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PMC PH Series User Manual

Proportioner
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JUNE 1, 2013
Before installing the PH Series Proportioner and start-up, carefully read all the technical
and safety documentation included in this manual.
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
Proportioner
Manual
Ref. # MN-04007
Polyurethane Machinery Corp.
Corporate: 1 Gusmer Drive, Lakewood, NJ 08701
Manufacturing: 2 Gusmer Drive, Lakewood, NJ 08701
Phone: 732-415-4400
http://www.polymac-usa.com
Fax: 732-364-4025
Pay special attention to the

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Summary of Contents for PMC PH Series

  • Page 1 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...

  • Page 2: Table Of Contents

    PH-20/PHX-20 Manual Warranty ……………………………………………………………………………………….. Safety and Handling …………………………………………………………………………. Characteristics Principal Heating System …………………………………………………………………. Hose Heating System ……………………………………………………………………… Double Acting Piston Metering Pumps …………………………………………………… Technical Specifications Electrical ……………………………………………………………………………………… Mechanical …………………………………………………………………………………… Description ……………………………………………………………………………………… Installation ………………………………………………………………………………………. 14 Proportioner Purging………………………………………………………………………….. 20 Digital Temperature Controller………………………………………………………………. 22 Start-Up ………………………………………………………………………......

  • Page 3: Warranty

    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”).
  • Page 4 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;...

  • Page 5: Safety And Handling

    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).
  • Page 6 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.

  • Page 7: Principal Heating System

    PH-20/PHX-20 Manual 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.

  • Page 8: Technical Specifications

    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...

  • Page 9: Description

    PH-20/PHX-20 Manual DESCRIPTION PH-20/PHX-20 Proportioners 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.
  • Page 10 PH-20/PHX-20 Manual 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.
  • Page 11 PH-20/PHX-20 Manual O. Inlet Material Strainer Screens (60 mesh) material from bulk supply.
  • Page 12 PH-20/PHX-20 Manual 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.
  • Page 13 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.

  • Page 14: Installation

    PH-20/PHX-20 Manual 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).
  • Page 15 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...
  • Page 16 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.
  • Page 17 PH-20/PHX-20 Manual 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. Fast-Lock Connection b.
  • Page 18 PH-20/PHX-20 Manual 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.
  • Page 19 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.

  • Page 20: Proportioner Purging

    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.
  • Page 21 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.

  • Page 22: Digital Temperature Controller

    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.

  • Page 23: Start-Up

    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.
  • Page 24 PH-20/PHX-20 Manual 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.

  • Page 25: Shutdown Procedures

    PH-20/PHX-20 Manual SHUT-DOWN Follow the recommended procedure in the indicated order for Proportioner temporary shut- down 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.

  • Page 26: Troubleshooting

    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.

  • Page 27: Heaters

    PH-20/PHX-20 Manual 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 Material Heater NOTE ! The Thermal Limit Switch is a safety switch in contact with the Heater...
  • Page 28 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.
  • Page 29 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.

  • Page 30: Hydraulic Drive System

    PH-20/PHX-20 Manual 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. MODEL INDIVIDUAL OHMS MEASUREMENT PH-20, 2000 PSI 1250 WATT 37 OHMS PHX-20, 3000 PSI 1500 WATT 31 OHMS Hydraulic Drive System...
  • Page 31 PH-20/PHX-20 Manual 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.
  • Page 32 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.

  • Page 33: Metering Pump Line

    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.
  • Page 34 PH-20/PHX-20 Manual TROUBLESHOOTING Metering Pump Line (cont’d) IF THE DIRECTIONAL LIGHT IS 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].
  • Page 35 PH-20/PHX-20 Manual b) Determine what material is NOT exiting the Mixing Chamber. Material c) Read the Pressure Gauge on the problem side and interpret the Supply 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;...
  • Page 36 PH-20/PHX-20 Manual 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: Directional Indicator Light Directional Indicator Light Iso Pressure Gauge...

  • Page 37: Hose Heating

    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;...
  • Page 38 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.
  • Page 39 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.
  • Page 40 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.

  • Page 41: Maintenance

    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.

  • Page 42: Inlet Material Screens

    PH-20/PHX-20 Manual 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.

  • Page 43: Hydraulic Drive System

    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.

