PMC PMCA-20 Series Manual
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PMC PMCA-20 Series Manual

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REVISION 1.0
Before installing the PMCA-20 Series Proportioner and start-up, carefully read all the
technical and safety documentation included in this manual. Pay special attention to the
information in order to know and understand the operation and the conditions of use of the
PMCA-20 Series Proportioner. All of the information is aimed at improving user safety and
avoiding possible breakdowns from the incorrect use of the PMCA-20 Series Proportioner.
PMCA-20
Proportioner
Manual
Pneumatic, Heated, Plural Component
Proportioner
For spraying Polyurethane Foam and
Coatings
For Professional Use Only
Not approved for use in
Explosive atmosphere locations
Ref. # MN-06001
Polyurethane Machinery Corp.
Headquarters: 1 Komo Drive, Lakewood NJ 08701
Manufacturing: 2 Komo Drive, Lakewood, NJ 08701
Phone: 732-415-4400
http://www.polymac-usa.com
Fax: 732-364-4025

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Summary of Contents for PMC PMCA-20 Series

  • Page 1 PMCA-20 Series Proportioner. All of the information is aimed at improving user safety and avoiding possible breakdowns from the incorrect use of the PMCA-20 Series Proportioner.

  • Page 2: Table Of Contents

    PMCA-20 Manual TABLE OF CONTENTS WARRANTY ..........................4 SAFETY AND HANDLING ...................... 6 CHARACTERISTICS ......................9 Principal Heating System ..................... 9 Hose Heating System ......................9 Double Acting Opposed Piston Metering Pumps ..............9 TECHNICAL SPECIFICATIONS ................... 10 Electrical ..........................10 Mechanical .........................
  • Page 3 PMCA-20 Manual Pump Line Assembly ......................44 Air Motor Assembly ......................46 “A” Pump Assembly; Size 60 & 40 ..................48 “R” Pump Assembly; Size 60 & 40 ..................49 Piston Assembly; Size 60 & 40 ..................50 Pumpbase Assembly ......................51 Pre Heater Assembly ......................

  • Page 4: Warranty

    Defective in material or workmanship, it is Customer’s responsibility to contact PMC and return the Product to PMC as directed by PMC, freight prepaid. If PMC determines that the Product is Defective and that such Defect is covered by this Warranty, PMC will credit Customer for the reasonable freight charges incurred by Customer in returning the Defective Product to PMC, and PMC (or its authorized agent) will, at PMC’s option, repair or replace...
  • Page 5 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 6: 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 authorized distributor or go online at our web site (www.polymac-usa.com).
  • Page 7 The introduction and follow-up of safety measures must not be limited to those described in this manual. Before starting up the PMCA-20 Series Proportioner, a comprehensive analysis must be made of the risks derived from the products to be...
  • Page 8 PMCA-20 Manual To prevent possible injury caused by incorrect handling of the raw materials and solvents used in the process, carefully read the Material Safety Data Sheet (MSDS) provided by your supplier. Deal with waste caused according to current regulations. Pour éviter toute blessure causée par une mauvaise manipulation des matières premières et les solvants utilisés dans le processus, veuillez lire attentivement la fiche signalétique (MSDS) fournies par votre fournisseur.

  • Page 9: Characteristics

    PMCA-20 Manual CHARACTERISTICS The PMC PMCA-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 Proportioner consists of one (1) independent Material Heater without internal seals. The...

  • Page 10: Technical Specifications

    Dimensions: ..................30in W x 26in D x 45in H NOTE! The PMCA Series is designed to be used with a PMC Spray Gun (3500 PSI, 241 Bar) or equivalent that is rated to the maximum pressure rating of the...

  • Page 11: Description

    PMCA-20 Manual DESCRIPTION PMCA-20...
  • Page 12 PMCA-20 Manual A. Control Panel Controls and regulates the operation of the PMCA-20 Series Proportioner. B. Isocyanate (Iso “A”) Metering Pump Meters the Isocyanate material. C. Polyol (Poly “R”) Metering Pump Meters the Polyol material. D. Heater Heats the incoming chemical to a temperature set by the operator.
  • Page 13 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 complete PMCA-20 Series control power circuit thus allowing NO power to the Heater, Hose or control system. P. Control Power The Control Power Switch only controls the 24 Volt DC necessary for any proportioner functions to operate.

  • Page 14: Installation

    Electrical Console and connect as shown in the above diagram. 2. Fill the Lube Reservoir (plastic bottle) with PMC pump lube or equivalent. It is not necessary to prime the system when using size 60 pumps. It is recommended to...

