,
unqualified personnel may cause damage to the unit 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 the Limit Switch will shut off
the Heater power. The Limit Switch will not re-set until the temperature in the
Heater is below 190 F. The system is designed that in case of an over
temperature a contactor located in the console will open disabling power to
both Heaters and the Hose.
Follow the recommended procedure in the indicated order to solve the problem and
avoid unnecessary repairs. Make sure all Switches are in the correct position and
Indicator Lights ON before determining the existence of a fault.
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PH-20/PHX-20 Manual
TROUBLESHOOTING
Heaters (cont’d)
PROBLEM
Primary heater does not heat and the display on the controller shows 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 to the next step.
2. Check the heater breaker in the main console, 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.
3. 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 relay 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 a LED light is lit on the relay.
If there is no LED light on the solid state relay move to the next step.
4. With 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 46 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.
5. Using a DC volt meter measure across position 9 and 10 on the back of the heater
controller. This is the output of the controller and sends power to the solid state
relay; your reading will be 4-6 volts DC. If there is no reading check to make sure
that the set temperature of the controller is above the actual temperature reading
on the controller. Before replacing the controller read across position 1 and 2 to
make sure that the controller is powered up, your reading will be 208 to 230 volts
AC. If there is no voltage detected; check for loose wires or a malfunction of the
heater circuit breaker.
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PH-20/PHX-20 Manual
TROUBLESHOOTING
Heaters (cont’d)
PROBLEM
Primary heater does not heat and the display on the controller shows an error message
EEEE
SOLUTIONS
1. Check position 6 and 7 on the heater controller for loose wires.
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.
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.
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PH-20/PHX-20 Manual
MODEL
INDIVIDUAL OHMS MEASUREMENT
PH-20, 2000 PSI
1250 WATT
37 OHMS
PHX-20, 3000 PSI
1500 WATT
31 OHMS
TROUBLESHOOTING
CAUTION! If the rod that is used in conjunction with the thermocouple is
defective do not operate the heater until the rod is replaced.
Hydraulic Drive System
Follow the recommended procedure in the indicated order to solve the problem and
avoid unnecessary repairs. Make sure all Switches are in the correct position and
Indicator Lights ON before determining the existence of a fault.
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 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.
CAUTION! Do not attempt to reset the Motor Contactor more than twice.
Failure of the Motor Contactor safety mechanism will occur and the Contactor
will become inoperable and/or the Motor damaged. The cause of the problem
must be determined and corrected.
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PH-20/PHX-20 Manual
Motor Contactor
PROBLEM
Hydraulic Pump does not develop pressure and the electric motor is not running.
SOLUTIONS
1. 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.
PROBLEM
Hydraulic Pump does not develop pressure
SOLUTIONS
1. Hydraulic Power Package
NOTE! Hydraulic pressure is not generated if the Motor Power Switch [X, page
12] is OFF or the Pump Switch [Y, page 12] is in the OFF position.
With the Pump Switch in the NORMAL position, the failure of the Hydraulic Pump to
develop pressure is loss of pump suction (prime). To ensure positive prime, check the
following:
a) Motor rotation (page 16).
b) Hydraulic Reservoir is filled to the correct level (page15).
c) Hydraulic Pump Case is filled with the proper hydraulic fluid (page 47).
d) Loose Inlet Plumbing: Check that all inlet plumbing to Hydraulic Pump is tight
ensuring no air leakage into the hydraulic system.
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PH-20/PHX-20 Manual
TROUBLESHOOTING
Hydraulic Drive System (cont’d)
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 47. In addition to the above, 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.
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PH-20/PHX-20 Manual
TROUBLESHOOTING
Metering Pump Line
Follow the recommended procedure in the indicated order to solve the problem and
avoid unnecessary repairs. Make sure all Switches are in the correct position and
Indicator Lights ON before determining the existence of a fault.
PROBLEM
Metering pumps do not change direction and the pressures on both of chemical
gauges are lower than normal.
SOLUTIONS
1. The top of the hydraulic piston shaft actuates a reversing switch at the end
of the stroke. The reversing switch in turn actuates the appropriate Directional
Valve Solenoid.