  • Page 44: Metering Pump Line

    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.

  • Page 45: Material Heater

    PH-20/PHX-20 Manual 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;...

  • Page 46: Parts Identification

    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;...

  • Page 47: Hydraulic Oil Specification

    PH-20/PHX-20 Manual 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: American Oil & Supply – PQ Iso 32 Fiske Bros. – Lubriplate Hyd. #0 Mobil DTE24 Cook’s Albavis 8 Gulf Oil –...

  • Page 48: Replacement Kits

    PH-20/PHX-20 Manual REPLACEMENT KITS Hydraulic Cylinder Rebuild Kit KT-05200 Description HI-05025-1 U-Cup HI-05025-2 Back-up Ring, Piston HI-05025-3 Wear Ring HI-05025-4 Rod Wiper HI-05025-5 Shaft Seal HI-05025-6 Back-up Ring, Bushing OR-00039A O-ring OR-00040A O-ring Heater Thermocouple Kit KT-05021 Description HI-05020 Body, Nut, Ferrule HI-05021 Thermocouple PUMP REBUILD KITS...

  • Page 49: Machine Spare Parts

    PH-20/PHX-20 Manual HEATER PARTS PART NUMBER DESCRIPTION QTY PER HEATER COMPLETE “A” SIDE HEATER, PH-20 PH-16 COMPLETE “R” SIDE HEATER, PH-20 PH-17 COMPLETE “A” SIDE HEATER, PHX-20 PH-18 COMPLETE “R” SIDE HEATER, PHX-20 PH-19 GM-06424-1 HEATER BODY GM-06424-2 PHONOLIC WASHER GM-05423-1250 HEATER CARTRIDGE, PH-20 GM-05423-1500...
  • Page 50 PH-20/PHX-20 Manual MOTOR LINE PARTS PART NUMBER DESCRIPTION EL-05224 ELECTRIC MOTOR, 3HP, 3 PHASE, 60HZ EL-05221 ELECTRIC MOTOR, 3HP, 1 PHASE, 60HZ HI-05001 BELL HOUSING HI-00065-01 MAGNALOY INSERT HI-00065-02 MAGNALOY HUB, 1-1/8 x 1/4 HI-00065-03 MAGNALOY HUB, ¾ x 3/16 HI-05006 HYDRAULIC PUMP HI-05004-1...
  • Page 51 PH-20/PHX-20 Manual HYDRAULIC TANK PARTS PART NUMBER DESCRIPTION RM-213 TANK LID HI-00014-04A GASKET, TANK TOP TN-05704 CASTERS HI-00002-A GROMMET, TANK TOP HI-05048 DRAIN PLUG RM-212 TRANSFORMER DOOR Y-STRAINER PARTS PART NUMBER DESCRIPTION YS-1 Y-STRAINER ASSY, A SIDE YS-2 Y-STRAINER ASSY, R SIDE RA-00074-00A Y-STRAINER (60 MESH) BALL VALVE ¾”...

  • Page 52: Hoses

    PH-20/PHX-20 Manual PART NUMBER DESCRIPTION 3/8 x 50’ LOW PRESSURE HOSE,2250 psi MA-00014A 3/8 x 50’ LOW PRESSURE HOSE,2250 psi W/TC WIRE MA-00014-TC ¼ x 10” GUN HOSE ASSY W/SCUFF JACKET 3500psi MA-00040A 3/8 x 50’ HIGH PRESSURE HOSE,3500 psi MA-00039A 3/8 x 50’...
  • Page 53 PH-20/PHX-20 Manual PART NUMBER DESCRIPTION HI-05070-1 MANIFOLD, HYDRAULIC DRAIN TUBE ¼” HI-05070-2 HI-05040-2 GAUGE, 0-2000 psi Bottom mount HI-05003 DIRECTIONAL VALVE GP-00100-5 ELBOW HI-05038 FITTING, HI-05200 HYDRAULIC CYLINDER PART NUMBER DESCRIPTION HI-05200-1 PISTON HI-05200-2 CYLINDER HI-05200-3 PORT BLOCK HI-05200-5 Bolt, TIE ROD HI-05201 MOUNTING PLATE HI-05202...

