Electronic Mix Solutions Plural Component Mixing System

Maintenance and Repair Manual

Replaces Part Sheet 77-0000

Part Sheet 77-2981

Table of Contents Component Names and Locations Component Descriptions Preventive Maintenance Maintenance Schedule Depressurization System Depressurization Procedure

1.1

Dispense Pump

10.1

1.2

Pump Operation

10.2

Drive Assembly

10.3

2.1

Fluid Assembly

10.4

2.2

Dispense Pump Parts List

10.5

Dispense Pump Flow Sensor

10.6

3.1

Flow Sensor Calibration

10.7

3.2

Flow Sensor Installation

10.8

Dispense Pump Removal

10.9

Seal Replacement & Pump Rebuild Procedure

10.10

Potentiometer Gear Calibration Procedure

10.11

5.1

Pump Troubleshooting Checklist

10.12

Poppet Valve Repair Instructions

5.2

Flow Sensor Cable Wiring

10.13

Poppet Valve Operation

5.3

Poppet Valve Troubleshooting Procedure

5.4

Sealing Properties

5.5

Cleaning and Maintenance Poppet Valve

4.1

Control Enclosure Control Enclosure Exterior

11.1

Control Enclosure Interior

11.2

6.1

Control Enclosure Parts List

11.3

Air Flow Switch Function Check

6.2

Solenoid Stacks

11.4

Air Flow Switch Repair Instructions

6.3

Air Flow Switch

Gun Box Mix Manifold

Gun Box Gun Holder Adjustment

12.2

Manual Flush Mix Manifold

7.1

Gun Box Air Connections

12.3

Programmable Flush Mix Manifold

7.2

Gun Box Mounting Information

12.4

Multicolor Mix Manifold

7.3

Gun Box Parts List

12.5

Mix Manifold Parts List

7.4

Gun Box Trigger Lines

12.6

Mix Manifold Maintenance Instructions

7.5

Gun Box Pneumatic Diagram

12.7

High Ratio Mix Kit

7.6

High Ratio Mix Kit Maintenance Hose & Static Mixer Assemblies

7.7 7.8

Alarm Guide

13.1

Power Outage Cleaning Procedure

14.1

Trigger Line Connection Reference

Color Stack Color Stack – 5 Color

8.1

Color Stack Parts List

8.2

Color Stack Repair Instructions

8.3

Flow Meter

2

12.1

Flow Meter Configuration

9.1

Flow Meter Calibration

9.2

Maintenance Guide

9.3

14.2

Enclosure Air Plumbing

15.1

Connecting Direct Power

16.1

Electrical Diagrams

17.1

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows:

!

WARNING

!

Hazards or unsafe practices which could result in severe personal injury, death or substantial property damage.

Caution

Hazards or unsafe practices which could result in minor personal injury, product or property damage.

!

NOTE Important installation, operation or maintenance information.

Warning

Read the following warnings before using this equipment. Read the Manual Before operating finishing equipment, read and understand all safety, operation and maintenance information provided in the operation manual.

Plural Component Materials Hazard Because of the vast number of chemicals that could be used and their varying chemical reactions, the buyer and user of this equipment must determine all facts relating to the materials used, including any of the potential hazards involved.

Wear Safety Glasses Failure to wear safety glasses with side shields could result in serious eye injury or blindness.

Noise Hazard You may be injured by loud noise. Hearing protection may be required when using this equipment.

De-energize, DEPRESSURIZE, Disconnect and Lock Out All Power Sources During Maintenance Failure to De-energize, disconnect and lock out all power supplies before performing equipment maintenance could cause serious injury or death.

Fire and Explosion Hazard Improper equipment grounding, poor ventilation, open flame or sparks can cause hazardous conditions and result in fire or explosion and serious injury.

Operator Training All personnel must be trained before operating finishing equipment.

Pinch Point Hazard Moving parts can crush and cut. Pinch points are basically any areas where there are moving parts.

Equipment Misuse Hazard Equipment misuse can cause the equip­ment to rupture, malfunction, or start unexpectedly and result in serious injury.

Know Where and How to Shut Off the Equipment in Case of an Emergency

Keep Equipment Guards in Place Do not operate the equipment if the safety devices have been removed.

Pressure Relief Procedure Always follow the pressure relief procedure in the equipment instruction manual.

High Pressure Consideration High pressure can cause serious injury. Relieve all pressure before servicing. Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and cause extremely serious injury.

Projectile Hazard You may be injured by venting liquids or gases that are released under pressure, or flying debris.

Static Charge Fluid may develop a static charge that must be dissipated through proper grounding of the equipment, objects to be sprayed and all other electrically conductive objects in the dispensing area. Improper grounding or sparks can cause a hazardous condition and result in fire, explosion or electric shock and other serious injury.

Toxic Fluid & Fumes Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, injected or swallowed. LEARN and KNOW the specific hazards or the fluids you are using.

CA PROP

65

PROP 65 WARNING WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE OPERATOR OF THE EQUIPMENT. FOR FURTHER SAFETY INFORMATION REGARDING BINKS AND DEVILBISS EQUIPMENT, SEE THE GENERAL EQUIPMENT SAFETY BOOKLET (77-5300).

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

3

Reassembly Callouts

AL AL

ACME Lubricant ACME Lubricant

GL

Lubricant

PG PG

Petroleum Gel Petroleum Gel

TS TS

Thread Sealant Thread Sealant

Refer to the icons below to avoid damage to part and aid assembly of mating parts. Different lubricants are called out depending on the function of the part and lubricant. These triangles are placed next Gunto the corresponding part number label on GL Gun exploded view drawings. Lubricant

AL

ACME Lubricant

AL GL

ACME Gun Lubricant Lubricant

GL PG

Gun Petroleum Lubricant Gel

PG TS

Petroleum Thread Gel Sealant

TS

Thread Sealant

This icon indicates the need for ACME Thread Lubricant. This lubricant should be applied periodically to the ACME threaded shaft to reduce friction and prevent damage to the ACME threads. Part #: E21-0008 Use DeVilbiss SSL-10 gun lube to lubricate O-rings and parts where friction is expected upon assembly. This material will be washed away easily by solvent, but will allow adequate lubrication of parts.

Use Petroleum Gel to lubricate threads or other part surfaces to prevent galling or other damage upon assembly. P.T.F.E tape or liquid pipe thread sealant is required on pipe threads to lubricate and prevent leaks. If using tape, wrap 2-3 times around the male threads. If using liquid, add a bead of sealant around entire 2nd male thread before tightening into female thread. Do not loosen sealed parts.

1.1 Component Names and Locations Zener Barrier

Dispense Pump

Pendant

This Maintenance and Repair Manual provides part number, troubleshooting, and assembly information for the Binks EMS. It is important to understand the names and locations of various components for use during operation and maintenance. Study the diagram and note the locations and names of the major components in the assembly. For more information regarding startup procedures, consult the Binks EMS Operation Manual 77-2980.

NOTE The assembly shown contains optional equipment.

Dispense Pump Flow Sensor

Color Stack

Mix Manifold (Multicolor)

Resin Enable Valve (Poppet Valve)

4

Flow Meter

Air Flow Switches

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

1.2 Component Descriptions

Poppet Valve—Pneumatic valve used to open and close ports on the Dispense Pump, mix manifold, and color stack.

Color Stack—Used as the inlet location of additional resin colors when ordered as a multicolor system. The additional colors must use the same hardener. It also serves as the location of solvent and flushing air for cleaning of the fluid lines. This component will not be present on single color systems.

Pendant—The controlling device used to set up the spray settings and operate the entire system.

Dispense Pump Flow Sensor—The optional device that monitors flow of material into the Dispense Pump. It can be fine tuned for high or low flow.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

Air Flow Switch—Used to send a pneumatic signal to the Programmable Logic Controller when atomizing air flows to the spray gun.

Mix Manifold—The location of continuous mixing of both the hardener and resin. Single color systems are flushed from this assembly down stream. Depending on the system, this component may have poppet valves, ball valves, or blank plates (if equipped with a color stack).

Dispense Pump—The device used to dispense hardener or catalyst to the mix manifold. The system PLC controls the pump’s stepper motor to precisely dispense hardener or catalyst at the required ratio.

Flow Meter— Communicates the flow rate of resin to the system PLC.

5

2.1 Preventive Maintenance The Binks EMS requires periodic inspection and proper maintenance. Follow the corresponding table as a guide to perform routine maintenance at suggested specified intervals. These intervals are recommendations and largely depend on the material being used. Use the visual inspection to determine if any components need attention.

Daily / Each Shift

As Needed

n E  nsure mixed material is properly flushed at the end of the shift. If needed, also perform at the beginning of each shift. Verify there are no air pockets in the fluid lines when shutting down.

n R  ebuild mix manifold – replace O-Rings and check valves within the manifold .

n Identify and correct air and fluid leaks on the system including fluid hoses, flow meter, dispense pump, and mix manifold. n E  nsure spray guns are functioning properly and air is not leaking from the air valve. n C  heck Alarm History and review errors with operator. Verify the issue has been addressed.

n R  ebuild dispense pump – this is needed if material begins to leak from top of the pump or if the Resin Only Calibration is correct, but the Resin+Hardener Calibration is inaccurate. n Inspect Air Flow Switch – Monitor response time between the spray gun and the opening response of the Resin Enable Valve. If improper behavior occurs, verify the operation of the Air Flow Switch and replace the diaphragm as needed.

n Ensure material supplies are filled.

n R  ebuild Poppet Valves – monitor valves for air leaks or slow response time to triggering on/off.

Monthly

n Inspect flow meter for excessive wear or buildup of material. Verify smooth dispense pump movement.

n C  heck static mixer hose at outbound side of the mix manifold. If static mix elements become clogged, replace the static mixer as needed. A symptom of clogging may be the increase of the dispense pump outlet pressures on home screen of pendant or balancing alarms.

n Perform Dispense Pump Potentiometer Calibration.

NOTE Active fluids vary greatly in their material properties. If a specified material clogs any component more frequently, adjust the maintenance schedule accordingly.

n Examine oil reservoir for hardener material. n C  heck all air and fluid lines for kinks or wear of any kind n Perform Resin+Hardener Calibration to ensure flow meter and dispense pump are working properly. n Ensure all poppet valves are triggering on and off properly. Remove valves and clean Plunger End. n Clean and rebuild the flow meter. n Clean and rebuild the mix manifold and check valves. n C  heck fluid hoses for buildup of material. Replace if needed. With plural component coatings, buildup of material will occur around the hose fittings. This is a potential source for contamination on the finished product.

