PMC PHX-2 User manual
POLYURETHANE
MACHINERY
CORPORATION
PHX-2 SERVICE MANUAL
1
REVISION 1.5
v
I. Table of Contents
I. Table of Contents ........................................................................................................................ 1
II.
List of Figures
............................................................................................................................... 3
1
WARRANTY
................................................................................................................................ 5
2
SAFETY AND HANDLING
...................................................................................................... 7
3
CHARACTERISTICS
................................................................................................................... 9
3.1
PRINCIPAL HEATING SYSTEM
.....................................................................................9
3.2
HOSE HEATING SYSTEM
..................................................................................................9
3.3
DOUBLE ACTING OPPOSED PISTON METERING PUMPS
......................... 10
3.4
PRESSURE BALANCE CONTROL SYSTEM
........................................................... 10
4
TECHNICAL SPECIFICATIONS
...........................................................................................11
4.1
ELECTRICAL
........................................................................................................................ 11
4.2
MECHANICAL
...................................................................................................................... 12
5
DESCRIPTION
............................................................................................................................13
6
INSTALLATION
.........................................................................................................................18
6.1
HEATED HOSE INSTALLATION
.................................................................................. 20
6.2
HOSE HEAT TRANSFORMER
...................................................................................... 22
7
PROPORTIONER PURGING
.................................................................................................24
8
PRESSURE BALANCE CONTROL
......................................................................................26
8.1
OPERATION
.......................................................................................................................... 26
9
DIGITAL TEMPERATURE CONTROLLER
.....................................................................27
10
START-UP
..................................................................................................................................29
11
SHUT DOWN
..............................................................................................................................32
11.1
SHORT-TERM
....................................................................................................................... 32
11.2
LONG-TERM
.......................................................................................................................... 32
12
TROUBLESHOOTING
..............................................................................................................33
12.1
HEATERS
................................................................................................................................ 34
12.2
HYDRAULIC DRIVE SYSTEM
......................................................................................... 37
12.3
METERING PUMP-LINE
................................................................................................. 39
12.4
HOSE HEATING
................................................................................................................... 43
12.5
PRESSURE BALANCE CONTROL
............................................................................. 46
13
MAINTENANCE
........................................................................................................................47
13.1
INLET MATERIAL SCREENS
........................................................................................ 48
13.2
ISO LUBRICATION SYSTEM
......................................................................................... 49
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PHX-2 SERVICE MANUAL
2
REVISION 1.5
v
13.3
HYDRAULIC DRIVE SYSTEM
......................................................................................... 50
13.4
METERING PUMP-LINE
................................................................................................. 51
13.5
PUMP SEAL REPLACEMENT
....................................................................................... 51
13.6
MATERIAL HEATER
......................................................................................................... 52
13.7
THERMOCOUPLE REPLACEMENT
........................................................................... 52
14
HYDRAULIC OIL SPECIFICATIONS
..................................................................................54
14.1
MANUFACTURERS
........................................................................................................... 54
15
PARTS IDENTIFICATION
......................................................................................................55
15.1
FRAME ASSEMBLY
........................................................................................................... 55
15.2
PROX SENSOR ASSEMBLY
............................................................................................ 57
15.3
HYDRAULIC MANIFOLD ASSEMBLY
....................................................................... 58
15.4
EXIT MANIFOLD ASSEMBLY
....................................................................................... 59
15.5
HYDRAULIC CYLINDER ASSEMBLY
.......................................................................... 60
15.5.1
HYDRAULIC CYLINDER REBUILD KIT
..................................................... 61
15.6
A & R SINGLE PUMP ASSEMBLY
............................................................................... 63
15.7
PUMP-LINE SEAL ORIENTATION
............................................................................. 65
15.8
PUMP-LINE ASSEMBLY
.................................................................................................. 66
15.8.1
PUMP REBUILD KIT
.......................................................................................... 67
15.9
INLET MONITORING ASSEMBLY
.............................................................................. 68
15.10
Y-STRAINER ASSEMBLY “A” SIDE
.......................................................................... 69
15.11
Y-STRAINER ASSEMBLY “R” SIDE
.......................................................................... 70
15.12
HEATER ASSEMBLY
......................................................................................................... 71
15.13
MOTOR-LINE ASSEMBLY
............................................................................................... 75
15.14
FINAL ASSEMBLY
.............................................................................................................. 77
15.15
PHX-2 HOSES........................................................................................................................ 84
15.15.1
HALF INCH HOSE KIT ...................................................................................... 85
15.16
LUBE BOTTLE COMPONENTS
.................................................................................... 86
15.17
BLEED VALVE KIT
............................................................................................................ 87
POLYURETHANE
MACHINERY
CORPORATION
PHX-2 SERVICE MANUAL
3
REVISION 1.5
v
II.
