PMC PK-25 User manual

PK-25 Proportioner
Service Manual
Ref. # 202977
Revision 1.5
FOR PROFESSIONAL USE ONLY
Not approved for use in European explosive atmosphere locations
1 Komo Dr.
Lakewood, NJ 08701
Phone: [phone]
URL: http://www.polymacusa.com

POLYURETHANE
MACHINERY
CORPORATION
PK-25 SERVICE MANUAL
POLYURETHANE
MACHINERY
CORPORATION
2
REVISION 1.5
I. Table of Contents
I. Table of Contents...................................................................................................................... 2
II. List of Figures ............................................................................................................................ 4
1 WARRANTY .............................................................................................................................. 5
2 SAFETY AND HANDLING .................................................................................................... 7
3 CHARACTERISTICS ................................................................................................................. 9
3.1 PRINCIPAL HEATING SYSTEM ......................................................................9
3.2 HOSE HEATING SYSTEM ................................................................................9
4 TECHNICAL SPECIFICATIONS .........................................................................................11
4.1 ELECTRICAL ...................................................................................................11
4.1 MECHANICAL ................................................................................................ 12
5 DESCRIPTION ..........................................................................................................................13
6 INSTALLATION .......................................................................................................................19
6.1 HEATED HOSE INSTALLATION ....................................................................20
6.1 HOSE HEAT TRANSFORMER ....................................................................... 23
7 PROPORTIONER PURGING ...............................................................................................24
8 DIGITAL TEMPERATURE CONTROLLER ...................................................................26
9 START-UP ................................................................................................................................27
10 SHUT DOWN ............................................................................................................................28
10.1 SHORT-TERM .................................................................................................28
10.2 LONG-TERM ...................................................................................................28
11 TROUBLESHOOTING ............................................................................................................29
11.1 HEATERS ........................................................................................................30
11.2 PNEUMATIC DRIVE SYSTEM ......................................................................... 33
11.3 METERING PUMP LINE ................................................................................. 35
11.4 HOSE HEATING ..............................................................................................38
12 MAINTENANCE ......................................................................................................................41
12.1 INLET MATERIAL SCREENS ........................................................................42
12.2 ISO LUBRICATION SYSTEM .........................................................................43
12.3 METERING PUMP-LINE ................................................................................44
12.4 PUMP SEAL REPLACEMENT ........................................................................44
12.5 MATERIAL HEATER ...................................................................................... 45
12.6 THERMOCOUPLE REPLACEMENT .............................................................. 45
13 PARTS IDENTIFICATION ....................................................................................................47
13.1 A & R SINGLE PUMP ASSEMBLY .................................................................. 47
13.2 PUMP-LINE SEAL ORIENTATION ................................................................49
13.3 PUMP-LINE ASSEMBLY ................................................................................50
13.4 Y-STRAINER ASSEMBLY “A” SIDE .............................................................. 52

POLYURETHANE
MACHINERY
CORPORATION
PK-25 SERVICE MANUAL
POLYURETHANE
MACHINERY
CORPORATION
3
REVISION 1.5
13.5 Y-STRAINER ASSEMBLY “R” SIDE .............................................................. 53
13.6 HEATER ASSEMBLY ...................................................................................... 54
13.7 TRANSFORMER ENCLOSURE ASSEMBLY ..................................................... 56
13.8 FINAL ASSEMBLY .......................................................................................... 58
13.9 PK-25 HOSES..................................................................................................64
13.10 LUBE BOTTLE COMPONENTS ................................................................... 65

POLYURETHANE
MACHINERY
CORPORATION
PK-25 SERVICE MANUAL
POLYURETHANE
MACHINERY
CORPORATION
4
REVISION 1.5
II. List of Figures
Figure 1: Hose Heating Diagram .....................................................................................................................9
Figure 2: Proportioner Dimensions............................................................................................................ 12
Figure 3: Component Identification - Front............................................................................................. 13
Figure 4: Component Identification - Back .............................................................................................. 14
Figure 5: Front Panel Description ............................................................................................................... 16
Figure 6: Transformer Enclosure ................................................................................................................ 18
Figure 7: Incoming Electrical Power Connections................................................................................ 19
Figure 8: Temperature Sensing Unit .......................................................................................................... 21
Figure 9: Transformer Tap Settings............................................................................................................ 23
Figure 10: OMRON Temperature Controller........................................................................................... 26
Figure 11: Pneumatic Drive System............................................................................................................ 33
Figure 12: Metering Pump-Line ................................................................................................................... 35
Figure 13: Inlet Strainer Components ....................................................................................................... 42
Figure 14: ISO Lubrication System.............................................................................................................. 43
Figure 15: Thermocouple Identification................................................................................................... 45
Figure 16: A & R Single Pump Assembly (202880/202881) ............................................................ 47
Figure 17: A & R Single Pump Cross Section ........................................................................................... 48
Figure 18: A & R Single Pump - Outlet ....................................................................................................... 49
Figure 19: A & R Single Pump Assembly - Inlet...................................................................................... 49
Figure 20: Pump-Line Assembly (202879).............................................................................................. 50
Figure 21: Y-Strainer Assembly "A" Side (YS-1) .................................................................................... 52
Figure 22: Y-Strainer Assembly "R" Side (202600).............................................................................. 53
Figure 23: Heater Assembly, PK-25 - A ..................................................................................................... 54
Figure 24: Heater Assembly, PK-25 - B ..................................................................................................... 54
Figure 25: Transformer Enclosure, PK-25 (203213)........................................................................... 56
Figure 26: PK-25 Final Assembly - A .......................................................................................................... 58
Figure 27: PK-25 Final Assembly - B .......................................................................................................... 59
Figure 28: PK-25 Final Assembly - C .......................................................................................................... 60
Figure 29: PK-25 Final Assembly - D.......................................................................................................... 61
Figure 29: Proportioner Hoses ..................................................................................................................... 64
Figure 31: Lube Bottle Components........................................................................................................... 65

