PMC PH-25, PHX-25, PH-40, PHX-40 Service Manual
Classic
PH/PHX-25
PH/PHX-40
Proportioners
Hydraulic, Heated, Plural Component
Proportioner
For spraying Polyurethane Foam and
Coatings
For Professional Use Only
Not approved for use in explosive
atmosphere locations
Service Manual
Ref. # MN-04014
Revision 3.3
September 23, 2016
Polyurethane Machinery Corp.
Corporate: 1 Komo Dr, Lakewood, NJ 08701
Manufacturing: 2 Komo Dr, Lakewood, NJ 08701
Phone: 732-415-4400
Fax: 732-364-4025
URL: 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.
TABLE OF CONTENTS
WARRANTY ............................................................................................................................ 1
SAFETY AND HANDLING ...................................................................................................... 3
CHARACTERISTICS .............................................................................................................. 5
PRINCIPAL HEATING SYSTEM ......................................................................................... 5
HOSE HEATING SYSTEM .................................................................................................. 5
DOUBLE ACTING OPPOSED PISTON METERING PUMPS ............................................. 5
PRESSURE BALANCE CONTROL SYSTEM ..................................................................... 6
PH(X)-25 TECHNICAL SPECIFICATIONS ............................................................................. 7
ELECTRICAL ....................................................................................................................... 7
MECHANICAL ..................................................................................................................... 7
PH(X)-40 TECHNICAL SPECIFICATIONS ............................................................................. 8
ELECTRICAL ....................................................................................................................... 8
MECHANICAL ..................................................................................................................... 8
DESCRIPTION ........................................................................................................................ 9
INSTALLATION ................................................................ .................................................... 13
HEATED HOSE INSTALLATION ....................................................................................... 15
TRANSFORMER SETTINGS ............................................................................................ 17
PROPORTIONER PURGING ................................................................................................ 19
PRESSURE BALANCE CONTROL ...................................................................................... 21
OPERATION ...................................................................................................................... 21
DIGITAL TEMPERATURE CONTROLLER .......................................................................... 22
START-UP ............................................................................................................................ 23
SHUT-DOWN ........................................................................................................................ 25
Short Term ......................................................................................................................... 25
Long Term.......................................................................................................................... 25
TROUBLESHOOTING .......................................................................................................... 26
HEATERS .......................................................................................................................... 27
HYDRAULIC DRIVE SYSTEM ........................................................................................... 31
METERING PUMP LINE .................................................................................................... 33
HOSE HEATING ................................................................................................................ 37
TABLE OF CONTENTS
PRESSURE BALANCE CONTROL ................................................................................... 41
MAINTENANCE .................................................................................................................... 42
INLET MATERIAL SCREENS ............................................................................................ 43
ISO LUBRICATION SYSTEM ............................................................................................ 44
HYDRAULIC DRIVE SYSTEM ........................................................................................... 45
METERING PUMP LINE .................................................................................................... 46
Pump Base Service .................................................................................................................... 46
Pump Seal Replacement ............................................................................................................ 47
METERING PUMP REMOVAL ................................................................................................... 47
MATERIAL HEATER ......................................................................................................... 48
Thermocouple Replacement ....................................................................................................... 48
Heating Rod ............................................................................................................................... 49
REPLACEMENT KITS .......................................................................................................... 50
HYDRAULIC OIL SPECIFICATIONS ................................................................................... 56
List of Manufacturers: ........................................................................................................ 56
PART IDENTIFICATION ....................................................................................................... 57
PUMPLINE ASSEMBLY .................................................................................................... 57
HYDRAULIC CYLINDER COMPLETE .............................................................................. 58
HYDRAULIC CYLINDER ASSEMBLY ............................................................................... 59
HYDRAULIC SEAL ASSEMBLY ........................................................................................ 60
HYDRAULIC PISTON ASSEMBLY .................................................................................... 61
“R” PUMP ASSEMBLY; SIZE 120 & 80 ............................................................................. 62
“A” PUMP ASSEMBLY; SIZE 120 ...................................................................................... 64
“A” PUMP ASSEMBLY; SIZE 80 ........................................................................................ 66
PISTON ASSEMBLY ......................................................................................................... 68
PUMP BASE ASSEMBLY .................................................................................................. 69
PH(X)-25 HEATER ASSEMBLY ................................ ........................................................ 70
PH(X)-40 HEATER ASSEMBLY ................................ ........................................................ 73
PRESSURE TRANSDUCER ASSEMBLY ......................................................................... 76
TRANSFORMER COVER ASSEMBLY ............................................................................. 77
Y-STRAINER ASSEMBLY ................................................................................................. 79
FRAME/TANK ASSEMBLY ................................................................................................ 80
MOTOR LINE ASSEMBLY ................................................................................................ 82
TABLE OF CONTENTS
PH-SERIES PROPORTIONER .......................................................................................... 84
LUBE BOTTLE COMPONENTS ........................................................................................ 87
HOSES .............................................................................................................................. 88
BLEED SYSTEM ............................................................................................................... 89
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.