List of Figures
Figure 1: Hose Heating Diagram .....................................................................................................................9
Figure 2: Pressure Balance Control Logic Diagram.............................................................................. 10
Figure 3: Proportioner Dimensions............................................................................................................ 12
Figure 4: Component Identification - Front............................................................................................. 13
Figure 5: Component Identification - Back .............................................................................................. 14
Figure 6: Inlet Strainer Components.......................................................................................................... 15
Figure 7: Front Panel Description ............................................................................................................... 16
Figure 8: Incoming Electrical Power Connections................................................................................ 18
Figure 9: Installation......................................................................................................................................... 19
Figure 10: Temperature Sensing Unit........................................................................................................ 21
Figure 11: Transformers Tap Settings....................................................................................................... 22
Figure 12: Pressure Balance Control Interface....................................................................................... 26
Figure 13: OMRON Temperature Controller........................................................................................... 28
Figure 14: EATON Countdown Counter .................................................................................................... 30
Figure 15: OMRON Countdown Counter................................................................................................... 31
Figure 16: Metering Pump-Line ................................................................................................................... 39
Figure 17: Pressure Balance Control Unit................................................................................................ 46
Figure 18: Inlet Strainer Components ....................................................................................................... 48
Figure 19: ISO Lubrication System.............................................................................................................. 49
Figure 20: Thermocouple Identification................................................................................................... 52
Figure 21: Frame Assembly (FR-10) .......................................................................................................... 55
Figure 22: Prox. Sensor Assembly (RM-243).......................................................................................... 57
Figure 23: Hydraulic Manifold Assembly (HI-05335)......................................................................... 58
Figure 24: Exit Manifold Assembly (HI-05343)..................................................................................... 59
Figure 25: Hydraulic Cylinder Assembly (HI-05336).......................................................................... 60
Figure 26: Hydraulic Seal Detail View........................................................................................................ 62
Figure 27: Hydraulic Piston Detail View................................................................................................... 62
Figure 28: A & R Single Pump Assembly (202587) .............................................................................. 63
Figure 29: A & R Single Pump Cross Section ........................................................................................... 64
Figure 30: A & R Single Pump Assembly Detail A.................................................................................. 65
Figure 31: A & R Single Pump Assembly Detail B.................................................................................. 65
Figure 32: Pump-Line Assembly (202588).............................................................................................. 66
Figure 33: Inlet Monitoring Assembly (KT-05005).............................................................................. 68
Figure 34: Y-Strainer Assembly "A" Side (YS-1) .................................................................................... 69
Figure 35: Y-Strainer Assembly "R" Side (YS-2) .................................................................................... 70
Figure 36: Heater Assembly, 6 Rod - A...................................................................................................... 71
Figure 37: Heater Assembly, 6 Rod - B ...................................................................................................... 71
Figure 38: Heater Assembly, 8 Rod - A...................................................................................................... 73
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PHX-2 SERVICE MANUAL
4
REVISION 1.5
v
Figure 39: Heater Assembly, 8 Rod - B ...................................................................................................... 73
Figure 40: Motor-Line Assembly ................................................................................................................. 75
Figure 41: Motor Comparison....................................................................................................................... 76
Figure 42: PHX-2 Final Assembly - A.......................................................................................................... 77
Figure 43: PHX-2 Final Assembly –B......................................................................................................... 78
Figure 44: PHX-2 Final Assembly - C.......................................................................................................... 79
Figure 45: PHX-2 Final Assembly - D.......................................................................................................... 80
Figure 46: Proportioner Hoses - Front ...................................................................................................... 84
Figure 47: Proportioner Hoses - Back........................................................................................................ 84
Figure 48: Lube Bottle Components........................................................................................................... 86
Figure 49: Bleed Valve Kit (202456).......................................................................................................... 87
POLYURETHANE
MACHINERY
CORPORATION
PHX-2 SERVICE MANUAL
1. WARRANTY
5
REVISION 1.6
1
WARRANTY
Polyurethane Machinery Corporation (hereinafter “PMC”) provides this
LIMITED WARRANTY
(hereinafter “Warranty”) to the original purchaser (hereinafter “Customer”) covering this equipment and
the original PMC manufactured accessories delivered with the equipment (hereinafter “Product”) against
defects in material or workmanship of the Product (hereinafter “Defect”or “Defective”) for a period of
one (1) year from the date of first purchase as shown on the original
PMC invoice (hereinafter
“Warranty Period”)
If during the Warranty Period under normal use, the Product is suspected by Customer to be
Defective in material or workmanship, it is Customer’s responsibility to contact PMC and return
the
Product to PMC as directed by PMC, freight prepaid. If PMC determines that the Productis
Defective and that such Defect is covered by this Warranty, PMC will credit Customer for the
reasonable freight charges incurred by Customer in returning the Defective Product to PMC, and
PMC
(or its authorized agent) will, at PMC’s option, repair or replace the Product, subject to the following:
1.