  • Page 15: Heated Hose Installation

    PMCA-20 Manual Heated Hose Installation CAUTION! The material delivery Heated Hoses are color coded Red and Blue allowing the user to recognize them. The Red corresponds to the Isocyanate (Iso “A”) and the Blue to the Polyol (Poly “R”). To avoid connection errors the Coupling Connections of the Iso “A”...
  • Page 16 Terminal prior to insertion. Repeat the above steps to connect the “Fast-Lock” Connectors that you will find on all Heated Hose power wire. NOTE: All PMC heated hose wire is # 6 AWG. CAUTION!
  • Page 17 PMCA-20 Manual TRANSFORMER SETTINGS The Hose Heat Transformer offers the ability of connecting to different output voltages depending on the total length of the Heated Hose in use, maximizing the heating ability of the Heated Hose. The factory setting is 18 volts for use with 60 feet of Heated Hose. Before starting the proportioner, ensure the setting matches the Heated Hose length installed.
  • Page 18 PMCA-20 Manual 7. Connect the Transfer Pump/Heated Hose Assemblies air supply and air dryer systems as required. Review the Installation Instructions for each to ensure proper set-up and operation. 8. Install the Material Transfer Pumps as follows WARNING! If Transfer Pumps have been previously used, pay special attention to connect each Pump to “its”...

  • Page 19: Proportioner Purging

    PMCA-20 Manual PROPORTIONER PURGING CAUTION! Use suitable Personal Protection Equipment (PPE) CAUTION! Follow the recommendations in the Safety Information provided by product suppliers when installing or working with the unit. NOTE! Before using the Proportioner it is necessary to purge the entire system, including Heated Hoses of mineral oil left over from Quality Control testing and air.
  • Page 20 PMCA-20 Manual 11. Turn ON Control Power (P, page 13). Red pilot will light. 12. Set Pump Switch (T, page 13) to NORMAL. Turn Pneumatic Pressure Control CLOCKWISE increasing material pressure to 400 psi. Both Material Pressure Gauges (G, J, page 12) should read the same. Check all Heated Hose Coupling connections for leakage.

  • Page 21: Digital Temperature Controller

    Manual DIGITAL TEMPERATURE CONTROLLER The PMCA-20 Series has two (2) Digital Temperature Controllers to manage the temperatures for the Primary Heater and the Heated Hose. The Hose Heater Controller is programmed different from the heater Controllers and therefore not interchangeable with them.

  • Page 22: Start-Up

    PMCA-20 Manual START-UP NOTE! Follow the recommended procedures in the order shown. CAUTION! The Start-up procedures assume that all of steps in Proportioner purging have been performed and no problems found. 1. Check the condition of the DOP in the Iso “A” Lube Reservoir. Replace the DOP if you see significant changes in the color or signs of solidification.

  • Page 23: Shut-Down

    PMCA-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 to OFF position. 2. Turn the Heater OFF. Hose Heater should remain ON. Never leave Proportioner ON if unattended.

  • Page 24: Troubleshooting

    This chapter contains information on possible faults that may interrupt the operation of the PMCA-20 Series. The information provided will serve as a guideline to detect and resolve problems. In any case, feel free to contact your PMC authorized distributor where a qualified technician will advise you.

  • Page 25: Heaters

    PMCA-20 Manual Heaters WARNING! Before troubleshooting 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; you must wait until they cool before handling. NOTE! The Thermal Limit Switch is a safety switch in contact with the Heater body.
  • Page 26 PMCA-20 Manual PROBLEM Primary heater does not heat and the display on the controller shows ambient temperature. SOLUTIONS 1. Check that the light on the OFF/ON switch is lit when the heater is turned on, if not replace the switch. If the light is on move to the next step.
  • Page 27 PMCA-20 Manual PROBLEM B -Primary heater does not heat and the display on the controller shows an error message. 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 28: Hose Heat

    PMCA-20 Manual Hose Heat CAUTION! All electrical testing must be done by a qualified electrician. PROBLEM Heated hose does not heat and the display on the controller shows ambient temperature. SOLUTIONS 1. Check that the light on the OFF/ON switch is lit when the heater is turned on, if not replace the switch.
  • Page 29 PMCA-20 Manual 7. With a DC volt meter read across position A1 and A2 on the solid state relay (smaller wires) if you have a reading of 4-6 volts DC replace the solid state relay. If there is no DC voltage to the relay move to the next step. 8.
  • Page 30 PMCA-20 Manual PROBLEM Hose will heat but does not come up to set temperature. SOLUTIONS 1. Check the tap setting on the transformer to ensure that the correct position has been selected for the length of hose being used. Depending on the machines incoming voltage you may have to move the tap setting higher (up one).