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.
2
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.
SAFETY AND HANDLING
This chapter contains important information on the safety, handling, and use of your
PH Series Proportioner.
Classic
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 equipment 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 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 Distributor or go online and visit our web site at
www.polymac-usa.com.
The
Classic
polyurea chemical systems, polyurethane foam chemical systems, and some two-component
epoxy systems.
PH Series Proportioner has been designed and built for the application of
3
SAFETY AND HANDLING
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.
WARNING! The design and configuration of the PH Series
Proportioner does not allow its use in potentially explosive
atmospheres, or the pressure and temperature limits
described in the technical specifications of this manual to be
exceeded.
Always use liquids and solvents that are compatible with the unit. If in doubt, consult your PMC
Distributor.
When working with the PH Series Proportioner, it is recommended that the operator wear
suitable clothing and elements of personal protection, including, without limitation, gloves,
protective goggles, safety footwear, and face masks. Use breathing equipment when working
with the PH Series Proportioner in enclosed spaces or in areas with insufficient ventilation. The
introduction and follow-up of safety measures must not be limited to those described in this
manual. Before starting up the PH Series Proportioner, a comprehensive analysis must be
made of the risks derived from the products to be dispensed, the type of application, and the
working environment.
4
100% circumferential coverage produces the most
uniform distribution of heat available.
CHARACTERISTICS
The
Classic
polyurea chemical systems, polyurethane foam chemical systems, and some specific twocomponent epoxy systems.
PH Series Proportioner has been designed and built for the application of
PRINCIPAL HEATING SYSTEM
The Proportioners consist of two (2) independent Material Heaters without internal seals. Each
heater for the PH(X)-25 Proportioner has four (4) Heating Elements rated at 1,000, 1,250 or
1,500 watts, each giving the Proportioner a total heat of 8,000, 10,000, or 12,000 watts. Each
heater for the PH(X)-40 Proportioner has six (6) Heating Elements rated at 1,250 1,500 or 1,750
watts each, giving the Proportioner a total heat of 15,000, 18,000 or 21,000 watts. The Material
Heater systems for all PH Series Proportioners contain the necessary control and safety
components for their precise operation. The Material Heater design allows a temperature
differential (ΔT) of 90ºF (32ºC) and material application temperatures of up to 190ºF (88ºC)
under normal ambient temperatures.
HOSE HEATING SYSTEM
The PH(X)-25 Proportioner is designed with a 3 KVA (90 V) Isolation Transformer that enables
effective heating of up to a total hose length of 310 feet (94 meters). The PH(X)-40 Proportioner
is designed with a 5 KVA (120 V) Isolation Transformer that enables effective heating of up to a
total hose length of 410 feet (123 meters). Both systems include an innovative hose heating
concept in which the continuous braid tinned-copper jacket is distributed evenly around the
circumference of the hose providing a uniform heating watt density and precise control of the
material application temperature. This hose heating element design is extremely resistant to
fatigue failure.
DOUBLE ACTING OPPOSED PISTON METERING PUMPS
The opposed double acting Pump Line is driven by a dual rod Hydraulic Cylinder. The in-line
pump system with opposed piston pumps provides a constant volume and guarantees uniform
pressures in both directions of pump movement. Different sized pumps allow for various
volumetric ratios to be achieved (1:4 to 1:1 to 4:1) between the chemical components used in
the process.