Failure to make contact with the reversing Switch may be caused by:
Deformation of the Reversing bushing or a bent or loose reversing switch
mounting plate.
Foreign material preventing the Reversing bushing from contacting the Switch.
If this is not the problem go to the next step
2. Passing of the Reversing bushing beyond the switch may be caused by:
Failure of the Switch and related components on the side of the over-run.
Failure of a component of the Direction Valve.
Mounting Plate is bent or is out of adjustment.
3. Failure of the reversing switch or reversing valve coil
If the pump directional indicator light is on check the reversing valve coil, each
coil should read approximately 19 ohms.
If the pump directional indicator light is off and there is no hydraulic pressure
check for a defective reversing switch.
33
PH-20/PHX-20 Manual
NORMAL
Material
Supply
TROUBLESHOOTING
Metering Pump Line (cont’d)
IF THE DIRECTIONAL LIGHT IS OFF PROCEED BELOW
BEFORE TROUBLESHOOTING THE REVERSING SWITCH PLATE MUST BE MOVED
AWAY FROM THE SWITCH.
a) Bleed the down the chemical pressures.
b) Ensure Pump Switch [Y, page 12] is OFF.
c) Turn on the motor [X, page 12].
d) Go to the Directional Valve and locate the Actuation Coils. Located in the middle of
each coil is small round tab that can be pushed in to manually shift the spool to
move the pumps. If the Reversing bushing is all the way to the bottom push in on
the right side coil. If it’s all the way to the top push in on the left side coil.
TURN OFF ALL ELECTRICAL POWER TO THE MACHINE.
Using an ohm meter check the reversing switch
TROUBLESHOOTING
Metering Pump Line (cont’d)
4. Safety Pressure Switch
Each Metering Pump has a Safety Pressure Switch [I, L, page 9] 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 [Y, page 11]. Lack of Direction Indicator Lights along
with high pressure indicated on one or both of the material Pressure Gauges [H, K] is
a indication of a 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 three most common causes are:
a) Cavitation of the Metering Pump on the low pressure side
b) Causing high pressure on the opposite side.
c) A restriction in the Spray Gun on the high pressure
side.
5. Pressure/Material Imbalance
In summary troubleshooting this problem requires the applicator
to:
a) Know what the NORMAL spray pressures are for the application in progress.
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PH-20/PHX-20 Manual
Lack of
Iso (A)
Material
Supply
Lack of
Poly (R)
Material
Supply
b) Determine what material is NOT exiting the Mixing Chamber.
c) Read the Pressure Gauge on the problem side and interpret the
reading.
d) In this example a lack of Iso (A) with fluctuating LOW
pressure on the Iso (A) side indicates the Metering Pump
is not developing sufficient pressure or material volume;
Cavitation.
In this example a lack of Poly (R) with HIGH pressure on the Poly
(R) side indicates the Metering Pump is developing sufficient
pressure; a stoppage after the Pressure Gauge is not allowing
the material to exit the Spray Gun.
Check Spray Gun for a blockage.
6. Cavitation
Cavitation occurs when the Metering Pump [B, or C, page 9] 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 cavitation 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 blown systems. 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 Transfer Pump
causes a vacuum and cavitation 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) Air volume insufficient for Transfer Pump or Transfer Pump Air Valve partially
closed will limit the ability of the Transfer Pump to operate at its maximum
capability.
d) Inlet Material Screen [O, page 11] obstructed (See MAINTENANCE section).
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.
35
PH-20/PHX-20 Manual
Directional Indicator Light
ON
Directional Indicator Light
ON
Iso Pressure Gauge
FALLS
Iso Inlet Ball does not seat
properly
Iso Discharge Ball does not
seat properly
Poly Pressure Gauge
FALLS
Poly Discharge Ball does
not seat properly
Poly Inlet Ball does not
seat properly
7. Pressure Loss: Discharge/Inlet Ball
Simultaneous observation of the material Pressure Gauge [H, K, page 9] and Direction
Indicator Light [Z page 12] is necessary to determine which direction the Metering
Pump fails to maintain pressure. Refer to the chart to determine problem:
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, Ball Seat.
For service see MAINTENANCE/Metering Pump Line/page 44.
36
PH-20/PHX-20 Manual
TROUBLESHOOTING
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.