6

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

2.2 Binks EMS Maintenance Schedule Binks EMS Daily Inspection Description

Inspection Method

System Flushed with Solvent

Visual

Check for Leaks

Visual

Clean Spray Guns

Visual

Check Alarm History

Visual

Check for Material Supply

Visual

Completed By

Date

Completed By

Date

Completed By

Date

Binks EMS Monthly Inspection Description

Inspection Method

Check Static Mixer for clogs

Visual

Examine Oil Reservoir

Visual

Check All Lines For Kinks and Wear

Visual

Perform Flow Meter Calibration Check

Test with Beaker

Check Poppet Valve Operation. Remove valves and clean Plunger End.

Disassemble

Clean Flow Meter

Disassemble

Clean Mix Manifold and Check Valves

Disassemble

Check Fluid Hoses for Material Buildup

Disassemble

Binks EMS As Needed Inspection Description

Inspection Method

Clean and Rebuild Mix Manifold

Disassemble

Clean and Rebuild Dispense Pump

Disassemble

Inspect and Rebuild Air Flow Switch

Disassemble

Rebuild Poppet Valves

Disassemble

Perform Potentiometer Calibration

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

Set Limits

7

3.1 Disconnect and De-energize! !

WARNING

Before attempting any maintenance or repair it is necessary to ensure the system is depressurized and disconnected from power. Follow all lockout / tagout procedures applicable to the this machine. The Binks EMS system uses electrical and pneumatic power sources and the paint materials are supplied to the machine under pressure. Make sure all energy sources are disconnected from the EMS and the machine has been de-energized before attempting work of any kind.

3.2 System Depressurization Procedure With air and pressurized working fluids, the Binks EMS is constantly under various states of fluid pressure. To perform maintenance and repair, shut down for extended periods, or store the machine, the unit should be completely depressurized for safety reasons. It may store up to 10 PSI of pressure even when pressurized tanks are disconnected. If high pressure fluid injection occurs, get immediate medical help to prevent serious injury. Follow the instructions below to depressurize the unit, and prevent injury of this sort.

1. Fluid lines containing mixed material must be flushed. This step must be done in MIX mode. Ensure all guns are in gun flush boxes and lids are closed. For more information regarding flushing, see the Binks EMS Operation Manual 77-2980. 2. Press the color button on the pendant. Load Color 0 (Solvent) and press F3 (Go).

6. P  ress F2 to engage the Dispense Pump and allow the pressure to exit the dispensing unit. Allow it to run for 5 seconds, and then press F2 again. 7. N  ext, press F3 for the valves to open and allow the pressure to exit via the Resin side. Press F3 again after about 5 seconds to stop the action. 8. T  urn the power switch to the OFF position.

3. Wait for the system to complete the flush sequence and load the solvent. This will remove mixed material from the fluid lines and the Mix Manifold. If there is any indication of mixed material in the fluid lines, load color 0 again, or switch the system to Flush mode as long as needed to clear any debris from the fluid lines. Always end with a color 0 load to remove air pockets from the fluid lines. 4. Close valves on all pressurized resin, hardener, and solvent supply lines to the system. This step should prevent the color stack/ Flow Meter from being exposed to fluid pressure.

9. N  ext, remove the air pressure input from the system. Release the back pressure. An air regulator should indicate that there is no longer pressure in the system. 10. Now that that fluid pressure has been released, the EMS fluid lines can be removed as needed. The unit may be stored in this depressurized state. Store the system in a dry location out of direct sunlight. 11. If disassembling the machine, be sure to verify it is disconnected from all power sources.

5. The working fluids in both the Color Stack (if equipped), and Dispense Pump are under pressure. To release this pressure, go to the Home Screen, and then the PRIME screen.

8

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

4.1 Cleaning and Maintenance There are no internal components or assembly groups which should require cleaning as long as the enclosure door is shut. If material seepage occurs, be sure to correct the problem and maintain a clean work area. To avoid hardening of the paint inside the unit and fluid lines, the system must be cleaned by a complete flushing procedure at the end of operations. See the Binks EMS Operations Manual 77-2980 for more information regarding flushing.

!

WARNING

Never expose electrical equipment to flammable liquids, including solvents or other flammable products.

Cleaning of Hoses and Tubing

Maintenance of Flow Meters

If the flushing procedures have been carried out properly, the system’s fluid lines should remain operationally ready. This will be true if the fluid lines are flushed periodically and if the Pot Life does not expire. Always finish operation with a color 0 load that removes all air from the fluid lines. If end of Pot Life occurs inside the system, it is recommended these fluid lines be replaced.

Generally the flow meters are maintenance-free. If the dispense pump movement appears ‘notchy,’ it may be time to examine the gears in the flow meter. The flow meters may need to be recalibrated at regular intervals depending on the type of material being used. It is possible the accuracy of the flow meter may degrade if not recalibrated. The use of abrasive or pigmented fluids will lead to wear which influences the accuracy of the inner gears.

Maintenance of Poppet Valves If a color change Poppet Valve has not been used for a prolonged period, it is recommended to remove the Poppet Valve and clean the corresponding passageway. Otherwise, it is possible for settling/ hardening of the material inside the passageway. If the valves do not operate properly, or if fluid leaks occur, the seals must be replaced. It is recommended, to check the Poppet Valves for proper operation on a regular basis.

!

Cleaning The Enclosure Exterior and Pendant The control enclosure’s exterior painted surfaces, must only be cleaned with a soft damp cloth and light cleaning agent. Cleaning of the display with solvents is not allowed. If high contamination of the display is expected, sticky transparent film is recommended. Protect from overspray.

WARNING

Read and understand all operating manuals for connected equipment. Failure to properly follow the operating instructions could result in injury or even death.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

9

5.1 Poppet Valve E21-0005

NOTE Loctite 271 must be applied when reinstalling item 5.

ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NUMBER

DESCRIPTION

E22-1201 E22-1202 E22-1203 E22-1204 E22-1205* E22-1206* E22-1207 E22-1208 E22-1209 E22-1210 E22-1211 E22-1212* E22-1213 E22-1214* E22-1215* E22-1034* E22-1035* E22-1218

CAP PISTON BODY VALVE BODY VALVE SHAFT PLUNGER END PACKING PACKING WASHER PACKING SPRING PISTON RETAINING NUT LOCKING NUT INDIICATOR PISTON SPRING PTFE O RING PISTON LARGE PISTON O RING SMALL PISTON O RING PLUG WASHER PLUG SCREW 5/32" NYLON ELBOW

AL

ACME Lubricant

GL

Gun Lubricant

PG

Petroleum Gel

TS

Thread Sealant

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1

* Items included in repair kit E21-0006

10

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

5.2 Poppet Valve Repair Instructions In the event of needed disassembly of the Poppet Valves, they can be removed and cleaned or repaired. All valves are triggered by the solenoids via the air lines. Every Poppet Valve operates the same, whether it is on the Dispenser pump, the color stack or the mix manifold poppet valve. The PTFE o rings may need to be replaced if the valve no longer seals completely.

1. F irst depressurize the system before taking any component of the EMS apart. See 3.2 System Depressurization Procedure. 2. D  isconnect the 5/32” air line from the desired Poppet Valve. Take note of the orientation for reinstall. Using a 9/32 wrench, unscrew the elbow (18) from the Piston Body (2). 3. N  ow that the air line is out of the way, use a 7/8” wrench to unscrew the entire Poppet Valve assembly. 4. O  nce the Poppet Valve has been removed, we can begin to take the valve itself apart. Remove the Cap (1) and underlying Piston Spring(11) by unscrewing it. 5. W  ith the Cap removed, both ends of the Valve Shaft are visible. Unscrew the Locking Nut Indicator (10) and set it aside. 6. U  nscrew the Piston Retaining Nut (9) from the Valve Shaft.

8. As needed, unscrew the Piston Body from the Valve Body (3). Be extremely careful not to damage the threads on either component. Be careful not to lose the Packing Spring (8) when the two sides are disconnected. 9. With the two sides apart, the Packing Washer (7), Packing Spring, and Packing (6) will need to be removed before accessing the Piston (13). 10. Remove the Piston and inspect the piston o rings (14 and 15). Replace as needed. 11. Reassembly is the opposite of disassembly. Make sure that the packing is placed in the Valve Body, nose down. Place the Packing Washer on top, and then reassemble with the Packing Spring. After the two sides are fastened together, slide the Valve Shaft back into place, along with all remaining parts. 12. Screw the Poppet Valve back into place, and reattach the elbow. If needed, relocate the Plug Screw so that the elbow fitting sits in an accessible outer location.

7. S lowly pull the Plunger End (5) away from the Body (3), and remove it from the assembly.

NOTE Upon reassembly, be sure to lubricate the valve shaft so that it moves freely.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

11

5.3 Poppet Valve Operation Proper operation of the Poppet Valve can be identified with a few simple tests. The sealing capability is necessary for the Binks EMS to operate as intended. The Poppet Valve is used throughout the unit and is a vital part of proper unit operation. The two positions of the valve are outlined below. Closed

Open/Energized

Recessed Indicator

Protruding Indicator

The Poppet Valve operates through a pneumatic signal to open and close passageways in the unit. The default position of a Poppet Valve is closed. The corresponding passageway will be sealed preventing movement of the fluid. When given the signal air from the Binks EMS, the Poppet Valve will be triggered open, allowing movement of fluids through the passageways. Signal is sent through 5/32” hose and directed into the valve body via an elbow. Energized Poppet Valves are visible by the protruding indicator, as shown above.

5.4 Poppet Valve Troubleshooting Procedure 1. Open Enclosure door and look for LED indicator light on solenoid stack responsible for valve operation. If the red light is not on when it should be on, the solenoid stack may be damaged or unplugged.

3. Depressurize the Binks EMS using 3.2 System Depressurization and unscrew the Poppet Valve in question.

2. Verify trigger signal is being sent through the 5/32” tubes with no air leaks. Verify no leaks are present at the plug screws or 5/32” elbow fitting. Main supply air should be greater than 75 psi for proper poppet valve peration.

5. Pull apart Poppet Valve and inspect Piston O rings. Replace if damaged.

4. Visually inspect the valve’s Plunger End for damage or wear. Replace if necessary.

6. Inspect inner springs and packing for damage. Replace if necessary.

5.5 Sealing Properties The Poppet Valve relies upon a Plunger End to seal the corresponding passageways and prevent fluid movement. When energized, the active movement of the Poppet Valve opens the passageways and allows movement. The corresponding diagram shows the function of the valve, along with identifying the various components. A worn seal may cause leakage and improper Binks EMS operation. Faulty seals can be identified by removal of individual Poppet Valves. Look for uneven wear along the Plunger End, along with worn or damaged Piston O Rings.

Indicator (open)

Open Valve

12

Closed Valve

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

6.1 Air Flow Switch E21-0015 14

12 7

5 6

8 9

4 10

7

2 13 3

NOTE

15

1

Air Cut Off Valve (E22-1536) and additional hardware included only if ordered with gun flush box. See gun flush box detail.