5
CHARACTERISTICS
1. Power supply
2. “A” side pressure reading
3. “R” side pressure reading
4. Maximum pressure
5. Maximum allowable
pressure differential
Logic Box
1. Continue pumping material
OR
2. Shut off pumps
PRESSURE BALANCE CONTROL SYSTEM
The Pressure Balance Control (PBC) system provides better control over a chemical pressure
imbalance. When the system is turned off, the Proportioner will perform as if there is no PBC
system and will continue pumping material. When the system is turned on, it will continually
monitor the pressure between the two chemicals (known as the pressure differential). If the
pressure differential becomes equal to or greater than the maximum allowable pressure
differential, the pumps will be shut off.
The Pressure Balance Control system can be simplified into a logic box diagram with inputs and
outputs. There are five inputs: the power supply from the main console, the pressure readings
from each chemical, the maximum pressure, and the maximum allowable pressure differential.
Inside the logic box, the actual pressure differential of the chemicals is compared to the
maximum allowable pressure differential. Depending on the circumstances of all five inputs,
there are only two possible outputs: either the pumps will continue to pressurize and move
material, or the pumps will shut off and flow will be lost.
Logic Box Repre sent ation
6
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.
PH(X)-25 TECHNICAL SPECIFICATIONS
ELECTRICAL
Main Voltage: ______________________________________ 3 x 208-230V, 50/60Hz
Electrical Consumption: (2 x 4 kW Heaters) _____________________ 40 A @ 3 x 230V
Electrical Consumption: (2 x 5 kW Heaters) _____________________ 49 A @ 3 x 230V
Electrical Consumption: (2 x 6 kW Heaters) _____________________ 57 A @ 3 x 230V
Main Voltage: _________________________________________ 1 x 208-230V, 60Hz
Electrical Consumption: (2 x 4 kW Heaters) _____________________ 61 A @ 1 x 230V
Electrical Consumption: (2 x 5 kW Heaters) _____________________ 70 A @ 1 x 230V
Electrical Consumption: (2 x 6 kW Heaters) _____________________ 78 A @ 1 x 230V
Material Heater Power: (2 x 4 kW) ______________________________________ 8 kW
Material Heater Power: (2 x 5 kW) _____________________________________ 10kW
Material Heater Power: (2 x 6 kW) _____________________________________ 12kW
Hose Transformer Power: _____________________________________ 3 KVA (90 V)
Electrical Motor Power: ______________________________________________ 3 HP
Frequency: (Single Phase) ___________________________________________ 60 Hz
Frequency: (Three Phase) _________________________________________ 50/60 Hz
MECHANICAL
Maximum working pressure (with 120 pumps): _________________ 2,000 psi (138 bar)
Maximum working pressure (with 80 pumps): __________________ 3,000 psi (207 bar)
Maximum production ratio 1:1 (with 120 pumps): ____________ 25 lbs/min (12.5 kg/min)
Maximum production ratio 1:1 (with 80 pumps): ________________ 1.4 GPM (5.6 L/min)
Minimum production: ______________________________________ 2 lb/min (1kg/min)
Maximum hose length: _________________________________________ 310 ft (93 m)
Approximate weight (Hydraulic Tank empty): _____________________ 420 lbs (190 kg)
Approximate weight (Hydraulic Tank full @ 20 gal, 76 liters): ________ 594 lbs (269 kg)
Dimensions: _______________________________________ 30in W x 26in D x 45in H
Dimensions (Metric): ____________________________ 76cm W x 66cm D x 114cm H
7
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.