Follow the recommended procedure in the indicated order to solve the problem and
avoid unnecessary repairs. Make sure all Switches are in the correct position and
Indicator Lights ON before determining the existence of a fault.
CAUTION! All electrical testing must be done by a qualified electrician.
PROBLEM
A- Heated hose does not heat and the display on the controller shows 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 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; 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.
5. Look at the two lights located on the front of the transformer. If the voltage light is
lit and the AMP light is off the problem could in the heated hoses. If the voltage light
is on there is power to the primary side of the transformer. 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.
37
PH-20/PHX-20 Manual
Hose Heating (cont’d)
Because the gun whip takes the most abuse it is most likely that the whip 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.
6. Open the console top and locate the solid state relay for the hose circuit, looking
over the console top (front of machine) it is the relay to the right. With the hose
turned on and there is a LED light lit 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.
7. Using a DC volt meter measure across position 5 and 6 on the back of the hose
controller this is the output of the controller and 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 controller is above ambient temperature. Before replacing the
controller read across position 1 and 2 to make sure that the controller is powered
up, your reading will be 208 to 230 volts AC.
If there is no DC voltage to the relay move to the next step.
PROBLEM
Hose does not heat and the display on the controller shows an error message (EEEE).
SOLUTIONS
1. Check position 6 and 7 on the heater controller 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.
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PH-20/PHX-20 Manual
TROUBLESHOOTING
Hose Heating (cont’d)
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.
PROBLEM
Heated hose controller shows excessive temperature
SOLUTIONS
1. Set the controller 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 on replace the controller.
If the light is off replace the solid state relay.
PROBLEM
Hose will heat but does not come 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.
39
PH-20/PHX-20 Manual
TROUBLESHOOTING
Hose Heating (cont’d)
PROBLEM
Hose does not heat and the display on the controller shows an error message.
SOLUTIONS
1. Check position 9 and 10 on the heater controller 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.
40
PH-20/PHX-20 Manual
MAINTENANCE
To achieve maximum output from the PH Series Proportioner, a daily or regular maintenance
schedule is required.
To prevent possible bodily harm caused by incorrect handling
of the raw materials and solvents used in the process, carefully
read the safety information provided by your supplier.
Deal with the waste created according to current regulations.
Disconnect the unit from the power supply before carrying out
any operation inside the electrical console.
The electrical maintenance of the machine must only be
performed by a qualified electrician.
To avoid damage caused by the impact of pressurized fluids,
do not open any connection or perform maintenance work on
components subject to pressure until the pressures have been
completely eliminated.
Use suitable protection when operating, maintaining or
remaining in the operating area of the unit. This includes, but
is not limited to, the use of masks, protective goggles, gloves,
shoes and safety clothing.
The unit includes components that reach temperature that are
liable to cause burns. The hot parts of the unit must not be
handled until they have cooled.
To prevent serious harm by crushing or loss of limbs, do not
work with the unit without the safety duly installed on all
moving parts. Make sure that all of the safety protections are
correctly fitted after all repair or maintenance work.
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.
41
PH-20/PHX-20 Manual
Material Inlet Strainer
MAINTENANCE
Inlet Material Screens [O, page 9]
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
Drum Pumps.
2. Desiccated 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.
NOTE! Inspect and clean Inlet Material Screens before Proportioner start-up.
They should not be cleaned after the days operation as the Proportioner
should be purged (see page 18) immediately after inspection and cleaning.
This is to reduce the risk of moisture contamination, contamination through
the reaction with the solvent used in the cleaning operation and cross-over at
the Spray Gun due to air entrapment.
To check the Inlet Material Screens, proceed as follows:
CAUTION! Make sure the Main Power Switch is OFF and incoming power is
locked OFF.
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 allowing the material to drain into the
container.
3. Completely unscrew the Strainer Screw.
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 or clean the Screen if
more than 20% of the Screen surface is
obstructed by residue.
42
PH-20/PHX-20 Manual
MAINTENANCE
Inlet Material Screens [O] (cont’d)
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 (page 20).
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 press 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 12 gal of approved hydraulic fluid. See page 47 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.
43
PH-20/PHX-20 Manual
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 80F and bleed all material pressure to zero.
