Manual - Polyurethane Machinery Corp (PMC)
Contents
1. 2 5 50 ne En 02 LV 0 L 7109 vO ZL LL lt 10 Loy of O 003 LINDYIO LO Y o 2 10 002 9 99 99 SG 66 GS oto 201 101 SS3Hd Y SSIHud 15 MANUAL REVISIONS REVISION DATE CHANGES APPROVED2. GUAGE FITTING EL 195 0 5000 PRESSURE TRANSDUCER HI 05006 5 6 JIC SWIVEL NUT RUN TEE 11 PART IDENTIFICATION 12 PART IDENTIFICATION TOLL al 4 F PRESSURE BALANCE CONTROL a mass SWITCH ROTARY 7 POS 15A 1 003003 CS 2 jJ 0 e 2 mnre GR _ KNOB DIA BLACK 12 FLOORSTOCK 8 32 x 1 4 HEX SOCKET BUTTON HEAD CAP SCREW Co fal 00 2 TERMINAL BLOCK 5 2 DOUBLE a aoso 12 2 MICRO CORDSETSODEGREE 00 ON EL 131 R LIGHT UNIT RED 24VDC EL 140 TERMINAL BLOCK 5 2MM NOT SHOWN Cia 13 WIRE SCHEMATICS POINT TO POINT DIAGRAM 4 lt O sr mama 11 915191 O 111 918191 O LADDER DIAGRAM 002 7 5 gt AQ 81 gl 001 U HAONGSNVHYL I V 001 y3ONASNVEL 3unssaud Lor 91 S 7 2 x 7 JG 7 25 51 e bi O ne HOLIMS O al 6 1 N 2 N Z Cu Br 9l Arz 00 9 902 2 H HX 50 Lo of 00 7 0
3. Allows the user to turn on off the Pressure Balance Control System specify the maximum allowable pressure differential and reset the system after resolving a pressure imbalance ON Light Indicates that the maximum allowable pressure differential has been specified by the user and the system is monitoring the actual pressure differential FAULT Light Indicates that the actual pressure differential has become equal to or greater than the maximum allowable pressure differential and the pumps have shut off D Pressure Transducer Converts pressure measurements into electrical signals so the system can interpret the signals and react accordingly OPERATION Position the selector switch on one of the three options Pressure differential number these consist of 300 PSI 20 7 bar 400 PSI 27 6 bar 500 PSI 34 5 bar 600 PSI 41 4 bar and 700 PSI 48 3 bar Selecting any of these numbers with the switch will activate the green ON light While the pressure differential numbers are selected the control box will continually monitor pressure on both sides of the Proportioner In the event that the pressure differential between both sides of the Proportioner is equal to or larger than the selected number a fault is given the red fault light is turned on and the active green light is turned off and shuts down if the selector switch is placed in this position the Proportioner will operate as though there is N
4. Product subject to the following 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 Product Maintenance It is the Customer s responsibility to maintain the Product properly See your maintenance schedule and owners manual for details The Warranty does not cover an improperly maintained Product 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 components and accessories shall be subject to the warranty offered to the Customer if any by the original manufacturer of such component or accessory 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 e Normal wear and tear Improper or unauthorized installation repair alteration adjustment or modification of the Product e Use of heating devices pumping equipment dispensers or other parts or accessories with the Product that have not been approved or manufactured by PMC e Failure to follow the operating instructions and recomm
5. WARNING Presents information to alert of a situation that might cause serious injuries if the instructions are not followed CAUTION Presents information that indicates how to avoid damage to the Proportioner or how to avoid a situation that could cause minor injuries NOTE Is relevant information of a procedure being carried out Careful study of this manual will enable the operator to understand the characteristics of the Pressure Balance Control Box and the operating procedures By following the instructions and recommendations contained herein you will reduce the potential risk of accidents during the installation use and maintenance of the Pressure Balance Control Box You will also provide a better opportunity for increased output incident free operation for a longer time and the possibility of detecting and resolving problems quickly and simply Keep this User Manual for future consultation of useful information at all times If you lose this manual ask for a new copy from your authorized PMC distributor or go online at our web site www polymac usa com When working with the Pressure Balance Control Box in conjunction with the 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 Proportioner in enclosed spaces or in areas with insufficie