PH(X)-40 TECHNICAL SPECIFICATIONS
ELECTRICAL
Main Voltage: ______________________________________ 3 x 208-230V, 50/60Hz
Electrical Consumption: (2 x 7.5 kW Heaters) ___________________ 75 A @ 3 x 230V
Electrical Consumption: (2 x 9.0 kW Heaters) ___________________ 89 A @ 3 x 230V
Electrical Consumption: (2 x 10.5 kW Heaters) _________________ 103 A @ 3 x 230V
Main Voltage: _________________________________________ 1 x 208-230V, 60Hz
Electrical Consumption: (2 x 7.5 kW Heaters) __________________ 130 A @ 1 x 230V
Material Heater Power: (2 x 7.5 kW) ___________________________________ 15 kW
Material Heater Power: (2 x 9.0 kW) ___________________________________ 18 kW
Material Heater Power: (2 x 10.5 kW) __________________________________ 21 kW
Hose Transformer Power: ____________________________________ 5 KVA (120 V)
Electrical Motor Power: ______________________________________________ 5 HP
Frequency: (Single Phase) ___________________________________________ 60 Hz
Frequency: (Three Phase) _________________________________________ 50/60 Hz
MECHANICAL
Maximum working pressure (with 120 pumps): _________________ 2,000 psi (138 bar)
Maximum working pressure (with 80 pumps): __________________ 3,500 psi (241 bar)
Maximum production ratio 1:1 (with 120 pumps): _____________ 40 lbs/min (20 kg/min)
Maximum production ratio 1:1 (with 80 pumps): ________________ 2.5 GPM (1.0 L/min)
Minimum production: _________________________________________ 2 lb/min (1 kg)
Maximum hose length: ________________________________ _______ 410 ft (123 m)
Approximate weight (Hydraulic Tank empty): _____________________ 420 lbs (190 kg)
Approximate weight (Hydraulic Tank full @ 20 gal (76 liters) ________ 594 lbs (269 kg)
Dimensions: _______________________________________ 30in W x 26in D x 45in H
Dimensions (Metric) ____________________________ (76cm W x 66cm D x 114cm H)
8
DESCRIPTION
CLASSIC PH-SERIE S
PROPORTIONER
9
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.
F. Hose Heating Transformer
Supplies the required voltage for material Heated Hoses.
G. Hydraulic Pressure Gauge
Indicates the pressure in the Hydraulic Drive System.
H. Isocyanate (Iso, A) Pressure Gauge
Indicates the pressure in the Isocyanate system.
I. Isocyanate (Iso, A) Safety Pressure Switch
Disables the pump circtuit 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 Gauge
Indicates the pressure in the Polyol system.
L. Polyol (Poly, R) Safety Pressure Switch
Disables the pump circuit 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.
O. Isocyanate (Iso, A) Inlet Material Strainer
Screens (60 mesh) material from bulk supply.
P. Polyol (Poly, R) Inlet Material Strainer
Screens (60 mesh) material from bulk supply.
10
DESCRIPTION
PUMP SIZE
CYCLES PER GAL (3.79 L)
120
16
80
24
R
CLASSIS PH-SERIE S
CONTROL PANEL
Q. 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
green pilot light will be lit.
R. Emergency Stop - Interrupts the PH Series control power circuit to stop all motion
and heating.
S. Control Power - Turns ON and OFF the control power to the complete electrical
circuit including Heaters and Hose Heater.
T. Heater Temperature Zones, A (Iso), R (Poly), HOSE - Turns ON and OFF power
to the specific Heaters. See page 22 for detailed Temperature Controller
instructions.
The Hose Heater Controller automatically controls the Hose Heater only when
using the TSU (Temperature Sensing Unit) probe.
U. Count 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 expires. There is an on/off switch to either activate this feature or deactivate
and not use it.
V. Cycle Counter – Indicates the number of pump cycles to calculate material usage.
11
DESCRIPTION
W. Motor Switch - Turns ON and OFF the Electric/Hydraulic Motor. When turned ON
the switch will be lit. In the event of an overload of the Motor, pilot light will turn
OFF and Motor will stop.
X. 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 retract position
and prevents the crystallization of Iso (A) on the Piston Rod. Turn the switch to
RETRACT position every time the unit is stopped by the operator (see Shut-Down,
page 25).
Y. Direction Indicator Light - Indicates the direction of movement of the Metering
Pumps. If excessive pressure occurs in the system, the pump circuit will be
disabled and the directional lights will be OFF.
Z. Heater Temperature Switch – A (Iso), R (Poly), HOSE – Turns ON and OFF
power to the specific Heaters and Hose.
AA. Auto Shut Down Switch - Turns ON and OFF power to the Auto Shut Down unit.
BB. Pressure Balance Control “FAULT” Light – Indicates that the pressure
differential is equal to or greater than the maximum allowable pressure differential.
CC. Pressure Balance Control “ON” Light – Indicates that the Pressure Balance
Control system is on and functioning.
DD. Pressure Balance Control Knob – Used to set the maximum allowable pressure
differential (in PSI) between the A (Iso) and R (Poly) pumps. See page 21 for more
information.
12
L1
L2
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.