  • Page 31: Pneumatic Drive System

    PMCA-20 Manual Pneumatic Drive System NOTE! 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 are ON before determining the existence of a fault.
  • Page 32 PMCA-20 Manual PROBLEM Pumps have stalled, pressures on the chemical gauges are lower than normal and the pump switch light is OFF. SOLUTIONS 1. Remove the two wires located on the “A” and “R” overpressure switches and check for continuity through each switch, the switches should be normally closed. If there is no continuity replace the switch.

  • Page 33: Metering Pump Line

    PMCA-20 Manual Metering Pump Line NOTE! 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.
  • Page 34 PMCA-20 Manual “A” GAUGE “R” GAUGE MATERIAL CONDITION NORMAL LACK OF ISO (A) LACK OF POLY (R) RESTRICTION OF ISO (A) RESTRICTION OF POLY (R)
  • Page 35 PMCA-20 Manual 3. Cavitation Cavitation occurs when the Metering Pump requires a larger volume of material than the supply system (Transfer Pump) can furnish. This creates a “void” of material in the Metering Pump. The most common causes of cavitation are: a.

  • Page 36: Maintenance

    PMCA-20 Manual MAINTENANCE NOTE! To achieve maximum output from the PMCA Proportioner, a daily or regular maintenance schedule is required. Inlet Material Screens Inspection of the Inlet Material Screens on a daily basis is no longer necessary as long as the following conditions are met.

  • Page 37: Iso Pump Lube System

    7. Repeat above for the Iso “A” side. 8. Proceed with Proportioner Purging operation (page 18). Iso Pump Lube System Daily: Check the condition of the PMC Lube Oil in the Iso Lube Reservoir. Replace the PMC Lube Oil if you see significant changes in the color or signs of solidification.

  • Page 38: Pump Base Service

    PMCA-20 Manual Pump Base Service To service Discharge/Inlet Ball 1. CLOSE appropriate Proportioner Inlet Material Supply Valve and remove the Air Line from the Transfer Pump. 2. Ensure all material pressure in the Proportioner system is zero and remove top screw plug from the top of the pump base.

  • Page 39: Material Heater

    PMCA-20 Manual 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 40 PMCA-20 Manual 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; you must wait until they have cooled before handling and bleed all material pressure to zero.

  • Page 41: Replacement Kits

    PMCA-20 Manual REPLACEMENT KITS 60 Iso “A” Pump Rebuild Kit (KT-05001-60) PART NUMBER DESCRIPTION OR-00011A O-ring OR-00020A O-ring OR-00044A O-ring OR-00046A O-ring PU-01001A-B06 Cylinder Bearing PU-01013A Flange Gasket PU-01014A-006 Piston Support Washer PU-01015A-006 Piston Seal Wiper PU-01016A-006 Piston Seal PU-01017A-006 Cylinder Seal PU-05029-60 60 Resin “R”...
  • Page 42 O-ring OR-00046A O-ring OR-00045A O-ring PU-01013A Gasket OR-00044A O-ring OR-00020A O-ring PMC Recommended O-ring Grease PART NUMBER DESCRIPTION GP-Lube Grease Lubriplate Grease TL-04003 Grease Tube for use w/ Grease Gun Heater Thermocouple Kit (KT-05021) PART NUMBER DESCRIPTION HI-05020 Body, Nut, Ferrule...

  • Page 43: Double Acting Proportioning Pump Diagram

    PMCA-20 Manual DOUBLE ACTING PROPORTIONING PUMP DIAGRAM FILL STROKE DISCHARGE STROKE...

  • Page 44: Part Identification

    PMCA-20 Manual PART IDENTIFICATION Pump Line Assembly (PL-4 & PL-5)
  • Page 45 PMCA-20 Manual PUMP LINE ASSEMBLY (PL-4 & PL-5) ITEM PART NUMBER DESCRIPTION NE-06009A AIR MOTOR ASSEMBLY (PAGE 46) "A" PUMP ASSEMBLY; SIZE 60 (PL-4) PU-05001-60 (PAGE 48) "A" PUMP ASSEMBLY; SIZE 40 (PL-5) PU-05001-40 (PAGE 48) "R" PUMP ASSEMBLY; SIZE 60 (PL-4) PU-05002-60 (PAGE 49) "R"...