11

ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PART NUMBER

DESCRIPTION

E22-1301 E22-1302 E22-1303* E22-1304 E22-1305 E22-1306 E22-1307* E22-1308 E22-1309 E22-1310 E22-1311* E22-1312 E22-1313 E22-1218* ——

MAIN BODY VALVE BODY DIAPHRAGM #10-32 COUPLING ASSEMBLY VALVE PILOT AMPLIFIER VALVE #10-32 X 1/4" TUBE ELBOW ELBOW REDUCER RETAINING SCREW BODY O RING AIRFLOW SWITCH TUBING 1/4 NPT HEX NIPPLE #10-32 X 5/32" TUBE ELBOW #10-32 X 2.25" SHCS

QTY. 1 1 1 1 1 1 2 1 1 4 1 1 2 1 4

* Items included in repair kit E21-0016

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

13

6.2 Air Flow Function Check After extended use, it may be necessary to check if the airflow switch is functioning properly. First verify that the switch is getting signal air. Remove the trigger line from the 5/32” elbow, and trigger the gun. Signal air should be flowing from the 5/32” hose. If signal air exits the hose, the Air Flow Switch must be disassembled for diaphragm replacement and/or cleaning. If signal air does not exit the hose, check main air supply and electrical connections inside the enclosure.

6.3 Air Flow Switch Repair Instructions After extended use, the Air Flow Switch may not function properly. There is a body o ring seal that may begin to leak, and also an inner diaphragm that may possibly tear. If either of these fail, the leak will no longer allow the switch to function properly. Replacement of either of these components, along with a thorough cleaning, should restore switch function. 1. First ensure that the machine is off, and that air pressure has been released. See 3.2 System Depressurization Procedure. Disconnect one side of the tubing (12). 2. Remove the valve assembly by unscrewing the #10-32 nipple coupling (4) and removing the entire valve assembly. 3. Both seals are held in place by the valve body (2). Remove the four retaining screws (10)from this body, and slowly separate the two bodies. 4. Inspect the diaphragm (3) for tears of any kind, and replace as needed. Do the same for the body o ring (11). Also ensure all passageways of the switch are free and clear of any debris. 5. Place the valve body over the diaphragm, with the holes lined up with the main body (1). Make sure the o ring is also lined with the valve body and main body. 6. Insert the 4 screws, and tighten down snugly. Make sure the o ring remains in place, sealing the valve body to the main body.

14

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

7.1 Manual Flush Mix Manifold E21-0022 / E21-0022-HR*

31

30

29 17 15

32

5

TS

PG 4

18

11

26

9

PG

10 20

13 28

PG 23 10 25

TS

33

9

7

11

13

21 9 6 PG

27

8

2 GL

1

AL

ACME Lubricant

GL

Gun Lubricant

PG

Petroleum Gel

TS

Thread Sealant

22* 12

18 15

32

19

24

16

NOTE *See 7.6 High Ratio Mix Kit for more information.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

15

7.2 Programmable Flush Mix Manifold E21-0023 / E21-0023-HR*

28

31

PG

30

29

19

TS

15 ft-lbs 5 26

4

PG

9 3

28

10 20

13 21

25

23

TS

10

2

9 33 11

11

8 7

13 9 6 PG

24 PG

28

1

AL

ACME Lubricant

GL

Gun Lubricant

PG

Petroleum Gel

TS

Thread Sealant

22*

GL

27 3

12

19

NOTE *See 7.6 High Ratio Mix Kit for more information.

16

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

7.3 Multicolor Mix Manifold E21-0024 / E21-0024-HR* 31

30

29 28

25

PG

14 4

5 9 26

13

PG

10 11

28

20

10

PG

9

23

TS

33

7

11

13 9

24

21 2

1

GL

22* 12

27

PG

AL

ACME Lubricant

GL

Gun Lubricant

PG

Petroleum Gel

TS

Thread Sealant

6

14

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

8

28

PG

19

NOTE *See 7.6 High Ratio Mix Kit for more information.

17

7.4 Mix Manifold Parts List ITEM NO.

PART NUMBER

DESCRIPTION

1 2 3 4 5 6 7

E22-1401 E22-1402 E22-1403 E22-1404 E22-1405 E22-1406 E22-1407 E22-1408

DISPENSE PUMP INLET PLATE CHECK PLATE FLUSH VALVE BLOCK RESIN ENABLE VALVE BLOCK BLANK RESIN PLATE MIX MANIFOLD BODY RETAINING NUT STANDARD MANIFOLD OUTLET

1 1 2 2 1 1 1

8

E22-1408-HR

1

9 10 11 12 13 14 15 16 17

E22-1409* E22-1410* E22-1411* E22-1212* E22-1413* E22-1414 E22-1415 E22-1416 E22-1417

HIGH RATIO MANIFOLD W/ RESTRICTOR SEALING O RING CHECK VALVE O RING MANIFOLD O RING PTFE O RING (PART OF ITEM 19)* BLANK PLATE O RING BLANK AIR/SOLVENT PLATE FLUSH CHECK VALVE AIR SIDE BALL VALVE SOLVENT SIDE BALL VALVE

QTY.

4 2 2 1 2 2 2 1 1

ITEM NO.

PART NUMBER

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

E22-1418 E21-0005 E21-0017 E21-0032 E22-1421 E22-1037 E22-1424 E22-1126 ---------------------E22-1020

34

E21-0031

DESCRIPTION

QTY.

MANUAL FLUSH VALVE BLOCK POPPET VALVE (INCLUDING O RING) RESIN CHECK VALVE (#2046) DISPENSE PUMP CHECK VALVE (#3624) RESTRICTOR 3/8 COMP TO 1/8TH NPT 90 ELBOW MANIFOLD OUTLET ELBOW MOUNTING BRACKET #10-32 X 2" SHCS #10-32 X 1" SHCS #10-32 X 1/2" SHCS #10 WASHER #10 LOCK WASHER 1/4-20 X 3/4" HHCS #10-32 X 1” FHCS DOWEL PIN MANUAL RATIO CHECK KIT (NOT SHOWN, PURCHASE SEPARATELY)

2 1 1 1 1 1 1 1 2 2 6 3 3 3 3 2 1

* Items included in repair kit E21-0021

7.5 Mix Manifold Maintenance Instructions With extended use of the Binks EMS, it is possible that the Mix Manifold will become clogged. This largely depends on the type of hardener used in the system. In order to resolve the problem, the Mix Manifold may have to be taken apart and cleaned. Damaged or clogged components should be replaced as needed. A thorough solvent cleaning will help to remove any deposits inside the manifold itself. The manifold may simply restrict flow, or it may become fully clogged due to the hardening of the mixed two component material. The check valves inside the manifold may also wear. This will be the case if hardened material occurs upstream of the manifold. Follow these steps to resolve the problem. 1. Load Color 0 to run Solvent through the Mix Manifold and fluid lines to clear them of resin. 2. Attempt to clean the manifold using the flush mode. Run this mode for 30 seconds, or as long as needed. The use of the air chop will aid in the cleaning process. 3. Power down the system using the 3.2 System Depressurization Procedure. 4. Disconnect the two fluid lines from the mix manifold by unscrewing the compression fittings (1 and 23). 5. We can now remove the Retaining Nut (7) and disconnect the Manifold Outlet Elbow(24) from the Mix Manifold Body (6). 6. Unscrew the hex screws (31) from the fluid back panel, and remove the Mix Manifold. 7. Remove the 5/32” Screws (28) and remove the Dispense Pump Inlet Plate (1).

18

8. Examine the inner passage ways of Manifold Body (6) and Outlet Elbow. The passageways of the Restrictor (22—If Equipped) may get clogged with hardened material. 9. If possible, remove the Restrictor with a hex wrench so that the Manifold Outlet (8) may be cleaned. 10. Clean the Mix Manifold and Manifold Outlet with a solvent, and be sure to remove any debris from the passageways. 11. Replace the restrictor and manifold outlet, if necessary. See 7.6 High Ratio Mix Kit. 12. If needed, replace the Check valves, noting the orientation and position. The Dispense Pump (21) and Resin (20) Check Valves are different. With prolonged use, these valves may wear out. Replace all o rings as needed.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

7.6 High Ratio Mix Kit Mixtures that have high ratios (above 20:1) or low dispense pump flow rates (below 30 cc/min) are recommended the use of a restrictor (22*) to help inject and mix material properly. The standard manifold outlet is enhanced to accept a restrictor which is used to maintain optimum mix performance. The restrictor screws into the outlet of the Mix Manifold. This option is indicated in the part number by the succeeding –HR (High Ratio). This manifold combination can also be used with the High Ratio Static Mix tube (E21-0003-HR).

Kit Contents

B

Restrictor

A Back Side

7.7 High Ratio Mix Kit Maintenance Inspect the Restrictor and Manifold Outlet(8) for clogs as needed. Material viscosity has a large impact on the durability of the restrictor. To remove, use a hex wrench to unscrew to the restrictor. If restrictor is so clogged that it cannot be removed, it may be necessary to order another High Ratio Manifold with Restrictor (E22-1408-HR). All passageways should be cleaned with solvent immediately when removed.

NOTE Restrictor and corresponding High Ratio Manifold Outlet are only present if ordered with this kit. The Standard Manifold Outlet is non threaded.

7.8 Hose & Static Mixer Assemblies

Connecting hoses and static mixer assemblies not included with mix manifold assemblies: E21-0004

resin hose assembly

E21-1046

hardener tube assembly

E21-0003

standard static mixer assembly

E21-0003-HR

high ratio static mixer assembly

E21-0044-K10

ten-pack of 1/4” ferrules (for hardener tubing)

E21-0045-K10

ten-pack of 3/8” ferrules (for resin tubing)

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

19

8.1 Color Stack – 5 Color

20

AL

ACME Lubricant

GL

Gun Lubricant

PG

Petroleum Gel

TS

Thread Sealant

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

8.2 Color Stack Parts List ITEM NO.

PART NUMBER

DESCRIPTION

QTY.

1 2 3 4 5

E22-1601 E22-1602 E22-1603 E22-1604 E22-1605 E22-1607 E22-1608 E22-1609 E22-1413 E22-1611 E22-1612

TOP PLATE PLUG COLOR BLOCK POPPET VALVE PLUG WITH SEAT & O RING POPPET VALVE PLUG SEAT THREADED ROD FOR 2 COLORS THREADED ROD FOR 3 OR 4 COLORS THREADED ROD FOR 5/6 COLORS BLANK PLATE O RING OUTLET BLOCK COLOR STACK OUTLET FITTING

1 1 2-4 1 0-1

6 7 8 9

2 2-4 1 1

ITEM NO.

PART NUMBER

DESCRIPTION

QTY.