Original Invoice: The original invoice must be kept as proof of the date of first sale and the
Product serial number. The Warranty does not cover any Product if the Original Invoice
appears to have been modified or altered, or when the serial number on the Product appears to
have been altered or defaced.
2.
Product Maintenance: It is the Customer’s responsibility to maintain the Product properly. See
your maintenance schedule and owner’s manual for details. The Warranty does not cover
an
improperly maintained Product.
3.
Non-PMC Components and Accessories: Non-PMC manufactured components and accessories
that
are used in the operation of the Product are not covered by this Warranty. Such compo
nents and
accessories shall be subject to the warranty offered to the Customer, if any, by the
original
manufacturer of such component or accessory.
4.
Other Warranty Exclusions: The Warranty does not cover any Product that PMC determines has
been damaged or fails to operate properly due to misuse, negligence, abuse, carelessness,
neglect,
or accident. By way of example only, this includes:
•
Normal wear and tear.
•
Improper or unauthorized installation, repair, alteration, adjustment, or 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.
POLYURETHANE
MACHINERY
CORPORATION
PHX-2 SERVICE MANUAL
1. WARRANTY
6
REVISION 1.6
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 RE-
SPONSIBLE, 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 forthree (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 War
ranty
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 conditionsproposed 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.
POLYURETHANE
MACHINERY
CORPORATION
PHX-2 SERVICE MANUAL
2.
SAFETY AND HANDLING
7
REVISION 1.6
2
SAFETY AND HANDLING
This chapter contains important information on the safety, handling, and use of your PH
Series Proportioner.
Before installing the PH Series Proportioner and
startup, 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.
WARNING! Symbol is presented in front of information to alert
of a
situation that might cause serious injuries if the instructions are not
followed.
CAUTION! Symbol is presented in front of information that indicates how
to avoid damage to the proportioner or how to avoid a situation that could
cause issues.
NOTE! Symbol is presented in front of relevant information of a
procedure being carried out.
Careful study of this manual will enable the operator to know the characteristics of the 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, and
maintenance of the PH Series Proportioner. You will provide a better opportunity for greater output,
incident-free operation for a longer time, and the possibility of detecting and resolving
problems quickly
and simply.
Keep this Operations Manual for future consultation of useful information.
If
you lose this
manual, ask for a new copy from your PMC Service Center or go online at our web site
(www.polymacusa.com).
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
POLYURETHANE
MACHINERY
CORPORATION
PHX-2 SERVICE MANUAL
2.
SAFETY AND HANDLING
8
REVISION 1.6
WARNING! The design and configuration of the PH Series Pro
portioner
does not allow its use in potentially explosive atmospheres, or the pressure and
temperature limits described in the technical specifi
cations of this manual to be
exceeded.
Always use liquids and solvents that are compatible with the unit. If in doubt, consult your
authorized PMC distributor.
When working with the 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
Safety
Data Sheet (SDS) provided by your supplier. Deal with the waste
caused according to current regulations.
To avoid damage caused by the impact of pressurized fluids, do
not
open any connection, or perform maintenance work on com
ponents
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 in
cludes,
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.
POLYURETHANE
MACHINERY
CORPORATION
PHX-2 SERVICE MANUAL
3.
CHARACTERISTICS
9
REVISION 1.6
3
CHARACTERISTICS
The PH Series Proportioner has been designed and built for the application of polyurea chemical
systems, polyurethane foam chemical systems, and some specific two-component epoxy
systems.
3.1
PRINCIPAL HEATING SYSTEM
The Proportioner consists of one (1) Material Heater without internal seals. The Low-
Pressure
Heater has three (3) Heating Elements per fluid side rated at 1,250, 1,500, or 1750 watts, each
giving the Proportioner a total heat output of 7,500, 9,000, or 10,500 watts. The High-Pressure Heater
has four (4) Heating Elements per fluid side rated at 1750 watts, each giving the Proportioners total heat
output of 14,000 watts. Every heating system provides the necessary control and safety components for
their precise operation. The Material Heater design allows for a controlled and precise temperature
differential (∆T) and material application temperatures of up to 190º F under
ambient temperatures.