  • Page 46: Air Motor Assembly

    PMCA-20 Manual Air Motor Assembly (NE-06009)
  • Page 47 PMCA-20 Manual AIR MOTOR ASSEMBLY ITEM PART NUMBER DESCRIPTION NE-0602 PISTON NE-604-1 PISTON CLAMP OR-00011A O-RING; CROSSOVER TUBE #014 NE-06009-9 #10-32 X 0.5 HEX SOCKET FLAT COUNTERSUNK OR-00050 O-RING; PISTON NE-0606 AIR MOTOR END PLATE OR-00048 O-RING; SHAFT OR-00049 O-RING; PORT BLOCK NE-0607 STAND OFF;...

  • Page 48: A" Pump Assembly; Size 60 & 40

    PMCA-20 Manual “A” Pump Assembly; Size 60 & 40 (PU-05001-60 & -40) "A" PUMP ASSEMBLY; SIZE 60 & 40 (PU-05001-60 & -40) ITEM PART NUMBER DESCRIPTION PU-05013 "A" PACKING RETAINER FLANGE OR-00020A #136 VITON LUBE CYLINDER O-RING PU-05026 TIE ROD; 3/8-24 PU-01013A CYLINDER FLANGE GASKET PU-05014-60...

  • Page 49: R" Pump Assembly; Size 60 & 40

    PMCA-20 Manual “R” Pump Assembly; Size 60 & 40 (PU-05002-60 & -40) "R" PUMP ASSEMBLY; SIZE 60 & 40 (PU-05002-60 & -40) ITEM PART NUMBER DESCRIPTION PU-05032-60 "R" PACKING RETAINER FLANGE; SIZE 60 (PU-05002-60) PU-05032-40 "R" PACKING RETAINER FLANGE; SIZE 40 (PU-05002-40) PU-05026 TIE ROD;...

  • Page 50: Piston Assembly; Size 60 & 40

    PMCA-20 Manual Piston Assembly; Size 60 & 40 PISTON ASSEMBLY ITEM PART NUMBER DESCRIPTION PU-05011-60 PISTON SHAFT; SIZE 60 PU-05011-40 PISTON SHAFT; SIZE 40 PU-01015A-006 PISTON WIPER SEAL; SIZE 60 PU-01015A-004 PISTON WIPER SEAL; SIZE 40 PU-01014A-006 WIPER RING; SIZE 60 PU-01014A-004 WIPER RING;...

  • Page 51: Pumpbase Assembly

    PMCA-20 Manual Pumpbase Assembly PUMPBASE ASSEMBLY ITEM PART NUMBER DESCRIPTION PU-05018 PUMP BASE PU-01003-DG INLET BALL SEAT GASKET PU-05019 INLET SEAT PU-05020 INLET BALL PU-05021 SPRING PU-05022A SLEEVE OR-00051B #218 AFLAS 80D O-RING PU-01003-IG DISCHARGE BALL SEAT GASKET PU-05024 DISCHARGE SEAT PU-05025 DISCHARGE BALL PU-05023-R...

  • Page 52: Pre Heater Assembly

    PMCA-20 Manual Pre Heater Assembly (PH-13)
  • Page 53 PMCA-20 Manual PRE HEATER ASSEMBLY (PH-13) ITEM PART NUMBER DESCRIPTION GM-06423-1 HEATER BLOCK GM-05423-1250 FIRE ROD; 1250W, 3/4 NPT, 17.5" GM-05423-7 SPRING 18" GM-06423-3 PHENOLIC ISOLATOR RM-06700-17 HEATER MOUNTING BRACKET EL-00006A OVERTEMP SWITCH FLOOR STOCK #6-32 X 3/8 HEX SOCKET BHCS GP-00100-1 1/4 PIPE NIPPLE HI-05058...

  • Page 54: Y-Strainer Assembly; "A" & "R" Side

    PMCA-20 Manual Y-Strainer Assembly; “A” & “R” Side (YS-1 & YS-2) Y STRAINER ASSEMBLY; “A” & “R” SIDE (YS-1 & YS-2) ITEM QTY PART NUMBER DESCRIPTION RA-00074-00A Y-STRAINER ASSEMBLY (INCLUDES ITEMS 4, 5, 6) HI-05016 3/4" SWIVEL FITTING RA-00074-03-30A REPLACEMENT SCREEN; 30 MESH RA-0007A-03-60A REPLACEMENT SCREEN;...