10 11 12 13 14 15 16 17 18 19 20

E22-1613 E22-1614 E22-1415 E21-0005 — — — — E22-1616 E22-1020 E22-1617

MOUNTING BRACKET ACORN NUT FLUSH CHECK VALVE POPPET VALVE 3/8” NPT PLUG #10 WASHER #10 LOCK WASHER 1/4-20 X 3/4” HHCS REDUCER BUSHING DOWEL PIN ADAPTER 1/4 NPT(F) X 3/8 NPS(M)

1 2 2 3-8 2-9 – – – 2 4-8 1

8.3 Color Stack Repair Instructions With lengthy use of viscous materials, it is possible that the color stack may become clogged or dirty and need a to be taken apart for cleaning. Damaged or clogged components should be replaced as needed. A thorough solvent cleaning will help to remove any deposits or particulates. Follow these steps to disassemble and clean the color stack.

1. L oad Color 0 to run Solvent through the Mix Manifold and fluid lines to clear them of resin and particulates.

8. Slide off the Color Blocks (3) one at a time, and examine for debris. If needed, unscrew the Poppet Valves (16) for access to all passageways.

2. If necessary, attempt to clean the manifold using flush mode on the Utility Switch. Run this mode for 30 seconds, or as long as needed.

9. Using a solvent, rinse out the Color Block and verify no material is in any of the passageways. If needed, soak individual color blocks until clean.

3. P  ower down the system using the 3.2 System Depressurization Procedure.

10. Upon reassembly, ensure all sealing o rings (10) are not damaged. If so, replace as needed.

4. W  e can now disconnect all fluid and solvent lines connected to the Color Stack.

11. Reassemble color blocks, poppet valves, and acorn nuts.

5. D  isconnect the air supply line by pressing on the push-loc fitting and pulling out the tube.

12. Remount the assembly to the fluid back panel.

6. N  ow it is safe to remove the color stack and Mounting Bracket (13) from the fluid back panel. 7. P  lace the assembly on a clean work bench and remove the two Acorn Nuts (14) along with the Top Plate (1). Depending on the material, wear protective gloves as needed to protect the hands.

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21

9.1 Flow Meter Configuration 8

10

5

9

In a single color system, there is no color stack. Instead, the flow meter mounts to a mounting bracket on the fluid panel. In this configuration, the Resin Enable Valve on the mix manifold acts as the open and close valve for the resin. Multi-Color System

SINGLE COLOR System 1

6 4 2 3 2 3

7

FLOW 4

8

FLOW 10

5

ITEM NO.

PART NUMBER

DESCRIPTION

9

QTY.

1 2

E22-1126 FLOW METER MOUNTING BRACKET E22-1117** STANDARD FLOW METER E21-0013 FLOW METER CONTACT 3 E21-0013-IS INTRINSICALLY SAFE CONTACT 2 4 E22-1122 FLOW METER OUTLET FITTING 3 5 E22-1123 FLOW METER INLET 1 COLOR SYSTEM 6 E22-1124 FLOW METER INLET MULTICOLOR SYSTEM 7 — #10-32 X 1/2” SOCKET HEAD CAP SCREW 8 — #10 WASHER 9 — #10 LOCK WASHER 10 — 1/4-20 X 3/4” HEX HEAD CAP SCREW ** Flow Meter with Contact: E21-0014 Flow Meter with Intrinsically Safe Contact: E21-0014-IS

1 1 1 1 1 1 1 2 4 4 4

6

NOTE 4

Flow through the flow meter in a multicolor system goes downwards, while flow through a single color system may go a separate direction. The flow should travel from the flow meter to the Mix Manifold, which is indicated by the flow direction arrow on the flow meter.

22

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

9.2 Flow Meter Calibration After extended use of the Binks EMS, it is possible that viscous materials may require the flow meter to be recalibrated. Recalibration will ensure that the system maintains the Set Ratio of the mixture. A Flow Meter Calibration can be performed simultaneously with an EMS ratio check. To accurately check the ratio, the color must be already loaded. If the color is not loaded, the calibration will not begin. The default cc/pulse is .2400.

1. E  nsure the desired color to be tested has been loaded. If needed, return to Color screen, and load the desired color. Both A and B components must be connected to the system, and ready to spray. The correct ratio values should be entered into the system for all colors to be calibrated.

9. If the measured volume is within the desired tolerance, the unit has successfully passed the Flow Meter Calibration. If it is more than 5% different than the calculated volume, note the pulse count, and enter the new value in the Flow Meter cc/pulse bar, and press enter.

2. N  avigate to the Set Up screen, and enter the Advanced password. Press F4 to advance until the Flow Meter Calibration - Resin+Hardener page is visible.

10. Repeat steps 1-9 to verify the new cc/pulse value. The new measured volume should match the Expected Volume. If these values match, the Flow Meter Calibration has been completed successfully.

3. M  ake sure to shut off atomizing air so that an accurate volume can be measured in a beaker. 4. P  lace a beaker or other fluid measuring device under the output of the spray gun. 5. P  ress F2 twice to start the test. This will reset the values to zero. Manually trigger the gun into the beaker. 7. A  fter triggering for at least 30 seconds, stop the metering at a convenient measurable fluid volume, such as 300cc. This volume will be the total volume of BOTH components at the specified ratio. 8. Input the measured volume into the Measured Volume field and press Enter. The program will then display the calculated cc/pulse.

!

11. If the two volumes are not within the 5% tolerance, proceed to the Flow Meter Calibration - Resin Only page to check the Dispense Pump performance. Repeat the above procedure for the Resin only calibration, the difference being that the total volume will be the volume of the resin component ONLY. 12. If the resulting actual volume is significantly different than the calculated volume after repeated tests, it is possible the Flow Meter may be clogged or sticking and may require disassembly and cleaning. 13. Go through the 10.10 Dispense Pump Troubleshooting Checklist to verify proper operation of the pump.

WARNING

The machine must be in MIX Mode for this procedure. After performing a flow meter calibration, mixed material will be loaded in the fluid lines. After every calibration, be sure to flush the fluid lines by performing a color 0 load.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

23

9.3 Flow Meter Maintenance Guide Cleaning, inspecting or repairing this gear flow meter is easily accomplished by following the procedure.

• Unscrew the sensor (not shown) from the flow meter body (6).

7

• Note the index marks (8). f these are absent, mark the body positions for correct reassembly. • Loosen and remove the HEX bolts with a 3/16” key wrench. The upper and lower housing should easily slide apart. • If the flow meter housings do not easily separate, reinsert 2 opposing bolts by a few turns. Holding the upper body, tap on the bolts with a hammer to separate the housing sections. • After separation, if necessary, the gears (4) & shafts may be lifted from the body for inspection and cleaning. Separate the gears & shafts. Thoroughly clean the bearing face inside the center hole of the gear. Clean any residue from the shaft surfaces.

8

6

5 9 4

3 • After cleaning all parts completely, ensure the gears are reinserted with the mark shown facing upward (9). Check for free & easy rotation of the gears.

2

• Replace O-ring (5) if deformed.

1

8 • To reassemble, align index marks on the side of the upper and lower housing. • Replace hex bolts (7) and tighten to 15 Nm. Do not use a hammer to force the housing closed. • After reassembly, a brief air blast may be applied to spin the gears. This should be clearly audible given a moderate background noise level. • Clean any debris from the pickup port & hand tighten the pickup sensor. Avoid over tightening. Do not use a wrench. Over tightening may cause a dimple to protrude into the meter cavity beneath the pickup transmitter and interfere with normal gear rotation.

NOTE The JVM-20 threaded fluid ports are ¼” NPT

24

ITEM NO.

PART NO.

DESCRIPTION

— 1 2 3 4 5 6 7

E22-1117 — E21-1051 E21-1049 E21-1048 E21-1050 — —

FLOW METER LOWER HOUSING LOCATING PIN SHAFT GEAR O-RING BODY HEX BOLTS

QTY.

1 2 2 2 1 1 6

JV-20KG w/ IDH-8 Shown

Image Ownership: Copyright AW Gear Meters http://www.awgearmeters.com

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

10.1 Dispense Pump The Dispense Pump is the solution to plural component mixing. It is the device used to dispense hardener or catalyst to the mix manifold. The system PLC controls the pump’s stepper motor to precisely dispense hardener or catalyst at the required ratio. The Dispense Pump can operate at a variety of mixture ratios, even up to 100:1 when equipped with the High Ratio Mix Kit.

ACME Shaft

Potentiometer and Gear

Stepper Motor Drive Assembly

Flag Indicator

Oil Reservoir Pressure Transducer

Fluid Assembly

Dispense Fluid Outlet

200cc —E21 -0034 400cc —E21 -0035 Hardener Fluid Inlet

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

25

10.2 Dispense Pump Operation Material is delivered by a dual acting piston and cylinder type pump. An inlet and an outlet valve on each end of the cylinder control the material flow. When the piston is moving down, the bottom inlet valve is closed, and the bottom outlet valve is open. As the piston moves down, the material in the cylinder below the piston is dispensed through the bottom outlet valve. Also as the piston is moving down, the top outlet valve is closed and the top inlet is open. This allows material to be drawn into the top of the cylinder above the piston. When the piston gets to the bottom of its stroke, the valve settings and the piston direction reverse. This causes the material in the top of the cylinder to be dispensed, and the bottom of the cylinder to be filled.

the dispenser output pressure. So when the dispenser reaches the limit of the potentiometer, the inlet valve will close, and the outlet valve will open. This continues dispensing material on the output side while filling material on the inlet side. At the point where the inlet side pressure is brought down to match the output pressure, the direction will reverse. The appropriate valves will open, and the side which was filling begins to dispense. The dispense pump is fitted with a rotary potentiometer with a gear. It is attached to the ACME threaded rod from the stepper motor. Movement of the piston rotates the shaft on the potentiometer communicating the position of the piston in its’ stroke.

A balance mechanism is programmed into the PLC control to minimize pressure fluctuations at piston reversals. This logic assumes that the inlet material pressure is higher than

Fluid Inlet Fluid Outlet

Open Valves

Closed Valves

Pressure Transducer

NOTE The 200cc and 400cc versions of the Dispense Pump operate in the same manner.

26

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

10.3 Drive Assembly 26

AL 1

13

3 2

4

40

41

39

45

49

41

48

41

12

9 10

8

11

37

38

46

PG 44

39 39

40

40

43 7 6 5 42

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

AL

ACME Lubricant

AL GL

ACME Gun Lubricant

GL PG

Gun Petroleum Lubricant Gel

TS PG

Thread Petroleum Sealant Gel

TS

Thread Sealant

27

10.4 Fluid Assembly E21-0034 / E21-0035

AL

ACME Lubricant

GL

Gun Lubricant

PG

Petroleum Gel

TS

Thread Sealant

Torque to 14Nm/10ft-lbs

28

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

10.5 Dispense Pump Parts List ITEM NO.

PART NUMBER

DESCRIPTION

1

E22-1001

2

E22-1002

3

QTY.

ITEM NO.

