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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: 732-415-4400 URL: http://www.polymacusa.com...
POLYURETHANE POLYURETHANE PK-25 SERVICE MANUAL MACHINERY MACHINERY CORPORATION CORPORATION Table of Contents Table of Contents ........................2 List of Figures ..........................4 WARRANTY ..........................5 SAFETY AND HANDLING ....................7 CHARACTERISTICS ......................... 9 PRINCIPAL HEATING SYSTEM ..............9 HOSE HEATING SYSTEM ................9 TECHNICAL SPECIFICATIONS ..................
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 b e Defective in material or workmanship, it is Customer’s responsibility to contact PMC and return the...
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• 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;...
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 REVISION 1.5...
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 2. SAFETY AND HANDLING WARNING! The design and configuration of the PK Series Proportioner does not allow its use in potentially explosive atmospheres, or the pressure and temperature limits described in the technical specifications of this manual to be exceeded.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 3. CHARACTERISTICS 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.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 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”...
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 4. TECHNICAL SPECIFICATIONS MECHANICAL 123 Pumps Maximum Working Pressure 2,000PSI (14MPa, 138bar) Maximum Production 28lb/min (14kg/min) Minimum Production 2lb/min (1kg/min) Volume per Cycle (Single Pump) 0.01859gal/cycle (0.07220L) Volume per Cycle (Both Pumps) 0.03788gal/cycle (0.14439L)
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 5. DESCRIPTION DESCRIPTION Figure 3: Component Identification - Front REVISION 1.5...
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 5. DESCRIPTION Figure 4: Component Identification - Back REVISION 1.5...
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Closed - Press down on red knob and turn Counterclockwise to close. J. A-Side Lube Pump 24 VDC peristaltic pump that pumps PMC approved lubricant from the “A” Side Lube Reservoir to the “A” Side Pump Shaft. The Lube Pump will cycle whenever the Pump Line enters the RETRACT stroke.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 5. DESCRIPTION M. A-Side Inlet 1/2” NPTF swivel fitting to connect to ISO supply hose and a ball valve to control flow. N. R-Side Inlet 3/4” NPTF swivel fitting to connect to POLY supply hose and a ball valve to control flow.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 5. DESCRIPTION T. 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.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 5. DESCRIPTION Figure 6: Transformer Enclosure AA. Hose Heat Circuit Breaker 63A Single Pole circuit breaker that protects the Heated Hose from over-amping. BB. SSR (Solid State Relay) Completes the hose heat circuit allowing amps to flow through the hose heat wires. The DC side is controlled by the Hose Heat Controller within the console.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 6. INSTALLATION 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.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 6. INSTALLATION 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) and Poly (R) Heated Hoses are different sizes to ensure correct orientation.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 6. INSTALLATION CAUTION! Ensure the proper mechanical and electrical connections of the Heated Hoses are made to avoid possible material leakage and Hose heat problems. 6. It is recommended the TSU (Temperature Sensing Unit) be installed between the last section of Heated Hose and the Gun Whip.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 6. INSTALLATION 7. Ensure the Manual Valves are CLOSED and connect the Coupling Block to the Heated Gun Whip. CAUTION! Excessive force closing or opening the Manual Valves may result in damage to the Manual Valves and/or Coupling Block.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 6. INSTALLATION HOSE HEAT TRANSFORMER The Hose Heat Transformer offers the ability of connecting to different output voltages depending on the total length of the Heated Hose in use, maximizing the heating ability of the Heated Hose. The factory setting is 18 volts for use with 60 feet of Heated Hose.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 7. PROPORTIONER PURGING PROPORTIONER PURGING WARNING! Use suitable Personal Protection Equipment (PPE) and follow the recommendations in the Safety Information provided by product suppliers when installing or working with the unit. WARNING! Do not turn the Temperature Controllers ON until the Proportioner purging procedure is complete and the Primary Heaters and Heated Hoses are filled with material.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 7. PROPORTIONER PURGING 6. Attach a minimum 1/2” air supply hose via an air compressor capable of outputting a minimum of 15 - 20 SCFM (425 - 566 l/min) to the 3/8” NPTF swivel fitting on the INCOMING AIR VALVE.
WARNING! The Controllers are factory programmed and are not field re-programmable. If a problem is encountered, contact your PMC Distributor. Do not attempt to change any of the programmed parameters. Do not substitute a Controller from an alternate supplier as its use may result in equipment damage and/or bodily injury.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 9. START-UP START-UP NOTE! Follow the recommended procedure in the order shown. CAUTION! The Start-up procedures assume that all steps in Proportioner purging have been performed and no problems were found. 1. Check the lube fluid level and service as required.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 10. SHUT DOWN 10 SHUT DOWN 10.1 SHORT-TERM Follow the procedure below for temporary shutdowns, such as lunch breaks: 1. Set Pump Switch (Item T, on page ) to the OFF position. 2. Turn both “A” and “R” Heaters OFF. Hose Heater should remain ON. Never leave Proportioner ON if unattended.
This chapter contains information on possible faults that may interrupt the operation of the PK Series Proportioner. The information provided will serve as a guideline to detect and resolve problems. In any case, feel free to contact your authorized PMC distributor, where a qualified technician will advise you.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING 11.1 HEATERS WARNING! Only qualified personnel should perform troubleshooting; unqualified personnel may cause damage to the unit, personnel, or property and put the operator at risk. The Heaters are components that reach high temperatures; you must wait until they cool before handling.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING • Problem: Primary heater does not heat and the display on the controller shows ambient temperature. Solutions: 1. Check that the light on the on/off switch is lit when the heater is turned on, if not replace the switch.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING • Problem: Primary heater does not heat and the display on the controller shows an error message (SERR). Solutions: 1. Check position 11 and 12 on the heater controller for loose wires.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING 11.2 PNEUMATIC DRIVE SYSTEM Figure 11: Pneumatic Drive System Frequent Pneumatic Drive System Problems Page 34 Pumps have stalled and pressure is lower than normal. Pumps have stalled and pressure is higher than normal.