3.2
HOSE HEATING SYSTEM
The system is designed with a 3 KVA Isolation Transformer that enables effective heating
of
up to a total hose length of 310 feet (also available with a 2KVA transformer and a 5 KVA
transformer for maximum hose lengths of 210 and 410, respectively). The system includes an
innovative hose heating concept in which the continuous braid 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.
Figure 1: Hose Heating Diagram
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PHX-2 SERVICE MANUAL
3.
CHARACTERISTICS
10
REVISION 1.6
3.3
DOUBLE ACTING OPPOSED PISTON METERING PUMPS
The opposed double acting Pump Line is driven by a double ended Hydraulic Cylinder.
The
in-line pump system with opposed piston pumps provides a constant volume and guarantees
uniform
pressures in both directions of pump movement.
3.4
PRESSURE BALANCE CONTROL SYSTEM
The Pressure Balance Control (PBC) system performs an automatic shutdown when a
chemical imbalance occurs. When the system is turned off, the Proportioner will perform as if
there
is no PBC system and will continue pumping material. When the system is turned on, it will continually
monitor the pressure between the two chemicals (known as the
pressure differential
).If the pressure
differential becomes equal to or greater than the
maximum allowable pressure
differential, the
pumps will be shut off.
The Pressure Balance Control system can be simplified into a logic box diagram with inputs and
outputs. There are five inputs: the power supply from the main console, the pressure readings
from each
chemical, the maximum pressure,
and the maximum allowable pressure differential.
Inside
the logic box, the
actual pressure differential of the chemicals is compared to the maximum allowablepressure differential.
Depending on the circumstances of all five inputs, there are only two possible outputs: either the pumps
will continue to pressurize and move material, or the pumps will shut
off and flow will be lost.
Figure 2: Pressure Balance Control Logic Diagram
11
REVISION 1.6
4
TECHNICAL SPECIFICATIONS
4.1
ELECTRICAL
PH-2 Detailed Electrical Specifications
Pressure
Material
Heater Power
Electrical
Consumption
(208-240VAC/1PH)
Electrical
Consumption
(208-240VAC /3PH)
Electrical
Consumption
(380VAC /3PH)
Power
Consumption
3,000PSI
7.5kW (3.75kW
[3x1250W]/side)
33A
19A
11A
7.5kW
9.0kW (4.50kW
[3x1500W]/side)
39A
23A
14A
9.0kW
10.5kW (5.25kW
[3x1750W]/side)
46A
26A
16A
10.5kW
14kW (7kW
[4x1750W]/side)
61A
35A
21A
14kW
Hose Transformer
70V
9A
5A
3A
2kVA
90V
13A
8A
5A
3.15kVA
120V
22A
13A
8A
5kVA
Electrical Motor
PHX-2
29A
17A
13A
5HP
Console
All
2A
2A
2A
-
PHX-2 Total Electrical Consumption
Material
Heater Power
Hose
Transformer
Total Electrical
Consumption
(208-240VAC/1PH)
Total Electrical
Consumption
(208-240VAC /3PH)
Total Electrical
Consumption
(380VAC /3PH)
7.5kW
90V
77A
46A
31A
9.0kW
83A
50A
34A
10.5kW
90A
53A
36A
14kW
105A
62A
41A
NOTES: Calculations for 208-240VAC specifications based off a 230VAC input.
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.
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PHX-2 SERVICE MANUAL
4 TECHNICAL SPECIFICATIONS
12
REVISION 1.6
4.2
MECHANICAL
61 Pumps
Maximum Working Pressure
3,000PSI (21MPa, 207bar)
Maximum Production
2.3gal/min (10.5L/min)
Minimum Production
2lb/min (1kg/min)
Volume per Cycle (Single Pump)
0.0093gal/cycle (0.03502L/cycle)
Volume per Cycle (Both Pumps)
0.035gal/cycle (0.07005L/cycle)
Cycles per 55gal (200L) Drum
5919 cycles
Maximum Hose Length
2KVA Transformer
210ft (64m)
3KVA Transformer
310ft (95m)
5KVA Transformer
410ft (125m)
Approximate Weight
Hydraulic Tank Empty
415lbs (166kg)
Hydraulic Tank Full (12gal)
450lbs (197kg)
Overall Dimensions (W x D x H)
37in x 25in x 54in (94cm x 63cm x 139cm)
Figure 3: Proportioner Dimensions
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MACHINERY
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PHX-2 SERVICE MANUAL
5.