6. 102 PH 25 PH 40 PHX 25 PHX 40 CHARACTERISTICS The Pressure Balance Control PBC Box provides better control over a chemical pressure imbalance When the system is turned off the Proportioner will perform as if there is no PBC box 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 set maximum allowable pressure differential the pumps will be shut off The Pressure Balance Control Box 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 allowable pressure 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 Logic Box Representation Power supply side pressure reading 1 Continue pumping material R side pressure reading Logic Box OR Maximum pressure Maximum allowable pressure differential 2 Shut off pumps DESCRIPTION POLYURETHANE MACHINERY CORPORATION A Selector Switch
7. O PRESSURE BALANCE CONTROL SYSTEM neither the red fault light nor the active green light will be lit The over pressure system will remain active for the machine and personnel protection Reset in the event of a pressure imbalance resolve the Proportioner imbalance position the selector switch on reset to clear the fault light and restore power to the Proportioner After the fault has been cleared position the switch in elther a Pressure Differential number or in the Off Position to continue operations TROUBLE SHOOTING This chapter contains information on possible faults that may interrupt the operation of the Pressure Balance Control System 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 WARNING Only qualified personnel should perform troubleshooting Unqualified personnel may cause damage to the unit and put the operator at risk To prevent possible injury caused by incorrect handling of the raw materials and solvents used in the process carefully read the safety data sheet 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 components subject to pressure until the pressure has been completely eliminated Use suitable protect
8. POLYURETHANE MACHINERY CORPORATION POLYMAC USA Pressure Balance Control Box For Better Control Over Chemical Pressure Imbalance For Professional Use Only Not approved for use in explosive atmosphere locations For Installation onto PH 25 PH 40 PHX 25 and PHX 40 Proportioners Manual Ref 07000 Polyurethane Machinery Corp Corporate 1 KOMO Drive Lakewood NJ 08701 Manufacturing 2 KOMO Drive Lakewood NJ 08701 Phone 732 415 4400 Fax 732 364 4025 http www polymac usa com Before installing and starting up the Pressure Balance Control Box 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 Pressure Balance Control Box All of the information is aimed at improving user safety and avoiding possible breakdowns from the incorrect use of the Pressure Balance Control Box TABLE OF CONTENTS WARRANTY Se cena einen pea 1 SAFELY AND HANDLING iii 3 PHYSICAL SPECIFICATIONS CHARACTERISTICS uuu as sss TR ee 6 DESCRIPTION aan 7 OPERATION see 8 TROUBLE SHOOTING 9 PART IDENTIFICATION use ae 11 EL 200 E A RE 11 199 POCO OS 12 WIRE SCHEMA UIC Saad 14 POINT TO POINT DIAGRAM nn denim ee 14 LADDER DIAGRAM uuu l uuu ee 15 MANUAL REVISIONS ansehe 16 Install the Pressure Balance Control Box
9. endations provided by PMC e Cosmetic damage e Fire flood acts of God or other contingencies beyond the control of PMC 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 for three 3 months from the repair or replacement date whichever is longer No Right
10. ion when operating maintaining or being present in the area where the equipment is functioning This includes 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 TROUBLE SHOOTING lf the Pressure Balance Control box is not working properly follow these steps to resolve the potential issue Jumper A r CRI 4 Control Unit 4 1 With the Main Power ON check the Power Run light on the Control Unit a OFF the Control Unit is not getting power Check for loose or poor wire connections between the Power Supply located in the main console and the Control Unit see pages 14 and 15 for wire schematics Also ensure that the jumpers between the two power terminals in the PBC box are inserted properly the Power Run light still does not turn on contact your authorized PMC distributor b If SOLID the Control Unit has power but no program Contact your authorized PMC distributor If BLINKING the Control Unit has