5
REVISION 1.5
POLYURETHANE
MACHINERY
CORPORATION
PK-25 SERVICE MANUAL
1. WARRANTY
1 WARRANTY
Polyurethane Machinery Corporation (hereinafter “PMC”) provides this LIMITED WARRANTY
(hereinafter “Warranty”) to the original purchaser (hereinafter “Customer”) covering this equipment and
the original PMC manufactured accessories delivered with the equipment (hereinafter “Product”)
against defects in material or workmanship of the Product (hereinafter “Defect”or “Defective”) for a
period of one (1) year from the date of first purchase as shown on the original PMC invoice (hereinafter
“Warranty Period”)
If during the Warranty Period under normal use, the Product is suspected by Customer to be
Defective in material or workmanship, it is Customer’s responsibility to contact PMC and return the
Product to PMC as directed by PMC, freight prepaid. If PMC determines that the 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.

6
REVISION 1.5
POLYURETHANE
MACHINERY
CORPORATION
PK-25 SERVICE MANUAL
1. WARRANTY
THE WARRANTY DESCRIBED HEREIN IS THE EXCLUSIVE REMEDY FOR THE
CUSTOMER AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED,
STATUTORY OR OTHERWISE, AND THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER WARRANTIES ARE HEREBY
DISCLAIMED. TO THE FULLEST EXTENT PERMITTED BY LAW, PMC SHALL NOT BE
RESPONSIBLE, WHETHER BASED IN CONTRACT, TORT (INCLUDING, WITHOUT
LIMITATION, NEGLIGENCE), WARRANTY OR ANY OTHER LEGAL OR EQUITABLE
GROUNDS, FOR ANY CONSEQUENTIAL, INDIRECT, INCIDENTAL , LOST PROFITS, SPECIAL,
PUNITIVE OR EXEMPLARY DAMAGES, WHETHER TO PERSON OR PROPERTY, ARISING
FROM OR RELATING TO THE PRODUCT, EVEN IF PMC HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH LOSSES OR DAMAGES.
• Non-Warranty Service by PMC: If PMC determines that the suspected Defect of the Product is
not covered by this Warranty, disposition of the Product will be made pursuant to the terms and
conditions of PMC’s written estimate on a time and materials basis.
• Continuing Warranty for Products Repaired or Replaced under Warranty: Following the repair or
replacement of a Product covered by this Warranty, such Product will continue to be subject to the
original Warranty for the remainder of original Warranty Period or 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.

7
REVISION 1.5
POLYURETHANE
MACHINERY
CORPORATION
PK-25 SERVICE MANUAL
2. SAFETY AND HANDLING
2 SAFETY AND HANDLING
This chapter contains important information on the safety, handling, and use of your PK
Series Proportioner.
Before installing the PK 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 PK Series Proportioner. All of the information is
aimed at improving user safety and avoiding possible
breakdowns from the incorrect use of the PK 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 PK 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 PK 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 PK Series Proportioner has been designed and built for the application of polyurethane foam
chemical systems, and some two-component epoxy systems

8
REVISION 1.5
POLYURETHANE
MACHINERY
CORPORATION
PK-25 SERVICE MANUAL
2. SAFETY AND HANDLING
WARNING! The design and configuration of the PK 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 PK 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 PK 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 PK
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.

9
REVISION 1.5
POLYURETHANE
MACHINERY
CORPORATION
PK-25 SERVICE MANUAL
3. CHARACTERISTICS
3 CHARACTERISTICS
The PK Series Proportioner has been designed and built for the application of 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 one (1) Heating Elements per fluid side rated at 1,250 Watts, giving the
Proportioner a total heat output of 7,500 Watts. The 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 2 KVA Transformer that enables effective heating of up to a
total hose length of 210 feet The system includes an innovative hose heating concept in which the
continuous braid tinned-copper jacket is distributed evenly around the circumference of the hose
providing a uniform heating watt density and precise control of the material application temperature.
This hose heating element design is extremely resistant to fatigue failure.
Figure 1: Hose Heating Diagram

10
REVISION 1.5
POLYURETHANE
MACHINERY
CORPORATION
PK-25 SERVICE MANUAL
3. CHARACTERISTICS
LOW PRESSURE (2250 PSI) HOSE WITHOUT SCUFF
PART NUMBER
DESCRIPTION
MA-00014A
3/8” x 50’ HOSEASY, LP, NO TC
MA-00014A-TC
3/8” x 50’ HOSEASY, LP, W/TC
MA-00014A-25
3/8” x 25’ HOSEASY, LP, NO TC
MA-00014A-TC-25
3/8” x 25’ HOSEASY, LP, W/TC
200001
3/8” x 50’ HOSEASY, LP, W/RTD
200010
1/2” x 50’ HOSEASY, LP, NO TC
200011
1/2” x 50’ HOSEASY, LP, W/TC
200012
1/2” x 50’ HOSEASY, LP, W/RTD
LOW PRESSURE (2250 PSI) HOSE WITH SCUFF
PART NUMBER
DESCRIPTION
200002
3/8” x 50’ HOSEASY, LP, W/RTD, W/SCUFF
200005
3/8” x 50’ HOSEASY, LP, NO TC, W/SCUFF
200006
3/8” x 50’ HOSEASY, LP, W/TC, W/SCUFF
200016
1/2” x 50’ HOSEASY, LP, NO TC, W/SCUFF
200017
1/2” x 50’ HOSEASY, LP, W/TC, W/SCUFF
200018
1/2” x 50’ HOSEASY, LP, W/RTD, W/SCUFF