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Pneumatic Solenoid Valve, replace the valve. It the Pneumatic Solenoid Valve is working properly, move to the next step. 5. The Multi Stage Air Cylinder is defective; contact your local PMC Distributor to inquire about a replacement.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING 11.3 METERING PUMP LINE Figure 12: Metering Pump-Line Frequent Pump-Line Problems Metering pumps do not change direction and the pressures on both of Page 35 chemical gauges are lower than normal. Cavitation.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING Switch affected (DO NOT LOOSEN SCREWS ON ALUMINUM MOUNTING BRACKET). Slide Proximity Switch up or down until it illuminates. Tighten set screw. c. Prox. Switch not receiving power. Check that the cable coming from the Prox. Switch that is not activating is securely fastened to the rest of the cable that runs back to the Console.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING • Problem: Pressure/Material Imbalance. Solutions: 1. Troubleshooting this problem requires the applicator to: a. Know what the NORMAL spray pressures are for the application in progress. b. Determine what material is NOT exiting the Mixing Chamber.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING 11.4 HOSE HEATING WARNING! Before correcting any kind of defect, make sure the Main Power Switch is OFF and incoming power is locked OFF. NEVER access the inside of the Control Panel with the Proportioner power supply ON. The Heated Hose are components which reach high temperatures;...
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING needs to be replaced. If the Amp Draw is less than the rated value, move on to the next step. 5. Check to see if the White Amps Indicator Light on the transformer box is on. If it is not on, check the wire connections on the spray hose.
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 11. TROUBLESHOOTING 2. Remove the transformer cover and check that the thermocouple wires are secure to the harness going up to the controller. If there are no loose connections, disconnect the wire from the TSU and connect it directly to the thermocouple harness coming out of the hose transformer.
CAUTION! All repairs performed by unqualified personnel or the use of parts other than supplied by PMC may cause damage to the unit and put the operator at risk. REVISION 1.5...
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 12. MAINTENANCE 12.1 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. 1. Material drums are stored within the recommended material storage temperature range and drums are not opened prior to installing the Proportioner Material Transfer Pumps.
8. Proceed with Proportioner Purging operation (See page 24). 12.2 ISO LUBRICATION 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. Ensure inside of Reservoir is wiped clean.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 12. MAINTENANCE 12.3 METERING PUMP-LINE WARNING! Before performing any maintenance, make sure the Main Power Switch is OFF and incoming power is locked OFF. Allow material temperature to cool below 80 F and bleed all material pressure to zero.
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 12. MAINTENANCE 12.5 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;...
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 12. MAINTENANCE 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;...
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION 13 PARTS IDENTIFICATION 13.1 A & R SINGLE PUMP ASSEMBLY Figure 16: A & R Single Pump Assembly (202880/202881) REVISION 1.5...
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION A & R SINGLE PUMP ASSEMBLY (202880/202881) ITEM PART NUMBER DESCRIPTION 200700 INLET BODY, LP 202763 RETAINING RING, INTERNAL, 1.023 ID 202782 PISTON VALVE, LP 202784 INLET VALVE, BTM FEED, LP 202787 SHCS, 3/8-16 X 4.000, ZP ALY STL...
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION 13.2 PUMP-LINE SEAL ORIENTATION Figure 18: A & R Single Pump - Outlet Figure 19: A & R Single Pump Assembly - Inlet REVISION 1.5...
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION 13.4 Y-STRAINER ASSEMBLY “A” SIDE Figure 21: Y-Strainer Assembly "A" Side (YS-1) Y-STRAINER ASSEMBLY “A” SIDE (202599) ITEM PART NUMBER DESCRIPTION HI-05016 3/4 MNPT X 3/4 NPTF SW HI-05017 3/4 MNPT UNION FTG...
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION 13.5 Y-STRAINER ASSEMBLY “R” SIDE Figure 22: Y-Strainer Assembly "R" Side (202600) Y-Strainer Assembly “R” Side (202600) ITEM PART NUMBER DESCRIPTION HI-05016 3/4 MNPT X 3/4 NPTF SW HI-05017 3/4 MNPT UNION FTG...
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION TRANSFORMER ENCLOSURE ASSEMBLY (203213) ITEM QTY PART NUMBER DESCRIPTION 201242 LIGHT UNIT, RED, 120VAC 201243 LIGHT UNIT, WHITE, 120VAC 201586 SHCS, #8-32 X 1.750, 18-8 SS 201593 NUT, K-LOCK, #8-32, 18-8 SS 201633 BHCS, #8-32 X 0.375, 18-8 SS...
POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION 13.8 FINAL ASSEMBLY Figure 26: PK-25 Final Assembly - A REVISION 1.5...
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION Figure 27: PK-25 Final Assembly - B REVISION 1.5...
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION Figure 28: PK-25 Final Assembly - C REVISION 1.5...
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POLYURETHANE PK-25 SERVICE MANUAL MACHINERY CORPORATION 13. PARTS IDENTIFICATION Figure 29: PK-25 Final Assembly - D REVISION 1.5...
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