Weekly: When the Proportioning Pumps are functioning properly it is
not unusual to a small amount of Poly (R) material to appear on the
Pump Shaft. This material should be wiped away so dirt does no
accumulate on the Pump Shaft and the Pump Shaft Packings are not
damaged.
Yearly or as required: It is not unusually for those who use the PH Series Proportioner on
a regular basis to rebuild the Proportioning Pumps on a yearly basis and service the
Hydraulic Drive System (page 41) at the same time, when the Proportioner is out of service.
Pump Seal Replacement
Refer to Parts Identification Drawing (pages 54 (PHX) (56PH) for reference.
NOTE!
When Iso (A) Proportioning Pump Cylinder is disassembled for service, all parts
included in the Seal Kit (KT-PAX or KT-PA) should be replaced.
When the Poly (R) Proportioning Pump Cylinder is disassembled for service, all parts
included in the Seal Kit (KT-PAX or 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 cleaning. Do not
use metal or abrasive tools that can scratch the contact surfaces.
44
PH-20/PHX-20 Manual
Thermocouple
Positive Contact
Thermocouple
Assembly
MAINTENANCE
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.
45
PH-20/PHX-20 Manual
MAINTENANCE
Material Heater (cont’d)
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.
Heating Rod
To replace 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 (see
page 39). Do not loosen or tighten Thermocouple Body.
2. Disconnect the suspect Heating Rod from the wire connections and test Heating
Rod again for proper electrical resistance. 1250 Watt Heating Rod is 37 ohms,
1500 Watt Heating Rod is 31 ohms.
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.
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.
6. Reconnect wire connections and replace Cover.
7. Ensure Heater is full of material prior to electrical testing.
46
PH-20/PHX-20 Manual
Mobil DTE24*
American Oil & Supply – PQ Iso 32
Fiske Bros. – Lubriplate Hyd. #0
Cook’s Albavis 8
Gulf Oil – Harmony 32AW (43AW)
SW – Alemite Hydraulic HD#0
Ashland-Valvoline AW15
Atlantic Richfield – Duro AWS-150
Texaco – Rando HD32 (HD A0
Shell - Tellus 32(25)
BP Oil – Energol HLP-C32
White & Bagley – EP Hyd. 150
Sun Oil - Sunvis 706
Exxon – Nuto H-32(44)
Chevron ISO32
A. Margolis – T.I.P.100-15-7
HYDRAULIC OIL SPECIFICATIONS
Recommended Hydraulic Oil Specification:
ISO/ASTM Viscosity Grade 32
Viscosity: 28.8 – 35.2 SSU@ 104 F
Rust and Oxidation Inhibited