  • Page 54: Phx20, 3000 Psi Pump Line-61

    PH-20/PHX-20 Manual A/R PUMP 3000 PSI – PHX-20 SIZE 61...
  • Page 55 PH-20/PHX-20 Manual A/R PUMP 3000 PSI - PHX-20 SIZE 61 PUMP PARTS LIST ITEM PART NUMBER DESCRIPTION PAX-045 OUTLET BODY PAX-053 INLET BODY PAX-064 PACKING NUT/GREASE CUP PAX-065 SCRAPER SEAL PAX-052 ROD SEAL ASSEMBLY PAX-051 ROD BUSHING PAX-062 FLUID ROD PAX-047 PISTON PA-063...

  • Page 56: Ph-20, 2000 Psi Pump Line-123

    PH-20/PHX-20 Manual A/R PUMP 2000 PSI – PH-20 SIZE 123...
  • Page 57 PH-20/PHX-20 Manual A/R PUMP 2000 PSI - PH-20 SIZE 123 PUMP PARTS LIST ITEM PART NUMBER DESCRIPTION PA-045 OUTLET BODY PA-046 PISTON VALVE PA-047 PISTON OR-916 O-RING BALL, 3/4” PA-048 PA-049 SPRING PA-050 SPRING RETAINER PA-051 ROD BUSHING PA-052 ROD SEAL ASSEMBLY PA-053 INLET BODY PA-054...

  • Page 58: Electrical Parts

    PH-20/PHX-20 Manual CONSOLE BOTTOM ELECTRICAL PARTS Part No. Description Quantity EL-116 HEATER BREAKER, 25 AMP EL-117 HOSE BREAKER, 20 AMP EL-114 CONTROL BREAKER, 3 AMP EL-110 MOTOR BREAKER, 32 AMP/1 PHASE EL-162 MOTOR BREAKER, 20 AMP/3 PHASE EL-122 POWER SUPPLY, DC EL-120 RELAY, DPDT (CONTACTOR) EL-119...
  • Page 59 PH-20/PHX-20 Manual CONSOLE PANEL ELECTRICAL PARTS Part No. Description Quantity EL-124 TOTALIZER EL-127 AUTO COUNT DOWN EL- T1 TEMPERTURE CONTROLLER, HOSE EL- T2 TEMPERTURE CONTROLLER, HEATER EMERGENCY STOP SWITCH Part No. Description Quantity EL-133-NO SWITCH, NORMALLY OPEN EL-107 E-STOP KNOB EL-131-R LIGHT EL-133-NC...
  • Page 60 PH-20/PHX-20 Manual CONTROL POWER SWITCH Part No. Description Quantity EL-18-R KNOB ASSY EL-130 INSERT, MOMENTARY EL-133-NC SWITCH, NORMALLY CLOSED EL-133-NO SWITCH, NORMALLY OPEN MOTOR SWITCH Part No. Description Quantity EL-129-R KNOB ASSY EL-131-R LIGHT EL-133-NO SWITCH, NORMALLY OPEN PUMP SWITCH Part No.
  • Page 61 PH-20/PHX-20 Manual LEFT DIRECTIONAL LIGHT Part No. Description Quantity EL-134 SOCKET EL-131-W BULB EL-138 LENS TRANSFORMER Part No. Description Quantity EL-150 BREAKER, 63 AMP...

  • Page 62: Electrical Schematics

    PH-20/PHX-20 Manual 220 Volt, 1 Phase...
  • Page 63 PH-20/PHX-20 Manual 220 Volt, 1 Phase...
  • Page 64 PH-20/PHX-20 Manual 220 Volt, 1 Phase...
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  • Page 66 PH-20/PHX-20 Manual 220 Volt, 1 Phase...
  • Page 67 PH-20/PHX-20 Manual 220 Volt, 3 Phase...
  • Page 68 PH-20/PHX-20 Manual 220 Volt, 3 Phase...
  • Page 69 PH-20/PHX-20 Manual 220 Volt, 3 Phase...
  • Page 70 PH-20/PHX-20 Manual 220 Volt, 3 Phase...
  • Page 71 PH-20/PHX-20 Manual 220 Volt, 3 Phase...
  • Page 72 PH-20/PHX-20 Manual 380 Volt, 3 Phase...
  • Page 73 PH-20/PHX-20 Manual 380 Volt, 3 Phase...

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