1 phase x 230 Volt
L3
L2
L1
3 phase x 380 Volt
3 phase x 230 Volt
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.
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 PH Series Proportioner works correctly, the electrical
supply must meet the specifications indicated on the Serial Number
Placard affixed to the Electrical Console.
13
INSTALLATION
Follow the recommended procedure in the indicated order to install the Proportioner:
1. Insert the main power cable by passing it through the strain relief at the bottom of the
Electrical Console and connect as shown in the above diagram.
2. Fill the Hydraulic Reservoir with 20 gallons (76 Liters) of approved hydraulic fluid. See
page 56 for 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 20 gallons (76 liters) or 80% of the tank max capacity.
3. Check the level of the hydraulic fluid in
the Hydraulic Pump Case: Disconnect
the Hydraulic Hose from the 90 fitting
and remove the Fitting from Hydraulic
Case. Add fluid as required to the top of
threaded hole. Reattach Fitting and
Hydraulic Hose.
NOTE! 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. Recheck rotation before
proceeding with Installation.
CAUTION! Ensure Main Power Switch is OFF and incoming power is
locked OFF before reversing power leads.
5. Fill the Lube Reservoir with PMC Pump Lube or suitable diluents. It is not necessary to
prime the system.
14
INSTALLATION
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 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 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.
a. For half inch hose assemblies, all required fittings and instructions are included in
kit 200212
3. Connect Air Hose Coupling Connections.
4. Connect the Heated Hose power wires to the “Fast-Lock” Connector (Part # KT-00029A)
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.
15
INSTALLATION
5. 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.
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, 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).
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.
Temperature Sensin g Un it
(TSU) Part # EL- 51A -4
16
INSTALLATION
RECOMMENDED TAP
SETTINGS
1
Tap
Feet
Meters
120V
410
125.0
105V
360
109.7
90V
310
94.5
75V
260
79.5
60V
210
64.0
45V
160
48.8
30V
110
33.5
18V
60
18.3
TRANSFORMER SETTINGS
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
(18 Meters) of Heated Hose1. Before starting the
Proportioner, ensure the setting matches the
Heated Hose length installed. If Heated Hose
sections are added or removed, the Tap setting
must be changed to a setting which will limit the
maximum amperage in the Heated Hose to 52
amps. The suggested tap settings are tabled
below2:
1
90V transformers (shown above) allow for a maximum hose length of 310 ft (94.5 m). 120V
transformers allow for a maximum hose length of 410 ft (125 m).
2
90V Transformers (shown above) are standard on all PH(X)-25 Proportioners. 120V
Transformers are standard for all PH(X)-40 Proportioners, and are also optional for PH(X)-25
Proportioners
17
INSTALLATION
7. 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.
8. Connect the Transfer Pump/Heated Hose Assemblies air supply and air dryer systems
as required. Review the Installation Instructions for each to ensure proper set-up and
operation.
9. Install the Material Transfer Pumps as follows:
WARNING! If Transfer Pumps have been previously
used, pay special attention to connect each Pump to
“its” specific material. Inadvertently changing the
Transfer Pumps will cause a chemical reaction
rendering them useless.
NOTE! Placing 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.
10. Ground the Transfer Pump as recommend by the material supplier. The
movement of product inside the Hoses can cause static electricity and
produce electrical discharges.
18
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.
NOTE! Before using the Proportioner it is necessary to purge the entire
system, including Heated Hoses of mineral oil and air left over from Quality
Control testing. The following procedure is also followed to purge air
entrapped by running out of material in the supply Drum/Reservoirs
resulting in a significant material pressure imbalance as indicated by the
Pressure Gauges and sprayed material.
1. Ensure the following before proceeding:
a. Air supply to Transfer Pumps is 90 - 110 psi (6-8 Bar).
b. Proportioner Inlet Valves are CLOSED.
c. All connections are tight.
d. Material should be stored to the material suppliers' recommended temperatures.
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 the Transfer Pump to move
material through the system. When all air spitting 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.
NOTE! Do not turn on the Count Down Counter.
