PMC PHDX-2 User manual

PHDX-2 Proportioner
Service Manual
Ref. # 202266
Revision 1.1
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
PHDX-2 SERVICE MANUAL
TABLE OF CONTENTS
Table of Contents
1 WARRANTY 5
2 SAFETY AND HANDLING 7
3 CHARACTERISTICS 9
3.1 PRINCIPAL HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 9
3.2 HOSEHEATINGSYSTEM.......................... 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
5.1 OPERATIONMENU ............................. 17
5.2 OPTIONSMENU ............................... 18
5.3 ALARMSMENU................................ 19
5.4 CHEMICALMENU .............................. 20
5.5 PROCESSDATAMENU ........................... 21
5.6 SETUPMENU................................. 22
5.7 BUTTONAPPEARANCE .......................... 23
6 INSTALLATION 24
6.1 HEATED HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 26
6.2 HOSE HEAT TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . 29
7 PROPORTIONER PURGING 30
8 PRESSURE BALANCE CONTROL 32
8.1 OPERATION.................................. 32
9 TEMPERATURE CONTROLS 33
9.1 OPERATION.................................. 33
10 START-UP 34
11 SHUT-DOWN 36
11.1 SHORT-TERM................................. 36
11.2 LONG-TERM ................................. 36
12 TROUBLESHOOTING 37
12.1 HEATERS ................................... 39
12.2 HYDRAULIC DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 42
12.3 METERING PUMP-LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REVISION 1.1 1

POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
TABLE OF CONTENTS
12.4 HOSEHEATING................................ 48
13 MAINTENANCE 51
13.1 INLET MATERIAL SCREENS . . . . . . . . . . . . . . . . . . . . . . . . 53
13.2 ISO LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 54
13.3 HYDRAULIC DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 55
13.4 METERING PUMP-LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
13.5 PUMP SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 56
13.6 MATERIALHEATER............................. 57
14 HYDRAULIC OIL SPECIFICATIONS 59
14.1 MANUFACTURERS.............................. 59
15 PARTS IDENTIFICATION 60
15.1 FRAMEASSEMBLY ............................. 60
15.2 PROX SENSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 62
15.3 HYDRAULIC MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . 63
15.4 EXIT MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 64
15.5 HYDRAULIC SEAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 65
15.6 HYDRAULIC PISTON ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 66
15.7 HYDRAULIC CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . 67
15.7.1 HYDRAULIC CYLINDER REBUILD KIT . . . . . . . . . . . . . . 68
15.8 A & R SINGLE PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 69
15.9 PUMP-LINE SEAL ORIENTATION . . . . . . . . . . . . . . . . . . . . . 71
15.10 PUMP-LINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
15.10.1 PUMP REBUILD KIT . . . . . . . . . . . . . . . . . . . . . . . . . 73
15.11 ”A” INLET MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . 74
15.12 ”R” INLET MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . 75
15.13 HEATERASSEMBLY............................. 76
15.14 MOTOR-LINE ASSEMBLY (1 PHASE) . . . . . . . . . . . . . . . . . . . 80
15.15 MOTOR-LINE ASSEMBLY (3 PHASE) . . . . . . . . . . . . . . . . . . . 82
15.16 FINALASSEMBLY .............................. 84
15.17 PHDX-2HOSES ................................ 89
15.17.1 HALF INCH HOSE KIT . . . . . . . . . . . . . . . . . . . . . . . . 90
15.18 LUBE BOTTLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 91
15.19 EXIT MANIFOLD ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . 92
REVISION 1.1 2

POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
LIST OF FIGURES
List of Figures
1 Pressure Balance Control Logic Diagram . . . . . . . . . . . . . . . . . . . . 10
2 Proportioner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Component Identification - Front . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Component Identification - Back . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Y-StrainerComponents.............................. 15
6 FrontPanelDescription ............................. 16
7 HMIOperationMenu............................... 17
8 HMIOptionsMenu................................ 18
9 HMIAlarmsMenu ................................ 19
10 HMIChemicalMenu ............................... 20
11 HMIProcessMenu ................................ 21
12 HMISetupMenu ................................. 22
13 ElectricalInstallation............................... 24
14 Component Identification - Misc . . . . . . . . . . . . . . . . . . . . . . . . . 25
15 Temperature Sensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
16 Transformers ................................... 29
17 Metering Pump-Line (PL-10) . . . . . . . . . . . . . . . . . . . . . . . . . . 44
18 PHDX-2 Console - Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . 45
19 FrameAssembly(FR-10)............................. 60
20 Prox Sensor Assembly (RM-243) . . . . . . . . . . . . . . . . . . . . . . . . . 62
21 Hydraulic Manifold Assembly (HI-05335) . . . . . . . . . . . . . . . . . . . . 63
22 Exit Manifold Assembly (HI-05343) . . . . . . . . . . . . . . . . . . . . . . . 64
23 Hydraulic Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
24 Hydraulic Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
25 Hydraulic Cylinder Assembly (HI-05336) . . . . . . . . . . . . . . . . . . . . 67
26 A & R Single Pump Assembly (202192) . . . . . . . . . . . . . . . . . . . . . 69
27 A & R Single Pump Cross Section . . . . . . . . . . . . . . . . . . . . . . . . 70
28 A & R Single Pump Assembly Detail A . . . . . . . . . . . . . . . . . . . . . 71
29 A & R Single Pump Assembly Detail B . . . . . . . . . . . . . . . . . . . . . 71
30 Pump-Line Assembly (PL-10) . . . . . . . . . . . . . . . . . . . . . . . . . . 72
31 ”A” Inlet Manifold Assembly (YS-6-PHX) . . . . . . . . . . . . . . . . . . . 74
32 ”R” Inlet Manifold Assembly (YS-7-PHX) . . . . . . . . . . . . . . . . . . . 75
33 Heater Assembly, 6 Rod - A . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
34 Heater Assembly, 6 Rod - B . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
35 Heater Assembly, 8 Rod - A . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
36 Heater Assembly, 8 Rod - B . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
37 Motor-Line Assembly - 1 Phase . . . . . . . . . . . . . . . . . . . . . . . . . 80
38 Motor-Line Assembly - 3 Phase . . . . . . . . . . . . . . . . . . . . . . . . . 82
39 PHDX-2 Final Assembly - A . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
40 PHDX-2 Final Assembly - B . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
41 PHDX-2 Final Assembly - C . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
42 PHDX-2 Final Assembly - D . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
43 Proportioner Hoses - Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
REVISION 1.1 3

POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
LIST OF FIGURES
44 Proportioner Hoses - Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
45 LubeBottleAssembly .............................. 91
46 In-PlantOption.................................. 92
47 In-TrailerOption ................................. 92
48 Exit Manifold Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
REVISION 1.1 4

POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 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 Cus-
tomer 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 deter-
mines 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:
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 prop-
erly. 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 ac-
cessories that are used in the operation of the Product are not covered by this War-
ranty. 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.
4. Other Warranty Exclusions: The Warranty does not cover any Product that PMC de-
termines 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 modifi-
cation of the product.
•Use of heating devices, pumping equipment, dispensers, or other parts or acces-
sories 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.
REVISION 1.1 5

POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 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 CON-
TRACT, TORT (INCLUDING, WITHOUT LIMITATION, NEGLIGENCE),
WARRANTY OR ANY OTHER LEGAL OR EQUITABLE GROUNDS, FOR
ANY CONSEQUENTIAL, INDIRECT, INCIDENTAL, LOST PROFITS, SPE-
CIAL, 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 pur-
suant 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.
REVISION 1.1 6

POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
2. SAFETY AND HANDLING
2 SAFETY AND HANDLING
This chapter contains important information on the safety, handling, and use of your
PHD Series Proportioner.
Before installing the PHD Series Proportioner and
start-up, carefully read all the technical and safety doc-
umentation included in this manual. Pay special atten-
tion to the information in order to know and understand
the operation and the conditions of use of the PHD Se-
ries Proportioner. All of the information is aimed at
improving user safety and avoiding possible breakdowns
from the incorrect use of the PHD Series Proportioner.
WARNING! Symbol is presented in front of information to
alert of a situation that might cause serious injuries if the instruc-
tions 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 PHD 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 PHD 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 at all
times. If you lose this manual, ask for a new copy from your PMC Service Center or go on
line at our web site (www.polymacusa.com).
The PHD Series Proportioner has been designed and built for the application of
polyurea chemical systems, polyurethane foam chemical systems, and some two-component
epoxy systems
REVISION 1.1 7

POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
2. SAFETY AND HANDLING
WARNING! The design and configuration of the PHD Series
Proportioner does not allow its use in potentially explosive atmo-
spheres 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 authorized PMC distributor.
When working with the PHD Series Proportioner, it is recommended that the opera-
tor 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 PHD 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 PHD Series Proportioner, a comprehensive
analysis must be made of the risks derived from the products to be dispensed, the type of
application, and the working environment.
To prevent possible injury caused by incorrect handling of the
raw materials and solvents used in the process, carefully read
the Material Safety Data Sheet (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.
REVISION 1.1 8

POLYURETHANE
MACHINERY
CORPORATION
PHDX-2 SERVICE MANUAL
3. CHARACTERISTICS
3 CHARACTERISTICS
The PHD 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 Proportioner a 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 190oF 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.
REVISION 1.1 9