11. nd safety clothing and breathing equipment Utiliser une protection appropri e utilisation d entretien ou d tre pr sents dans la r gion o le mat riel fonctionne Cela inclut mais n est pas limit l utilisation de lunettes de protection gants chaussures et v tements de s curit et un quipement respiratoire 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 L quipement comprend des l ments qui atteignent des temp ratures lev es et peuvent provoquer des br lures Les parties chaudes de l quipement ne doit pas tre manipul ou touch jusqu ce qu ils aient compl tement refroidi 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 L quipement comprend des l ments qui atteignent des temp ratures lev es et peuvent provoquer des br lures Les parties chaudes de l quipement ne doit pas tre manipul ou touch jusqu ce qu ils aient compl tement refroidi DANGER DANGER PHYSICAL SPECIFICATIONS Supply Operating Voltage Power Consumption For Installation On 24 VDC 2 16 W 516 2 27 kg 3 95 100 x 8 625 219 x 4 00
12. nt ventilation The introduction and follow up of safety measures must not be limited to those described in this manual Before starting up the 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 gt P SAFETY AND HANDLING 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 viter toute blessure caus e par une mauvaise manipulation des mati res premi res et les solvants utilis s dans le processus veuillez lire attentivement la fiche signal tique MSDS fournies par votre fournisseur To avoid damage caused by the impact of pressurized fluids do not open any connection or perform maintenance work on the components subject to pressure until the pressure has been completely eliminated Pour viter les dommages caus s par l impact des fluides sous pression ne pas ouvrir un lien ou d effectuer des travaux d entretien sur les l ments soumis la pression jusqu ce que la pression a t compl tement limin Use suitable protection when operating maintaining or being present in the area where the equipment is functioning This includes but is not limited to the use of protective goggles gloves shoes a
13. power and is programmed properly Proceed to the next step 2 With Main Power ON turn the Rotary Switch to a Pressure Differential Number and check the Amber light on 1CR a If OFF 1CR is not activating properly Check for loose or poor wire connections between the Control Unit and 1CR see pages 14 and 15 for wire schematics b If ON 1CR is activating but the mechanical switch inside the relay may not be functioning properly If the system has faulted i e a pressure imbalance exists the ON light turns off and the FAULT light turns on but the pumps do not shut off check for continuity between contacts 11 and 12 1 If there is continuity contact your authorized PMC distributor lf there is discontinuity proceed to the next step 3 With Main Power OFF a Check all remaining wires to ensure secure and proper connections b Check for continuity across the ON light terminals and the FAULT light terminals These light units are LEDs light emitting diodes which means that only one direction has continuity similar to a check valve When checking for continuity make sure to use the correct terminals on the multimeter i e positive goes to X1 and negative common goes to X2 4 Contact your authorized PMC distributor for further assistance Amber Light Rotary Switch 10 PART IDENTIFICATION EL 200 18 2 gt EL 200 ITEM PART NUMBER DESCRIPTION HI 05006 6 1 4 NPT X 6
14. s 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 SAFETY AND HANDLING This chapter contains important information on the safety handling and use of your Pressure Balance Control Box Before installing using and performing maintenance on your Pressure Balance Control Box carefully read and comprehend all the technical and safety information included in this manual The information is aimed at enhancing user safety and avoiding possible breakdowns caused by incorrect or improper use Always disconnect the console from the main power source before performing ANY maintenance on electrical equipments
15. using the provided instructions lf instructions are lost or not provided contact an authorized PMC distributor download or print an instruction manual from www polymac usa com If components are not fully installed the unit or proportioner may not work properly If there are problems understanding or installing the unit please contact an authorized PMC distributor 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 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 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
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