Manufacturers:
* Preferred
47
PH-20/PHX-20 Manual
P/N
Description
QTY
HI-05025-1
U-Cup
2
HI-05025-2
Back-up Ring, Piston
2
HI-05025-3
Wear Ring
1
HI-05025-4
Rod Wiper
2
HI-05025-5
Shaft Seal
2
HI-05025-6
Back-up Ring, Bushing
2
OR-00039A
O-ring
2
OR-00040A
O-ring
2
P/N
Description
QTY
HI-05020
Body, Nut, Ferrule
1
HI-05021
Thermocouple
1
P/N
Description
QTY
KT-PAX
PHX pump rebuild kit (3000 psi), see page 52
1
KT-PA
PH pump rebuild kit (2000 psi), see page 54
1
REPLACEMENT KITS
Hydraulic Cylinder Rebuild Kit
KT-05200
Heater Thermocouple Kit
KT-05021
PUMP REBUILD KITS
48
PH-20/PHX-20 Manual
PH-16
COMPLETE “A” SIDE HEATER, PH-20
1
PH-17
COMPLETE “R” SIDE HEATER, PH-20
1
PH-18
COMPLETE “A” SIDE HEATER, PHX-20
1
PH-19
COMPLETE “R” SIDE HEATER, PHX-20
1
GM-06424-1
HEATER BODY
2
GM-06424-2
PHONOLIC WASHER
4
GM-05423-1250
HEATER CARTRIDGE, PH-20
3
GM-05423-1500
HEATER CARTRIDGE, PHX-20
3
GM-05423-7
SPRING
3
KT-05020
THERMOCOUPLE KIT
1
HI-05034
O-RING PLUG
3
EL-00006A
OVER TEMP SWITCH
1
HI-05036
¼” PIPE PLUG
2
HI-05026
OUTLET HEATER FITTING “R”
1
HI-05027
OUTLET HEATER FITTING “A”
1
HI-05059
INLET HEATER FITTING
1
HI-05088
¼”M x ¼”F, NPT FITTING
1
GP-00100-3
¼” RUNNING TEE
1
HI-05028
GAUGE, 0-3000 PSI (PH-20)
1
HI-00035
GAUGE, 0-5000 PSI (PHX-20)
1
EL-00021
REVERSING SWITCH
1
RM-216
REVERSING SWITCH BRACKET
1
RM-217
REVERSING SWITCH PLATE
1
RM-218
REVERSING SWITCH COVER, FRONT
1
RM-219
REVERSING SWITCH COVER, BACK
1
RM-220
REVERSING SWITCH TRIP ARM
1
RM-221
REVERSING SWITCH TRIP SHAFT
1
HEATER PARTS
PART NUMBER DESCRIPTION QTY PER HEATER
REVERSING SWITCH PARTS
PART NUMBER DESCRIPTION QTY
49
EL-05224
ELECTRIC MOTOR, 3HP, 3 PHASE, 60HZ
1
EL-05221
ELECTRIC MOTOR, 3HP, 1 PHASE, 60HZ
1
HI-05001
BELL HOUSING
1
HI-00065-01
MAGNALOY INSERT
1
HI-00065-02
MAGNALOY HUB, 1-1/8 x 1/4
1
HI-00065-03
MAGNALOY HUB, ¾ x 3/16
1
HI-05006
HYDRAULIC PUMP
1
HI-05004-1
HYDRAULIC PUMP CONTROL KNOB
1
HI-05006-3
HYDRAULIC PUMP INLET PIPE
1
HI-00005-03
ACCESS COVER
1
EL-05228
TRANSFORMER, 72 VOLTS
1
EL-150
BREAKER, 63 AMPS
1
EL-00118A-00-1
BREAKER MOUNT
1
EL-05235
THERMOCOUPLE HARNESS
1
EL-05230-01
CONDUIT, ¾” FLEX
2 FT
EL-05230-02
CONDUIT CONNECTOR, STRIGHT
1
EL-05230-03
CONDUIT CONNECTOR, 90 DEGREE
1
RM-00019
#6 WIRE
2x3 FT
KT-00029A
HOSE CONNECTOR
2
EL-000P7
STRAIN RELIEF, SMALL
1
EL-000P12
STRAIN RELIEF, LARGE
2
PH-20/PHX-20 Manual
MOTOR LINE PARTS
PART NUMBER DESCRIPTION QTY
HOSE TRANSFORMER PARTS