PART NUMBER

DESCRIPTION

POTENTIOMETER GEAR

1

26

E22-1028

ACME THREAD SHAFT

1

POTENTIOMETER

1

27

E22-1030 i w l s

PACKING GLAND O RING

1

E22-1003

POTENTIOMETER HOLDER

1

4

E22-1004

POTENTIOMETER BRACKET

1

28

E22-1031 i l E22-1056 w s

200cc FLUID CYLINDER O RING 400cc FLUID CYLINDER O RING

2

5

E22-1005

BASE PLATE

1

29

E22-1032 i w l s

FLUID TUBE O RING

4

6

E22-1006

SHAFT BUSHING

1

30

E22-1007

RETAINER

1

200cc PISTON O RING 400cc PISTON O RING

2

7

E21-1054 i E21-1055 w

8

E22-1008

NON-SLOTTED MOTOR STANDOFF

1

31

E22-1034

PLUG WASHER

1

9

E22-1009

SLOTTED MOTOR STANDOFF

1

32

E22-1035

PLUG SCREW

1

10

E22-1010

LEAD SCREW COUPLING

1

33

E22-1036

OIL RESERVOIR

1

11

E22-1011

INDICATOR

1

34

E22-1038

1/8 NPT X 1/4 COMP ELBOW

1

12

E22-1012

MOTOR MOUNT

1

35

E21-0005

POPPET VALVE

4

13

E21-0010

STEPPER MOTOR

1

36

E21-0011

PRESSURE TRANSDUCER

2

200cc PISTON HEAD 400cc PISTON HEAD

—

SET SCREW

2

14

E22-1014 E22-1050

37

1

38

—

LOCKING NUT

2

—

1/4 LOCK WASHER

14

QTY.

15

E22-1212 i w l s

O-RING (PART OF ITEM 35)

1

39

16

E22-1016

PACKING GLAND

1

40

—

1/4 WASHER

14

17

E22-1017

BASE PLATE STANDOFF

2

41

—

10-32 X 1/2" SHCS

10

18

E22-1018

PACKING NUT

1

42

—

10-32 X 7/8" SHCS

4

1

43

—

10-32 X 1/2" MACHINE SCREW

2

4

44

—

1/4-20 X 1/2" HHCS

4

45

—

1-4-20 X 3/4" SHCS

2

46

—

1/4-20 X 3" HHCS

4

19

E22-1019 i w

PACKING SEAL ASSEMBLY

20

E22-1020

DOWEL PIN

21

E22-1021 E22-1052

200cc TOP DISPENSE BLOCK 400cc TOP DISPENSE BLOCK

1

22

E22-1022

FLUID TUBE

2

47

—

1/4-20 X 5.75" HHCS

4

23

E22-1023

DISPENSE PUMP STANDOFF

4

48

—

#10 LOCK WASHER

2

24

E22-1024 E22-1053

200cc CYLINDER 400cc CYLINDER

1

49

—

#10 WASHER

2

50

E22-1058

1/8 STREET ELBOW

1

25

E22-1025 E22-1057

200cc BOTTOM DISPENSE BLOCK 400cc BOTTOM DISPENSE BLOCK

1

51

E22-1059

1/8 NPT X 3/8 NPS NIPPLE

1

Rebuild Kit Description

KIT PART NUMBER

200cc Dispense Pump Rebuild Kit

E21-0001 i

200cc Dispense Pump Seal Kit

E21-0002 l

400cc Dispense Pump Rebuild Kit

E21-0029 w

400cc Dispense Pump Seal Kit

E21-0030 s

Packing Seal Oil

0114-559433

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

ITEMS INCLUDED

QTY.

E21-1054 E22-1019 E22-1030 E22-1031 E22-1032 E22-1212 E22-1030 E22-1031 E22-1032 E22-1212 E22-1019 E22-1030 E22-1032 E22-1055 E22-1056 E22-1212 E22-1030 E22-1032 E22-1056 E22-1212

2 1 1 2 4 4 1 2 4 4 1 1 4 2 2 4 1 4 2 4

—

550 ml

29

10.6 Dispense Pump Flow Sensor The Dispense Pump Flow Sensor is used to sense liquid flow into the Dispense Pump. It may be necessary to perform a proper calibration on occasion to ensure that it works properly for lower flow rate systems (< 400cc/min). This device will tell the PLC when there is no liquid flow, and after a user specified amount of time, an alarm will sound. The amount of time that the device hangs up on the yellow light is the method to determine if the device is operating properly or not.

10.7 Flow Sensor Calibration Procedure 1. Have a helper trigger the gun with the system hooked up to the correct material supply. 2. When the friend stops triggering the gun, watch the lights on the side of the flow switch body. 3. The ‘hang up’ time of the yellow light should be no more than 2 seconds. If hang up time is longer, Insert a Phillips head screw driver into the slot and turn it counter-clockwise one turn in order to decrease the hang up time. 4. Have the helper trigger the gun again and watch the amount of yellow light hang up. 5. When resuming triggering, the green lights should turn on. If not, the adjustment setting is too far in. Turn the dial about 1 turn clockwise and repeat step 4.

NOTE The Flow Sensor should be reset when major changes to the system have been made, such as with the addition of a gun box, or during start up procedures. Recalibration may be needed if the sensor does not operate correctly or if the No Resin Flow alarm sounds.

30

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

10.8 Flow Sensor Installation The Dispense Pump Flow Sensor may be ordered with a Binks EMS unit, or it may be added at a later date. The sensor aids the PLC Board in determining if the hardener material is flowing to the Dispense Pump or not. Follow the procedure below to install the Dispense Pump Flow Sensor. The dispense pump flow sensor kit is part number E21-0025.

INSTALLATION

Before mounting and removing the sensor, make sure that no pressure is applied to the system.

ELECTRICAL CONNECTION

The unit must only be connected by an electrician. The national and international regulations for the installation of electrical equipment must be observed.

1. Be sure the Binks EMS has been depressurized and disconnected from power. For more information regarding this procedure, see 3.2 System Depressurization Procedure. 2. Replace the Dispense Pump inlet elbow and fittings with the flow sensor kit’s ferrule-lock elbow. 3. Mount the flow sensor to the 1/4” tube end, making sure to apply thread sealant or P.T.F.E tape. 4. Open the door to the Control Enclosure by turning the latch Counter-clockwise. 5. Unscrew the cord grip (46 on 11.2) to allow cord access into the enclosure.

7. R  emove the cover from the left vertical wire tray. 8. P  lace the free length of the cord in the wire tray, allowing the brown, blue, and black wires access to the PLC Board. 9. C  onnect the brown wire to 24v DC power from the power supply (36 on 11.2). 10. C  onnect the black wire to 2091 Cat Flow Switch (Cat Flow Switch on 17.1). 11. C  onnect the blue wire to Analog Ground number 2 (Analog Ground on 17.1). 12. C  ontact your Binks representative or authorized distributor to configure the Binks EMS to enable the Dispense Pump Flow Sensor.

6. Plumb the flow sensor’s wiring through the cord grip and into the control enclosure.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

31

10.9 Dispense Pump Removal The EMS Dispense Pump can easily be removed from the system if needed. It should be flushed of material prior to removal or disassembly.

1. First ensure that the system is powered off and disconnected from the electrical power source. Completely de-pressurize the system by following the 3.2 System Depressurization Procedure. Disconnect the hardener supply line from the Dispense Pump inlet or optional flow sensor.

5. T  o remove the complete assembly, the stepper motor leads need to be disconnected from power. Disconnect the 4 corresponding wires, taking note of their original positions. If needed, the Stepper Motor (13) itself can be removed once the entire assembly is out.

2. Disconnect the pressure transducer and optional flow sensor cables by unscrewing the thumb nuts and unplugging the wiring.

6. U  nscrew the two 5/32” Screws (44) for the Potentiometer Gear (2) and Potentiometer Holder (3). Remove the potentiometer and gear assembly, being careful to not damage the teeth on the gear.

3. Disconnect the compression fitting and associated hardener tube assembly from the Top Dispense Block (21). This is the hose that connects to the Mix Manifold. 4. Disconnect all 5/32” air lines from the Poppet Valves (35) in the assembly.

7. U  se a 7/16” wrench to remove the four 1/4” mounting screws (47), and carefully lower the assembly downward and out of the enclosure. Do not drop the Dispense Pump.

Stepper Motor The stepper motor is fitted internally with what is called an ACME nut. Stepper operation causes this nut to rotate, resulting in movement of the dispense piston. The coupler guide pin retards rotation of the ACME shaft (26). Thus, stepper rotation results in linear motion of the ACME and piston shafts. The position sensor must be removed to replace the stepper motor. The stepper motor may be removed by removing its bolts and wires and unthreading it from the ACME shaft. The ACME shaft should be lubricated periodically with a small amount of ACME Thread Lubricant (E21-0008).

Dispense Pump Seal The Dispense Pump is equipped with an oil barrier between the dispense top seal and the outside air. This is to prevent the hardening of any material which may seep past the piston top seal. The barrier is contained between the seal in the travel housing and the dispenser top seal. The oil reservoir (33) should be filled with Seal Oil. Appearance of dispensed material (catalyst/ hardener) in the oil reservoir is an indication of worn seals.

32

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

10.10 Seal Replacement and Pump Rebuild Procedure After lengthy use, the dispense pump seals will begin to leak. This occurs when hardener becomes visible in the Oil Reservoir (33). The dispense pump is designed to be taken apart, so that the seal kit may be easily replaced. In order to complete this procedure, the machine must be completely removed from power, and the system must be completely depressurized. See 3.2 System Depressurization Procedure. 1. E  nsure that power to the machine is completely disconnected. Disconnect the fluid lines leading to the Dispense Pump Flow Sensor, and the port to the Mix Manifold (F3). Remove all sensor cables from the Pressure transducers (48). Remove air trigger lines from 5/32” fittings. 2. U  sing a 7/16” socket, loosen the locking nut (37) connecting the Piston Shaft (15) to the Lead Screw Coupling (10). With a hex wrench, remove the set screw (38) and locking nut. 3. R  emove the inner four 7/16” hex screws from the Base Plate (5), slowly slide the fluid assembly down and out from the unit. Make sure that it does not drop when removing the bolts. Place the two Base Plate Standoffs (17) in a safe place. 4. U  nscrew the Packing Gland (16) using a large adjustable wrench. The worn packings will be inside or underneath this fitting. 5. U  sing a spanner, unscrew the Packing Nut (18) to gain access to the various bit of packing.

11. Return the Base Plate Standoffs to their original positions, and tighten the hex screws, making sure that the Pressure Transducers are facing the rear of the unit. 12. Align the Set Screw with the Screw Coupling (10) and Piston Shaft, and tighten the set screw. Then, tighten the locking nut. 13. Connect all sensors along with all fluid and air lines. 14. Since the potentiometer gear was not removed, the system should not need to be calibrated. If for some reason the stepper motor moved with the rod assembly disconnected, a potentiometer calibration must be performed.