6. Turn Hydraulic Pressure Control (N, page 10) full COUNTERCLOCKWISE.
7. Turn ON Main Power (Q, page 11). Green pilot will light.
8. Turn ON Control Power (S, page 11). Switch will light.
9. Turn ON Motor Power (W, page 12). Switch will light.
19
PROPORTIONER PURGING
10. Set Pump Switch (X, page 11) to NORMAL. Turn Hydraulic Pressure Control
CLOCKWISE (N, page 10) increasing material pressure to 400 psi (27 bar). Both
Material Pressure Gauges (H, K, page 10) should read the same.
11. Check all 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.
20
PRESSURE BALANCE CONTROL
The PH Series Proportioner has been designed with a pressure balance control system.
This system will give the operator of this machine the ability to control a pressure
imbalance within certain predetermined parameters.
The system consists of:
Selector Switch
Fault Light
On Light
Control Unit
Pressure Transducers
Relay
OPERATION
Position the selector switch on one of the three options:
Pressure differential number – these consist of 300, 400, 500, 600, and 700
PSI. Selecting any of these numbers with the switch will activate the green ON
light. While the pressure differential numbers are selected, the control box will
continually monitor pressure on both sides of the Proportioner. In the event that
the pressure differential between both sides of the Proportioner is equal to or
larger than the selected number, a fault is given (the red fault light is turned on
and the active green light is turned off) and shuts down.
Off – if the selector switch is placed in this position, the Proportioner will operate
as though there is NO PRESSURE BALANCE CONTROL SYSTEM (neither the
red fault light nor the active green light will be lit). The over pressure system will
remain active for the machine and personnel protection.
Reset – in the event of a pressure imbalance, resolve the Proportioner
imbalance, position the selector switch on reset to clear the fault light and restore
power to the Proportioner. After the fault has been cleared, position the switch in
either a Pressure Differential number or in the Off Position to continue
operations.
21
DIGITAL TEMPERATURE CONTROLLER
The PH Series has three Digital Temperature Controllers to manage the temperatures for the
Primary Heaters (Iso (A), Poly (R)) and the Heated Hose. The Hose Heater Controller is
programmed different from the Iso (A) and Poly (R) 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 (Q, page 11) is ON,
Control Power (S, page 11) is ON, and 01
Display light is lit.
2. Press and release button. The display will
read SP1.
3. Press and release or button to display the current material temperature set-point.
4. 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.
5. Press and release and together to return to the actual material temperature in the
Primary Heater/Hose Heater.
WARNING! The Controllers are factory programmed and are
not field re-programmable. If a problem is encountered,
contact your PMC Distributor. Do not attempt to change any
of the programmed parameters. Do not substitute a
Controller from an alternate supplier as its use may result in
equipment damage and/or bodily injury.
NOTE! The Temperature Controller normally displays the actual material
temperature. When lit, the “01” display in the upper left indicates power is
sent to the designated heating system. The “01” display goes out when the
material temperature has reached its set-point. The “01” display will
continue to cycle on and off indicating the Controller is maintaining the
material temperature set-point.
22
START-UP
NOTE! Follow the recommended procedures 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 condition of the PMC pump lube in the Iso (A) Lube Reservoir (page 14).
Replace the PMC pump lube if you see significant changes in the color or signs of
solidification. Ensure inside of Reservoir is wiped clean.
2. Check the hydraulic fluid level and service as required.
3. 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.
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 (Q page 11).
6. Turn ON Control Power (S, page 11).
7. Turn ON Hose Heater (T, page 11) 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 (W, page 12).
10. Set Pump Switch (X, page 11) to NORMAL. One of the Directional Indicator Lights (Y,
page 12) will light indicating Metering Pump direction and the Metering Pump Shafts will
begin to move.
NOTE! The Material Pressure Gauges (H, K, page 10) should be
approximately equal and remain constant throughout the Metering Pump
cycle. If not, refer to Trouble Shooting section.
23
START-UP
120 Pumps
80 Pumps
16 cycles = 1 gal (3.79 L)
24 cycles = 1 gal (3.79 L)
NOTE! 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 pressure1 and check
each Material Pressure Gauge.
12. COUNT DOWN COUNTER
NOTE! 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 pump circuit 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
13. Proceed with Installation and Start-up of the Spray Gun as per the Gun manual.
1
Stall pressure: When materials are at recommended application temperature and Metering
Pumps are pressurized but not moving. This pressure is normally 100 – 200 psi (7-14 Bar)
greater than the developed spray pressure as recommended by the material supplier.
24
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