DESCRIPTION
15
REVISION 1.6
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.
Hydraulic Cylinder Assembly
Transfers power from hydraulic pump to material pumps.
E.
Isocyanate (Iso, A) Inlet Manifold Assembly
Provides Isocyanate temperature and pressure readings prior to heating and pressurizing.
F.
Polyol (Poly, R) Inlet Manifold Assembly
Provides Polyol temperature and pressure readings prior to heating and pressurizing.
G.
Exit Manifold Assembly
Provides pressure reading of material after heating and pressurizing.
H.
Isocyanate (Iso, A) Lube Reservoir
Provides lube to the Isocyanate pump shaft.
I.
Hydraulic Manifold Assembly
Provides pressure reading of hydraulic fluid and controls direction of flow.
J.
Motor
Provides power for hydraulic pump.
K.
Hose Heating Transformer - Right side (inside of hydraulic tank)
Supplies the required voltage for material Heated Hoses.
L.
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.
M.
Inlet Material Strainer
Screens (60 mesh) material from bulk supply.
Figure 6: Inlet Strainer Components
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PHX-2 SERVICE MANUAL
5.
DESCRIPTION
16
REVISION 1.6
Figure 7: Front Panel Description
N.
Main Power
Turns ON and OFF main power to the control panel. It must be turned ON for any operation
to
be performed with the unit. When turned ON, the red pilot will light.
O.
Emergency Stop
Interrupts the PH- Series control power circuit to stop all motion and heating.
P.
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 into the pump to prevent
crystallization of Iso (A) on the Piston Rod. Press the RETRACT key every time the unit is
stopped by the operator (See Section 11 on page 31).
Q.
Direction Indicator Lights
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.
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.
Temperature Controllers
Displays the temperature of the chemicals. See Section 9 on page 26 for detailed Temperature
Controller instructions.
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PHX-2 SERVICE MANUAL
5.
DESCRIPTION
17
REVISION 1.6
U.
Totalizer
Indicates the number of pump cycles to calculate material usage for both A and R side combined:
Model
Pressure
Pump Size
Cycles per Gal (3.79L)
PHX-2
3,000PSI
61
55
V.
Auto Shut Down Switch
Turns ON and OFF power to the Auto Shut Down unit.
W.
Auto Shut Down Counter
Used to set the number 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.
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.
Pressure Balance Control Knob
Used to set the maximum allowable pressure differential (in PSI) between the A (Iso) and R
(Poly)
pumps. See page 25 for more information.
Z.
Pressure Balance Control “ON” Light
Indicates that the Pressure Balance Control system is on and functioning.
AA. Pressure Balance Control “FAULT” Light
Indicates that the pressure differential is equal to or greater than the maximum allowable
pressure
differential.
POLYURETHANE
MACHINERY
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PHX-2 SERVICE MANUAL
6.
INSTALLATION
18
REVISION 1.6
6
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 elec
trical
supply must meet the specifications indicated on the Serial Num
ber Placard
affixed to the Electrical Console.
1.
Insert the main power cable by passing it through the wire stop at the bottom of the electrical
console and connect as shown in the diagram above.
2.
Fill the Hydraulic Reservoir with 10 gallons (37 Liters) of approved hydraulic fluid. See page
53
for hydraulic oil specifications.
NOTE! Do not fill the tank to maximum capacity; use the
Visual Level Indicator on the tank to make
sure the
amount of hydraulic fluid is not more than 10 gal (37 L) or
80% of the tank’s maximum capacity.
3.
To check the level of the hydraulic fluid in the Hydraulic Pump Case, disconnect the Hydraulic Hose
from the 90-degree fitting and remove Fitting from Hydraulic Case. Add fluid as required.
Reattach
Fitting and Hydraulic Hose. Turn the hydraulic pressure control knob counterclockwise until
it stops, that is the lowest hydraulic pressure setting.
Figure 8: Incoming Electrical Power Connections
POLYURETHANE
MACHINERY
CORPORATION
PHX-2 SERVICE MANUAL
6.
INSTALLATION
19
REVISION 1.6
Figure 9: Installation
CAUTION! Ensure that the emergency stop is not engaged.
4.
Three Phase Proportioner Only:
Check the Electric Motor to ensure rotation is clockwise
when
viewing the end of the Electric Motor. A counterclockwise 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 rotation before proceeding with Installation.
5.
Fill the Lube Reservoir with PMC Pump Lube or suitable dilutants. It is not necessary to prime
the system.
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