PART NUMBER DESCRIPTION QTY
50
RM-213
TANK LID
1
HI-00014-04A
GASKET, TANK TOP
1
TN-05704
CASTERS
4
HI-00002-A
GROMMET, TANK TOP
1
HI-05048
DRAIN PLUG
1
RM-212
TRANSFORMER DOOR
1
YS-1
Y-STRAINER ASSY, A SIDE
1
YS-2
Y-STRAINER ASSY, R SIDE
1
RA-00074-00A
Y-STRAINER (60 MESH)
1
RA-00078A
BALL VALVE ¾”
1
HI-05015
¾ NPT ELBOW
1
HI-05016
¾ “ x ¾” SWIVEL FITTING “R” SIDE
1
HI-05017
¾” HEX NIPPLE
1
HI-05018
¾ “ x ½” SWIVEL FITTING “A” SIDE
1
SP-00009A
REPLACEMENT SPRING
1
RA-00074-02A
REPLACEMENT GASKET
1
RA-00074-03-80A
REPLACEMENT SCREEN, 80 MESH
1
RA-00074-03-60A
REPLACEMENT SCREEN, 60 MESH
1
RA-00074-03-30A
REPLACEMENT SCREEN, 30 MESH
1
HI-00035
PHX PRESSURE GAUGE, FLUID 0-5000 PSI
2
HI-05028
PH PRESSURE GAUGE, FLUID 0-3000 PSI
2
HI-05040-2
PRESSURE GAUGE, HYDRAULIC 0-2000PSI
1
PH-20/PHX-20 Manual
HYDRAULIC TANK PARTS
PART NUMBER DESCRIPTION QTY
\
Y-STRAINER PARTS
PART NUMBER DESCRIPTION QTY
PRESSURE GAUGES
PART NUMBER DESCRIPTION QTY
HEATED HOSES and REPLACEMENTS
51
MA-00014A
3/8 x 50’ LOW PRESSURE HOSE,2250 psi
1
MA-00014-TC
3/8 x 50’ LOW PRESSURE HOSE,2250 psi W/TC WIRE
1
MA-00040A
¼ x 10” GUN HOSE ASSY W/SCUFF JACKET 3500psi
1
MA-00039A
3/8 x 50’ HIGH PRESSURE HOSE,3500 psi
1
MA-00039A-TC
3/8 x 50’ HIGH PRESSURE HOSE,3500 psi W/TC WIRE
1
MA-00014A-TC-35
3/8 x 35’ LOW PRESSURE HOSE,2250 psi W/TC WIRE
1
MA-00039A-TC-35
3/8 x 35’ HIGH PRESSURE HOSE,3500 psi W/TC WIRE
1
MA-00014A-A-50
3/8 x 50’ “A” SIDE LOW PRESSURE HOSE,2250 psi
1
MA-00014A-R-50
3/8 x 50’ “R” SIDE LOW PRESSURE HOSE,2250 psi
1
MA-00040A-A
¼ x 10” “A” SIDE GUN HOSE, 3500psi
1
MA-00040A-R
¼ x 10” “R” SIDE GUN HOSE, 3500psi
1
MA-00005A-50
50’ SCUFF JACKET
1
MA-00005A-35
35’ SCUFF JACKET
1
MA-00005A-10
10’ SCUFF JACKET
1
HI-05047-1
HOSE, FLUID PUMP TO HEATER 16.5”
2
HI-05047-2
HOSE, HYDRAULIC PUMP TO TANK 9”
1
HI-05047-3
HOSE, BOTTOM HYDRAULIC CYL. TO MANIFOLD 17.5”
1
HI-05047-4
HOSE, TOP HYDRAULIC CYL. TO MANIFOLD 13”
1
HI-05013
HOSE, HYDRAULIC PUMP OUTLET 24”
1
EL-51A
TSU ASSEMBLY
1
EL-51A-2
TSU PROBE REPLACEMENT
1
EL-00051A-1
TSU BODY
1
EL-00051A-3
FITTING, 1/8 NPT x #4 JIC SWIVEL
1
EL-00051A-4
FITTING, 1/4 NPT x #5 JIC MALE (A)
1
EL-00051A-5
FITTING, 1/4 NPT x #6 JIC SWIVEL (R)
1
EL-00051A-6
FITTING, 1/4 NPT x #6 JIC (R)
1
EL-00051A-7
FITTING, 1/4 NPT x #5 JIC SWIVEL (A)
1
EL-00051A-8
INSULATION
1
PART NUMBER DESCRIPTION QTY
HYDRAULIC/MACHINE HOSES
PH-20/PHX-20 Manual
HOSE TEMPERATURE SENSING UNIT (TSU)
PART NUMBER DESCRIPTION QTY