E22-1018 Packing Nut

6. U  sing Needle Nose Pliers, and other tools, remove and replace the Seal Assembly (19) in the same orientation as removed. 7. O  nce all the packings are correctly oriented on the Piston Shaft (15), slide the Packing Gland back in place, and screw it together. 8. S crew the Packing Nut back in place. Refill Oil Resevoir with seal oil (0114-009433).

E22-1019 Packing Seal Assembly

9. If rebuilding pump, the Piston O Rings (30) and Fluid Cylinder O Rings (28) must be replaced. Unscrew the four 5.75” hex head cap screws (47), and separate the Cylinder (24) from the two pump blocks. 10. Replace the two Piston O Rings and Fluid Cylinder O Rings, being careful to make sure they seat properly. Reattach the hex head screws, and torque to no more than 10 ft-lbs.

E22-1016 Packing Gland

E22-1030 Packing Gland O-ring

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

33

10.11 Potentiometer Gear Calibration Procedure If the Potentiometer Gear is removed from the ACME threaded shaft for any reason, the system will have to be recalibrated to ensure proper functionality so that no damage will be done to the dispensing unit during the next use. Put the system in Standby mode for the following procedure. For more detail about usage of the Pendant, refer to the Binks EMS Operation Manual and Startup Guide 77-2980.

1. If the Potentiometer Holder (3) or Bracket (4) has been removed for any reason, the Potentiometer Gear (1) will have to be readjusted to ensure sufficient play between the ACME Threaded Rod (26) and gear teeth. First, ensure the Potentiometer Bracket is mounted securely in place. 2. Next, loosen the two screws (44) that hold the Potentiometer Holder in place. 3. Slide the holder out so that the Potentiometer Gear no longer engages the ACME threaded rod. Hand-tighten the screws so that the Potentiometer gear will not engage the ACME threaded rod for the next step. 4. Go to the Dispense Pump Calibration screen by using the Advanced password for the unit. 5. Using the JOG UP option, move the rod assembly upwards so that the indicator moves near the top of the indicating slot. Pressing the F1 button will start and stop this action.

!

WARNING

The stepper motor will not stop automatically at the top of its working envelope. Be careful not to allow the motor to continue running when the indicator is near the top of the slot. Damage may occur to the unit if this happens. Use caution when performing this step.

6. Perform this step only if the Potentiometer Gear has become loose on the Potentiometer shaft (1), or has been removed for any reason. The Potentiometer Gear is held on to the potentiometer shaft by a Set Screw (38). Loosen this set screw and Locking Nut (37) so that the gear may rotate without turning the potentiometer shaft. Slide the gear onto the shaft and place it 1/8” from the inner retaining nut. Tighten the set screw and ensure that the potentiometer shaft turns with the potentiometer gear. 7. The center value shown on the Manufacturing Setup screen of the Pendant is the current reading of the Potentiometer position. With the teeth disengaged from the ACME shaft, rotate the gear until the value of the Pendant shows 0.5. This is the factory setting of the potentiometer for the highest position of the rod assembly.

Improper gear/shaft engagement

Correct gear/shaft engagement

9. If the gear engages correctly, but the rod assembly does not travel the full distance, the travel limits may need to be reset. To set the upper limit, the last command used must have been JOG UP. If this is the case, simply press F3 (SET LIMIT) to set the upper limit. This value should be about .5, and if it was accepted, it will show on the left side of the Manufacturing Setup screen.

NOTE Always leave about 1/2" of travel when setting pump limits. Never let the indicating flag “bottom out” during its travel.

10. To set the lower limit, the JOG DOWN button (F2) must be pushed. When the middle value shows about 4.5, press F2 again and stop the movement. Press F3 (SET LIMIT) to set the lower limit. If accepted, it will show on the right side of the setup screen. 11. The Dispense Pump should be calibrated and ready to use after completing step 11. To verify this, go to the Home screen, and then navigate to the PRIME screen. Press F2 and verify that the dispense pump travels up and down through the limits that you just set. If not, return to step 4 and repeat the procedure.

8. Keeping the current position of the Potentiometer Gear, now loosen the screws from the Potentiometer Holder, and slide it over so that the teeth engage the ACME threaded rod. Ensure to leave about a quarter millimeter of play between the two. Tighten the screws. Be sure not to over tighten the threads. Damage may occur if careful attention is not used.

34

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

10.12 Dispense Pump Troubleshooting Checklist The Dispense Pump has multiple components needed to verify proper operation of the Dispense Pump, go through this checklist to identify potential problems with the pump before disassembling.

Dispense Pump Troubleshooting Checklist Description

Pass/Fail

Check for air in all fluid lines. There must be no air bubbles present. ________

Verify there are no leaks anywhere on the pump body. There should be no major leaks present.

Examine the Oil Reservoir. Look for overflowing or hints of hardener material in the reservoir.

Check the unit is not in an Alarm state. It is possible an Alarm is not allowing the pump to run.

Visually inspect the ACME threaded rod. Look for damage and engagement with the potentiometer gear.

Verify the flag indicator is tightly securing the ACME rod to the pump rod. Inspect the Pump rod for hardened material that may prevent movement.

________

________

________

________

________

Change the Binks EMS to Standby mode and go to the PRIME screen. Trigger the gun and Dispense Pump (F2). Ensure Poppet Valve operation. Confirm a constant stream of material is exiting the gun.

________

Examine the stepper motor. Verify smooth operation when the pump is running. There should not be any ‘notchy’ movement of the pump. Unusual movement could be attributed to a flow meter that needs cleaning.

________

If any of the steps are not successfully passed, correct the problem. If the problem is still not corrected, it may be necessary to remove the Dispense Pump and clean it thoroughly after flushing it with a solvent. No passageways should be clogged with material.

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35

10.13 Flow Sensor Cable Wiring INSTALLATION

Before mounting and removing the sensor, make sure that no pressure is applied to the system.

ELECTRICAL CONNECTION

The unit must only be connected by an electrician. The national and international regulations for the installation of electrical equipment must be observed.

Disconnect power before connecting the unit as follows:

WIRING DIAGRAM +

BROWN

1

4

2

3

BLACK

LOAD –

BLUE

OUTPUT: AP8X SHORT CIRCUIT AND OVERLOAD PROTECTED

Cable Assembly Wiring Colors: Pin 1 – Brown Pin 2 – Not Used Pin 3 – Blue Pin 4 – Black

Image Ownership: Copyright Turck Inc., http://www.turck-usa.com

36

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

11.1 Control Enclosure Exterior

43

Front Exterior View

32

31 42

30

61

Bottom Exterior View

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

37

11.2 Control Enclosure Interior

38

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

11.3 Control Enclosure Parts List ITEM NO.

PART NUMBER

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13

E22-1101 E22-1102 E22-1103 E21-0012 E22-1105 E22-1106 E22-1107 E22-1108 E22-1109 E22-1110 E22-1111 E22-1112 E22-1113

120V FUSE HOLDER 24VDC FUSE HOLDER 24VDC POWER SUPPLY PLC BOARD STEPPER MOTOR CONTROL WIRE TRAY A6-A10 SOLENOID STACK A11-A15 SOLENOID STACK A16-A20 SOLENOID STACK GUN 1 PRESSURE SWITCH GUN 2 PRESSURE SWITCH GUN 1 IN BOX PRESSURE SWITCH GUN 2 IN BOX PRESSURE SWITCH

1 1 1 1 1 3 1 1 1 1 1 1 1

14

E21-0034 E21-0035

200cc DISPENSE PUMP FLUID ASSY. 400cc DISPENSE PUMP FLUID ASSY.

1

E22-1115 E22-1116 E22-1117 E22-1118 E22-1119 E22-1120 E22-1121 E22-1122 E22-1123 E22-1124 E22-1125 E22-1126 E22-1127 E22-1128 E22-1129 E22-1130

CORIOLIS FLOW METER SMALL FLOW METER STANDARD FLOW METER 4 FOOT FLOW METER CABLE 3 PIN (IS) 4 FOOT FLOW METER CABLE 6 PIN 25 FOOT FLOW METER CABLE 3 PIN (IS) 25 FOOT FLOW METER CABLE 6 PIN FLOW METER OUTLET FITTING FLOW METER INLET 1 COLOR FLOW METER INLET MULTI-COLOR COLOR STACK OUTLET FITTING FLOW METER MOUNTING BRACKET INTRINSICALLY SAFE BARRIORS DISPENSE PUMP FLOW SENSOR DISEPENSE PUMP FLOW SENSOR CABLE ALARM LIGHT WITH HORN

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1

17

19

22 23 24 25 26 27 28 29 30

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

QTY.

ITEM NO.

PART NUMBER

DESCRIPTION

QTY.

31 32 34 35 36 37 38 39 40 41 42 43 45 46 47 48 49 50 51 52 53 54 55 56 57 58 61 62 — —

E22-1131 E22-1132 E22-1134 E22-1135 E22-1136 E22-1137 E22-1138 E22-1139 E22-1140 E22-1141 E22-1142 E22-1143 E22-1145 E22-1146 — — — — — — E22-1152 E22-1153 E22-1154 E22-1155 E22-1156 E22-1157 E22-1160 E22-1161 E22-1162 E22-1163

ON OFF SWITCH UTILITY SWITCH ENCLOSURE TERMINAL BLOCKS DOUBLE HIGH TERMINAL BLOCK GROUNDING TERMINAL BLOCKS END ANCHORS STEPPER MOTOR CONTROL BOARD SOLENOID MOUNTING BRACKET SOLENOID COVER PLATE DISPLAY PENDANT 25 FOOT POWER CORD WITH GRIP MAIN AIR BULKHEAD TRANSDUCERS CORD GRIP 6-32 x 1/4" MACHINE SCREW 6-32 x 5/8" MACHINE SCREW 6-32 x 1" MACHINE SCREW 8-32 x 1/2" MACHINE SCREW 10-32 x 1/4" MACHINE SCREW #10 LOCK WASHER 120V FUSE 24VDC FUSE EXHAUST AIR BULKHEAD SOLENOID MANIFOLD TEE PRESSURE TRANSDUCER CABLE CONTROL BOARD STANDOFF DISPLAY PENDANT HOLDER FLUID BACK PANEL OPTIONAL LIGHT BEACON (GREEN RED) LIGHT BEACON REPLACEMENT BULB

1 1 1 2 4 2 4 1 1,2 1 1 1 1 1 4 4 6 2 8 8 1 1 1 0,2,4 2 4 1 1 – –

39

11.4 Solenoid Stacks The Solenoid stacks are used to convert electrical signal from the PLC Board into pneumatic air signal. If the o rings are not installed correctly and form an improper seal, the Binks EMS may not work properly. Below illustrates the various components of a Solenoid Stack.

10

13 8

3

7

2

3 Air Inlet Air Exhaust

ITEM NO.