  • Page 55: Air Machine

    PMCA-20 Manual Air Machine (PMCA-20-1600 & PMCA-20-2400)
  • Page 56 PMCA-20 Manual...
  • Page 57 PMCA-20 Manual AIR MACHINE (PMCA-20-1600 & PMCA-20-2400) ITEM QTY PART NUMBER DESCRIPTION FR-3 TANK/BASE ASSEMBLY PUMPLINE ASSEMBLY; SIZE 60 (PMCA-20-1600) PL-4 (PAGE 44) PUMPLINE ASSEMBLY; SIZE 40 (PMCA-20-2400) PL-5 (PAGE 44) PH-13 PREHEATER 7500KW (PAGE 52) EL-06200 CONSOLE ASSEMBLY EL-05225 90V TRANSFORMER RM-05700-25 TRANSFORMER COVER;...
  • Page 58 PMCA-20 Manual FLOOR STOCK #8-32 NUT MQ-01009-02A LUBE BOTTLE LID EL-192 TERMINAL BLOCK EL-193 INRUSH CURRENT LIMITER FLOOR STOCK #8-32 CROSS RECESSED PAN HEAD SCREW RM-06700-27 TRANSFORMER COVER; REAR FLOOR STOCK #8-32 X 1/4 HEX SOCKET BHCS RM-05700-26 TRANSFORMER COVER; TOP EL-05700-27 TRANSFORMER KNOB FLOOR STOCK...
  • Page 59 PMCA-20 Manual HI-05069 ELBOW; 1/8 X 90 DEGREE HI-05094 3/8 NPT RUNNING TEE RM-PAR216P64 PARKER BRASS NIPPLE RM-PAR-2203P4 PARKER BRASS TEE RM-PAR216P4 PARKER BRASS NIPPLE HI-05076 1/4 NPT CAP EL-00088-01A HEYCO SR INCOMING POWER FLOOR STOCK #10-32 X 1-1/2 HEX SHCS FLOOR STOCK #8-32 X 1/2 HEX SOCKET BHCS MQ-01006A...

  • Page 60: Lube Bottle Components

    PMCA-20 Manual Lube Bottle Components LUBE BOTTLE ASSEMBLY ITEM PART NUMBER DESCRIPTION MQ-01009-01A LUBE BOTTLE MQ-01009-02A LUBE BOTTLE LID MA-00024A 1/2" X 3' PLASTIC TUBING RETURN MA-00025A 3/8" X 3' PLASTIC TUBING SUPPLY RA-00068A CHECK VALVE RA-06008 CHECK VALVE TN-04196 HOSE CLAMP GP-00960-1-GAL PUMP LUBE GALLON (NOT SHOWN)

  • Page 61: Hoses

    PMCA-20 Manual Hoses...
  • Page 62 PMCA-20 Manual HOSES ITEM PART NUMBER DESCRIPTION 3 FT RM-E-87-0101 POLY TUBING HI-05066 FLUID HOSE; 3/8 X 32" HI-05056 FLUID HOSE; 3/8 X 3' MA-00025A LUBE HOSE; 3/8 X 18" RA-00068A CHECK VALVE MA-00049A AIR HOSE; 1/4 X 3' 3 FT EL-05230-01 FLEX CONDUIT;...

  • Page 63: Technical Service Bulletin

    June, 2013 REF: PMC AIR MACHINES All PMC air driven machines manufactured after June 10 , 2013 have been fitted with an air manifold that will require only one air line to the machine. The manifold has provisions to supply air to the transfer pumps and the spray gun.
  • Page 64 PMCA-20 Manual PA, PAX, F-16, P-30 AIR MANIFOLD INLET AIR 90-120 PSI AIR HOSE TO HEATED HOSE (MA-00049A) REMOVE SAFETY CAP AND CONNECT THE TRANSFER PUMP AIR LINE (MA-00037A) NOTE: 1- MA-00049A is included with the machine. 2- MA-00037A is included in the GHO-A-PKG transfer pump package.
  • Page 65 PMCA-20 Manual PMCA AIR MANIFOLD REMOVE SAFETY CAP AND CONNECT THE TRANSFER PUMP AIR LINE (MA-00037A) INLET AIR 90-120 PSI AIR HOSE TO HEATED HOSE (MA-00049A) NOTE: 1- MA-00049A is included with the machine. 2- MA-00037A is included in the GHO-A-PKG transfer pump package.

  • Page 66: Manual Revisions

    PMCA-20 Manual MANUAL REVISIONS REVISION DATE CHANGES APPROVED 20-Feb-15 Updated illustrations and tables Vadams...

This manual is also suitable for:

Mn-06001

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