HI-02 HYDRAULIC MANIFOLD ASSEMBLY
52
HI-05070-1
MANIFOLD, HYDRAULIC
1
HI-05070-2
DRAIN TUBE ¼”
1
HI-05040-2
GAUGE, 0-2000 psi Bottom mount
1
HI-05003
DIRECTIONAL VALVE
1
GP-00100-5
ELBOW
1
HI-05038
FITTING,
1
HI-05200-1
PISTON
1
HI-05200-2
CYLINDER
1
HI-05200-3
PORT BLOCK
2
HI-05200-5
Bolt, TIE ROD
4
HI-05201
MOUNTING PLATE
1
HI-05202
MOUNTING PLATE, PUMP YOKE
1
HI-002
NUT, YOKE
1
HI-05025-1*
U CUP
2
HI-05025-2*
RING, BACK UP
2
HI-05025-3*
RING, WEAR
1
HI-05025-4*
ROD WIPER
2
HI-05025-5*
SEAL, SHAFT
2
HI-05025-6*
RING, BACK UP
2
OR-00039A*
O-RING
2
OR-00040A*
O-RING
2
PART NUMBER DESCRIPTION QTY
PART NUMBER DESCRIPTION QTY
PH-20/PHX-20 Manual
HI-05200 HYDRAULIC CYLINDER
NOTE: * Included in Hydraulic Rebuild Kit KT-05025
53
PH-20/PHX-20 Manual
A/R PUMP 3000 PSI – PHX-20 SIZE 61
54
ITEM
PART NUMBER
QTY
DESCRIPTION
1
PAX-045
1
OUTLET BODY
2
PAX-053
1
INLET BODY
3
PAX-064
1
PACKING NUT/GREASE CUP
4*
PAX-065
1
SCRAPER SEAL
5*
PAX-052
2
ROD SEAL ASSEMBLY
6
PAX-051
1
ROD BUSHING
7
PAX-062
1
FLUID ROD
8
PAX-047
1
PISTON
9
PA-063
1
BOLT
10
PAX-046
1
PISTON VALVE
11*
OR-116
1
O-RING
12
PAX-059
1
BALL ½”
13
PAX-049
1
SPRING
14
PAX-050
1
SPRING RETAINER
15
PAX-055
1
PISTON BUSHING
16*
PAX-052
1
ROD SEAL ASSEMBLY
17
PAX-058
1
INLET VALVE
18*
OR-916
1
O-RING
19
PA-048
1
BALL ¾”
20
PAX-061
1
SPRING, FOOT VALVE
21
PA-050
1
SPRING RETAINER
22
PA-056
4
CAP SCREW
23
PA-057
4
CAP SCREW
24*
OR-030
1
O-RING
25
PA-066
2
GREASE FITTING
PH-20/PHX-20 Manual
A/R PUMP 3000 PSI - PHX-20 SIZE 61 PUMP PARTS LIST
PACKING KIT PART NUMBER
KT-PAX
*ASTERISKS DENOTES PARTS INCLUDED IN THE SEAL KIT
55
PH-20/PHX-20 Manual
A/R PUMP 2000 PSI – PH-20 SIZE 123
56
ITEM
PART NUMBER
QTY
DESCRIPTION
1
PA-045
1
OUTLET BODY
2
PA-046
1
PISTON VALVE
3
PA-047
1
PISTON
4*
OR-916
1
O-RING
5
PA-048
1
BALL, 3/4”
6
PA-049
1
SPRING
7
PA-050
1
SPRING RETAINER
8
PA-051
1
ROD BUSHING
9*
PA-052
2
ROD SEAL ASSEMBLY
10
PA-053
1
INLET BODY
11*
PA-054
1
PISTON SEAL ASSEMBLY
12
PA-055
1
PISTON BUSHING
13*
OR-035
1
O-RING
14
PA-056
4
CAP SCREW
15
PA-057
4
CAP SCREW
16
PA-058
1
INLET VALVE
17
PA-059
1
BALL,1”
18 *
OR-920
1
O-RING
19
PA-060
1
BALL STOP
20
PA-061
1
FOOT VALVE SPRING
21
PA-062
1
FLUID ROD
22
PA-063
1
BOLT
23
PA-064
1
PACKING NUT/GREASE CUP
24 *
PA-065
1
SCRAPER SEAL
25
PA-066
2
GREASE FITTING
PH-20/PHX-20 Manual
A/R PUMP 2000 PSI - PH-20 SIZE 123 PUMP PARTS LIST
PACKING KIT PART NUMBER
KT-PA
*ASTERISKS DENOTES PARTS INCLUDED IN THE SEAL KIT
57
Part No.