1

4 6

40

DESCRIPTION

1 SOLENOID MANIFOLD BODY 2 SOLENOID ELECTRIC ACTUATOR ASSEMBLY 3* SOLENOID SUPPLY/EXHAUST FTTING 4 SOLENOID MANIFOLD PLUG 5 SOLENOID WIRE HARNESS (NOT SHOWN) 6 SOLENOID AIR PILOT FITTING 7* SOLENOID RETAINING SCREW 8* SOLENOID MATING CLIP LARGE 9 SOLENOID MATING CLIP SMALL 10* SOLENOID SUPPLY/EXHAUST FITTING O RING 11 SOLENOID PILOT O RING 12 SOLENOID CHANNEL CLIP 13* GASKET * Item included in E21-0042 Solenoid Repair Kit

QTY. 1 5 2 2 5 5 10 5 5 2 5 5 1

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

12.1 Gun Box E21-0028 The Gun Box option aids with flushing spray guns, especially if multiple colors will be sprayed. It both sends and receives signal to the PLC Board for a gun flushing procedure. It is possible to use either 1 or 2 Gun Boxes with the Binks EMS (except if a single color system is ordered).

12.2 Gun Box Gun Holder Adjustment 1. V  erify the gun box lid needs adjustment. Typically due to the lid not closing, or the gun not being triggered automatically. 2. L oosen the screws on the side of the unit so that the Gun Seat (8) is able to slide freely in the slot.

4. If the trigger is not being depressed, continue moving the gun seat upwards. 5. T  ighten and test the actuation of the unit. If needed, begin the procedure again at step 1.

3. A  djust the holder up and down so that the actuator is triggered when the gun box lid assembly (3) is closed.

12.3 Gun Box Air Connections Below is a description of Gun Box trigger connections. See 12.6 Gun Box Trigger Lines, or refer to the EMS Operation Manual 77-2980 for more information.

Trigger (TRG) — Pneumatically actuated valve that triggers the spray gun when the lid is closed. Receives signal from PLC (A19, A18). Gun In Box (GIB) — Trigger signal sent to the PLC (A23, A24) when the spray gun is in the Gun Box. Air Cut Off (ACO) — Triggers the Air Cut Off Valve at the Air Flow Switch (A2). Controls Atomizing Air of the spray gun. Air (AIR) — Supply Air needed to run the Gun Box.

NOTE Gun Box trigger lines and all other 5/32” trigger lines should be free of sharp bends and kinks.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

41

12.4 Gun Box Mounting Information

Back View Front View

Left Side View

42

Right Side View

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

12.5 Gun Box Parts List ITEM NO.

PART NUMBER

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

E22-1501 E22-1502 E22-1503 E22-1504 E22-1505 E22-1506 E22-1507 E22-1508 E22-1509 E22-1510 E22-1511 E22-1512 E22-1513 E22-1514 E22-1515 E22-1516 E22-1517 E22-1518 E22-1519 E22-1520 E22-1521 E22-1522 E22-1523 E22-1218 E22-1525 E22-1526

GUN BOX BODY COVER LID ASSEMBLY GUN IN BOX BRACKET TOGGLE PLATE BLOCK ARM GUN SEAT HINGE PUSH CAP TRIGGER CAP HANDLE HANDLE ADAPTER GUN SUPPORT SPRING SPACER SUPPORT SPACER TRIGGER SOLENOID PUSH SOLENOID AIR PILOTED SWITCH VALVE AIR PILOT 5/32" TUBE Y ADAPTER 5/32" TUBE x 1/8" NPT TEE FITTING 5/32" TUBE x 1/8" NPT ELBOW 5/32" TUBE x #10-32 ELBOW AIR SWITCH TORSION SPRING

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

QTY.

ITEM NO.

PART NUMBER

DESCRIPTION

1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 5 1 2 1

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

E22-1527 E22-1528 E22-1529 E22-1530 E22-1531 E22-1532 E22-1533 E22-1534 E22-1535 E22-1536 E22-1537 E22-1538 E22-1539 E22-1540 E22-1552 E22-1542 E22-1543 E22-1544 E22-1545 E22-1546 E22-1547 E22-1548 E22-1549 E22-1550 E22-1551 E22-1552

COMPRESSION SPRING GROMMET S.S. CHAIN LINK S.S. CHAIN CONNECTOR SPRING PLUNGER 1/4" x 1" S.S. DOWEL PRESSURE INDICATOR GREEN 5/32" TUBE TEES 5/32" TUBE BULKHEAD AIR CUT OFF VALVE (NOT SHOWN) #4-40 x 3/4" SHCS SS #8-32 x 5/8" SHCS SS #8-32 x 1" SHCS SS #8-32 Nut SS #10-32 x 1/2" SHCS SS 5/16" Lock Washer SS 5/16" WASHER SS 5/16"-18 x 1/2" BHCS SS 5/16"-18 x 3/4" BHCS SS 5/16"-18 x 3" BHCS SS 3/8" Lock Washer SS 3/8" Washer SS 3/8" Lock Nut SS 3/8"-16 x 1/2" BHCS SS 5/8" x 1-1/2" x 1/16" Washer SS Handle Link

QTY. 1 1 4 2 1 1 1 1 5 1 1 2 4 4 4 4 4 2 2 2 1 2 1 2 2 2

43

12.6 Gun Box Trigger Lines A pictorial view of the 5/32” tube connections to the gun box is useful when setting up the Binks EMS with gun flush boxes. Each gun flush box unit will connect to a separate positions on the control enclosure. For more information regarding the exact air connection locations, refer to the Binks EMS Operations Manual 77-2980.

44

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

12.6 Gun Box Trigger Lines

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

(cont.)

45

12.7 Gun Box Pneumatic Diagram

46

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

12.7 Gun Box Pneumatic Diagram

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

(cont.)

47

13.1 Alarm Guide The built in alarms of the BINKS EMS are used to help prevent damage to the unit. When triggered, a buzzer on the front panel of the enclosure sounds to warn of the issue. These faults are also triggered if connections on the unit are not in place, or if material is not flowing properly. Refer to the table below to diagnose the EMS alarms, along with suggested troubleshooting. If at any time the alarm issue can not be found, the fault can be disabled so the machine can still mix without the buzzer sounding until the problem can be resolved.

Warning Buzzer

Fault

Cause

Suggested Troubleshooting

Low Inlet Pressure

Dispense pump input pressure is below the set limit

Ensure supply valve is open Check for adequate pressure in the supply line Verify minimum inlet pressure setting on Dispense Pump setup screen Compare supply inlet pressure to the pendant reading Ensure pressure transducers are functioning properly

High Outlet Pressure

Dispense pump outlet pressure Check for pinched hoses leading to mix manifold is above the set limit Verify supply pressure is below set limit Verify dispenser pump poppet valve operation Remove and inspect static mixer Verify resin pressure is less than outlet pressure settings Verify maximum outlet pressure settings on Dispense Pump Pressure setup screen Remove and inspect Mix Manifold components Ensure pressure transducers are functioning properly

Ratio Fault

Current ratio is outside of tolerance

Check for air in the fluid lines Programmed tolerance too low. Increase as needed or perform a Flow Meter Calibration Reduce coating flow rate

Resin Flow

Resin flow sensed when system Verify Resin Enable Valves is closed is not spraying Check Resin Enable Valve needle and seat for wear Ensure flow meter is not detecting pulses of material—refer to DIN0 LED on PLC Board

No Hardener No Flow is detected through Flow Dispense Pump Flow Sensor when the dispense pump is running

Check Hardener supply Check Connection of Flow Sensor cable Adjust Flow Sensor at minimum flow rate so display moves off red signal Flow Sensor out of adjustment—see Flow Sensor Calibration procedure in section 10.6

Upper Transducer Fault

48

Improper electrical signal from Verify electrical connection and wiring upper pressure transducer Ensure upper Pressure Transducer is functioning properly

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

13.1 Alarm Guide

(cont.)

Fault

Cause

Suggested Troubleshooting

Lower Transducer Fault

Improper electrical signal from lower pressure transducer

Verify electrical connection and wiring

Check Pump

Dispense pump output incorrect for Resin flow

Check for air in the fluid lines

Ensure lower Pressure Transducer is functioning properly

Reducer coating flow rate Verify Dispense Pump Poppet Valve operation Verify Potentiometer Gear engagement to ACME rod. Check pump for proper operation

No Resin Flow

Atomization air flow with no Ensure no air leaks including spray gun and Air Flow switch paint flow Ensure Blow Off Time has not been exceeded Verify Resin Enable Valve opens when spray gun is triggered Check connections on flow meter If alarm repeats and material is flowing through spray gun, refer to Flow Meter Detail, section 9.1

Upper Balancing Fault

Dispense pump upper reversal not balanced

Lower Balancing Fault

Dispense pump lower reversal Air in lower chamber of dispense pump . not balanced Inadequate supply pressure– Inlet pump pressure should be greater than outlet pump pressure

Pot Life

Material at end of programmed pot life

Color Change A color change sequence has Fault been interrupted—this may be caused by other faults

Air in upper chamber of dispense pump Inadequate supply pressure– Inlet pump pressure should be greater than outlet pump pressure

Flush out mixed material remaining in the fluid lines Change Utility Switch to Flush Mode and trigger spray gun Resolve other Faults first Ensure spray gun is triggered Verify gun(s) are in Gun Flush Box and lid has been closed Restart color change with a color 0 (Solvent) flush Ensure proper operation of Gun Flush Box

High Resin Flow Rate

Resin flow rate is above set limit

Check for air in fluid supply Verify Max Resin Flow Rate on Advanced Settings setup screen Adjust fluid regulator to ensure limit is not reached

Component B Catalyst Flow is detected Flow Fault without pump operation

Check unit for fluid leaks Adjust Flow Sensor so display returns to red signal after gun stops triggering. Adjust Flow Sensor at minimum flow rate so display moves off red signal Flow Sensor out of adjustment—see Calibration procedure for Dispense Pump Flow Sensor

Air Flow Detected

Atomization air was detected Turn of atomization air during Color Change or when Ensure proper operation of Air Flow Switch Utility switch was in FLUSH or STANDBY mode Check operation of Gun 1 (or 2) Pressure Switch in Control Enclosure Ensure proper operation of Gun Flush Box, if equipped Verify proper operation of Air Cut Off Valve, if equipped

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

49

14.1 Power Outage Cleaning Procedure In the event of a facility power outage, the Binks EMS can be cleared of material manually as long as there is air pressure supplied to the unit. If the fluid lines are not cleared, it is possible that the mix manifold, fluid lines, and spray gun may become clogged with hardened material. Poppet Valves can be manually triggered to open passageways in the unit. By pressing the blue manual trigger-switches upwards, the solenoid stack will trigger the corresponding Poppet Valve. Trigger according to the references below.