Description
Quantity
EL-116
HEATER BREAKER, 25 AMP
2
EL-117
HOSE BREAKER, 20 AMP
1
EL-114
CONTROL BREAKER, 3 AMP
1
EL-110
MOTOR BREAKER, 32 AMP/1 PHASE
1
EL-162
MOTOR BREAKER, 20 AMP/3 PHASE
1
EL-122
POWER SUPPLY, DC
1
EL-120
RELAY, DPDT (CONTACTOR)
1
EL-119
CONTACTOR, 25 AMP
1
EL-118
MOTOR CONTACTOR
1
EL-161
MOTOR OVERLOAD, 3 PHASE ONLY
1
EL-34
RELAY, SSR 50 AMP (A/R HEATER)
2
EL-35
RELAY, SSR 95 AMP (HOSE)
1
PH-20/PHX-20 Manual
CONSOLE BOTTOM ELECTRICAL PARTS
58
Part No.
Description
Quantity
EL-124
TOTALIZER
1
EL-127
AUTO COUNT DOWN
1
EL- T1
TEMPERTURE CONTROLLER, HOSE
1
EL- T2
TEMPERTURE CONTROLLER, HEATER
2
Part No.
Description
Quantity
EL-133-NO
SWITCH, NORMALLY OPEN
1
EL-107
E-STOP KNOB
1
EL-131-R
LIGHT
1
EL-133-NC
SWITCH, NORMALLY CLOSED
1
Part No.
Description
Quantity
EL-133-NO
SWITCH, NORMALLY OPEN
1
EL-131-R
LIGHT
1
Part No.
Description
Quantity
EL-134
SOCKET
1
EL-132-G
LIGHT
1
EL-135
LENS
1
Part No.
Description
Quantity
EL-103
MOUNTING KIT
1
EL-100
DISCONNECT
1
EL-105
HANDLE
1
PH-20/PHX-20 Manual
CONSOLE PANEL ELECTRICAL PARTS
EMERGENCY STOP SWITCH
HOSE (1) / HEATER (2) SWITCH
MAIN POWER LIGHT ASSEMBLY
MAIN POWER SWITCH
59
Part No.
Description
Quantity
EL-18-R
KNOB ASSY
1
EL-130
INSERT, MOMENTARY
2
EL-133-NC
SWITCH, NORMALLY CLOSED
1
EL-133-NO
SWITCH, NORMALLY OPEN
1
Part No.
Description
Quantity
EL-129-R
KNOB ASSY
1
EL-131-R
LIGHT
1
EL-133-NO
SWITCH, NORMALLY OPEN
1
Part No.
Description
Quantity
EL-128-W
KNOB ASSY
1
EL-133-NO
SWITCH, NORMALLY OPEN
2
Part No.
Description
Quantity
EL-129-G
KNOB ASSY
1
EL-131-G
LIGHT
1
EL-133-NO
SWITCH, NORMALLY OPEN
1
EL-133-NC
SWITCH, NORMALLY CLOSED
1
Part No.
Description
Quantity
EL-134
SOCKET
1
EL-131-W
BULB
1
EL-138
LENS
1
PH-20/PHX-20 Manual
CONTROL POWER SWITCH
MOTOR SWITCH
PUMP SWITCH
AUTO COUNT DOWN SWITCH
RIGHT DIRECTIONAL LIGHT
60
Part No.
Description
Quantity
EL-134
SOCKET
1
EL-131-W
BULB
1
EL-138
LENS
1
Part No.
Description
Quantity
EL-150
BREAKER, 63 AMP
1
PH-20/PHX-20 Manual
LEFT DIRECTIONAL LIGHT
TRANSFORMER
61
220 Volt, 1 Phase
PH-20/PHX-20 Manual
62
220 Volt, 1 Phase
PH-20/PHX-20 Manual
63
220 Volt, 1 Phase
PH-20/PHX-20 Manual
64
220 Volt, 1 Phase
PH-20/PHX-20 Manual
65
220 Volt, 1 Phase
PH-20/PHX-20 Manual
66
220 Volt, 3 Phase
PH-20/PHX-20 Manual
67
220 Volt, 3 Phase
PH-20/PHX-20 Manual
68
220 Volt, 3 Phase
PH-20/PHX-20 Manual
69
220 Volt, 3 Phase
PH-20/PHX-20 Manual
70
220 Volt, 3 Phase
PH-20/PHX-20 Manual
71
380 Volt, 3 Phase
PH-20/PHX-20 Manual
72
380 Volt, 3 Phase
PH-20/PHX-20 Manual
73
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