Programmable Flush Systems: Air Flush: 255,257 Solvent Flush: 255, 259 Manual Trigger Switch

Manual Flush Systems: Air Flush: 255 and Open Air Ball Valve. Solvent Flush: 255 and Open Solvent Ball Valve

14.2 Trigger Line Connection Reference In the case of unit disassembly and trigger line replacement, use the reference below to reconnect the solenoid trigger lines. Single color units do not use all Solenoids.

50

Solenoid No.

Location

DESCRIPTION

Manual Flush

PROG. Flush

MultiColor

247

Dispense Pump

Top In

X

X

X

249

Dispense Pump

Top Out

X

X

X

251

Dispense Pump

Bottom In

X

X

X

253

Dispense Pump

Bottom Out

X

X

X

255

Mix Manifold

Resin Enable Valve

X

X

X

257

Color Stack/Mix Manifold

Air On

X

X

259

Color Stack/Mix Manifold

Solvent On

X

X

261

Color Stack

Color 1

X

263

Color Stack

Color 2

X

265

Color Stack

Color 3

X

267

Color Stack

Color 4

X

269

Color Stack

Color 5

X

271

Color Stack or Gun Box

Color 6 or Trigger 2

X

X

273

Gun Box

Trigger 1

X

X

275

N/A

Unused

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

15.1 Air Enclosure Plumbing Below is a diagram of the air plumbing inside the Enclosure. The diagram shows all three Solenoid Stacks present for a multicolor system. Supply air enters the enclosure and is split between all Solenoid Stacks. Exhaust plumbing routes all exhaust air out of the enclosure. This prevents moisture contamination of the wiring and PLC Board using push-loc connections. TOP VIEW

Supply Air

NOTE Exhaust

Air plumbing should not need to be adjusted except in the case of hose replacement. Exhaust plumbing should always be vented out of the enclosure.

16.1 Connecting Direct Power The Binks EMS can be connected to direct power if needed, instead of the standard 3 pronged cord. Inspect the diagram and follow the procedure below. 1. V  erify that all power at the source is turned off. 2. O  pen control enclosure door. 3. U  se existing 0.875” diameter hole with a compatible cord grip on the top right side of the control enclosure as the power cord port. 4. C  onnect the electrical cord to the appropriate terminals as shown in fig. 6. 5. C  lose control box and turn on power at breaker. 6. P  ower may now be turned on, on the unit.

!

WARNING

Always disconnect from power and lock out all power sources before working with electrical power. This step should be completed by a trained electrical professional to prevent serious injury.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

51

52

DIN0-RESIN FLOWMETER DIN1-MIX MODE DIN2-CC MODE DIN3-AIR FLOW PRESSURE 1 DIN4-CAT FLOW SWITCH DIN5-GUN IN BOX 1 DIN6-GUN IN BOX 2 DIN7-AIR FLOW PRESSURE 2 RTN0/7 DCC DIN8-SOLVENT FLOWMETER DIN9-COLOR CHANGE 0 DIN10-COLOR CHANGE 1 DIN11-COLOR CHANGE 2 DIN12-COLOR CHANGE 3 DIN13-COLOR CHANGE 4 DIN14-COLOR CHANGE 5 DIN15-COLOR CHANGE 6 RTN8/15 DCC

AIN0-TOP PRESSURE TRANS. ANALOG GROUND AIN1-BOTTOM PRESSURE TRANS. ANALOG GROUND AIN2-POSITION SENSOR ANALOG GROUND AIN3 ANALOG GROUND AIN4 ANALOG GROUND AIN5 ANALOG GROUND AIN6 ANALOG GROUND AIN7 ANALOG GROUND

STEPPER DIRECTION ANALOG GROUND AOUT1 ANALOG GROUND AOUT2 ANALOG GROUND AOUT3 ANALOG GROUND

0 1 2 3 4 5 6 7 RTN0 DCC 8 9 10 11 12 13 14 15 RTN1 DCC

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8

+24 VDC DCC 4

SWITCH 1 2 3

ROT SW ON DIP SW 1-4

-

-

OFF

8/4 CH. ANALOG/ NETWORK TOP BOARD

0

-

RS-232

SWITCH LAYOUT DISCRIPTION

16 X 16 GPIO CONTROL BOARD

-

ON

DCC

V+ 0/7 DOUT0-(LEAVE OPEN) 2451- GENERAL FAULT SOL 247- TOP INLET SOLENOID SOL 249- TOP OUTLET SOLENOID SOL 251- BOTTOM INLET SOLE. SOL 253- BOTTOM OUTLET SOLE. SOL 255- RESEN ENABLE SOLE. SOL 257- AIR ENABLE DCC V+ 8/15 SOL 259- SOLVENT ENABLE SOL 261- COLOR 1 ENABLE SOL 263- COLOR 2 ENABLE SOL 265- COLOR 3 ENABLE SOL 267- COLOR 4 ENABLE SOL 269- COLOR 5 ENABLE SOL 271- COL. 6 OR GUN TRIG 2 SOL 273- GFB GUN TRIGGER 1

/DOUTA- STEPPER STEP /DOUTB /DOUTC /DOUTD

A B C D +VOUT 0 1 2 3 4 5 6 7 DCC +VOUT 8 9 10 11 12 13 14 15 DCC

17.1 Electrical Diagrams

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

L1

FU L1

340

L1

L2

L2

L2

FU 120

1041

341

1041

14GA RED

MAIN SWITCH

L2 STEPPER MOTOR CONTROL

146

145

144

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179

126

127

128

129

130

131

132

133

134

135

136

137

138

139

+24VDC TO 140

164

161

160

159

125

DCC TO 140

DCC

163

DCC

124

GND

DCC

123

+24VDC

162

3 AMP

1201

122

121

120

119

+24VDC

157

117

+24VDC

156

116

158

155

115

+24VDC POWER SUPPLY

154

114

L2

153

113

PS 126

152

112

1061

151

118

150

111

14GA WHT

110

14GA RED

149

148

109

1061

SW 106

5.0 AMP

108

14GA RED

1061

14GA RED

147

1061

L1

143

107

106

105

104

103

142

141

102

140

101 GND

100

+24DC TO 200

+24VDC

+24VDC

+24VDC

+24VDC

+24VDC

+24VDC

FROM 139 +24VDC

DCC

+24VDC

305

303

CB 160

CB 160

DCC

+24VDC

1651

1571

WHITE

WHITE

BROWN

1521

217

2011

BROWN

OR

ZB 141

4 6 P&F I.S. 8 BARRIER 1 5 3

+24VDC

1491

+24VDC

201

DCC +24VDC 2011

WHITE

BLACK

RED

2011

1411

WHITE RED

RED

1421

PIN-4

PIN-5

PIN-6

343

FM 155

P2

P1

PT152

P2

P1

PT149

BLACK

DCC

WHITE

FM 141

BLACK

PIN-4 PIN-6 PIN-5

FM 141

PIN-C PIN-A PIN-B

DCC TO 200

DCC

STEPPER MOTOR STEP

CONTROLLER BOARD

SOLVENT FLOW METER (OPTIONAL)

DISPENSER BOTTOM PRESSURE TRANSDUCER

DISPENSER TOP PRESSURE TRANSDUCER

RESIN FLOW METER W/O IS BARRIER

RESIN FLOW METER W/ IS BARRIER (OPTIONAL)

FROM 139 DCC

CCD

CCD

CCD

120 VAC SUPPLY L1 L2 GND

17.1 Electrical Diagrams (cont.)

53

54

1

PS 207

*

DCC TO 240

266 267 268 269 270 271 272 273 274 275 276 277 278 279

226

227

228

229

230

231

232

233

234

235

236

237

238

239

264

224 265

263

223

225

262

257

222

SOLVENT FLOW METER

256

255

254

253

252

251

250

249

261

DCC

AIR FLOW PRESSURE SWITCH 2

GUN IN BOX 2 SIGNAL (OPTIONAL)

GUN IN BOX 1 SIGNAL (OPTIONAL) *JUMPER NEED IF NO GUN FLUSH BOX

CATALYST FLOW SWITCH (OPTIONAL)

248

247

221

2017

DCC

2115

2113

204

2111

2091

AIR FLOW PRESSURE SWITCH 1

260

3

3

3

2 3

2071

246

245

244

243

242

220

PS 215

PS 213

PS 211

3

363

CC MODE

*JUMPER NEED IF NO GUN FLUSH BOX

MIX MODE

241

240

259

1

1

1

FS 209

1

*

2051

212

2031

RESIN FLOW METER

219

157

+24VDC

+24VDC

+24VDC

+24VDC

+24VDC

+24VDC

SW 203 STAND BY MIX CC

CONTROLLER BOARD A CB 160

24DC TO 300

+24VDC

FROM 239 +24VDC

258

24DC TO 240

+24VDC

+24VDC

+24VDC

+24VDC

+24VDC

+24VDC

143

2011

FROM 179 DCC

218

217

216

215

214

213

212

211

210

209

208

207

206

205

204

203

202

201

200

FROM 179 24DC

CB 160

DCC

364

DCC

2731 RED

2711 RED

2691 RED

2671 RED

2651 RED

2631 RED

2611 RED

2591 RED

2571 RED

2551 RED

2531 RED

2511 RED

2491 RED

2471 RED

2451

1

1

1

1

1

1

1

1

1

1

1

1

1

1

X1

SOL 273

SOL 271

SOL 269

SOL 267

SOL 265

SOL 263

SOL 261

SOL 259

SOL 257

SOL 255

SOL 253

SOL 251

SOL 249

SOL 247

R

HN 245

2

2

2

2

2

2

2

2

2

2

2

2

2

2

X2

DCC

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC BLACK

DCC

GFB 1 GUN TRIGGER (OPTIONAL)

COLOR 6 OR GFB 2 GUN TRIG (OPTIONAL)

COLOR 5 ENABLE (OPTIONAL)

COLOR 4 ENABLE (OPTIONAL)

COLOR 3 ENABLE (OPTIONAL)

COLOR 2 ENABLE (OPTIONAL)

COLOR 1 ENABLE (OPTIONAL)

SOLVENT ENABLE SOLENOID (OPTIONAL)

AIR ENABLE SOLENOID (OPTIONAL)

DCC TO 300

DCC

RESIN ENABLE SOLENOID

BOTTOM OUTLET SOLENOID

BOTTOM INLET SOLENOID

TOP OUTLET SOLENOID

TOP INLET SOLENOID

FAULT LIGHT / HORN

FROM 239 DCC

17.1 Electrical Diagrams (cont.)

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

149

1491

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

24DC TO 340

360 361

320

321

3 4 5 6

365 366 367 368 369 370 371 372 373 374 375 376 377 378 379

325

326

327

328

329

330

331

332

333

334

335

336

337

338

339

1

244

2

206

364

3501

3521

RED

3511

CW

S

RED/WHITE

PO 356

BS 360 C

3491 GREEN

L2

BLACK

3581

WHITE

3561

3461

DCC

1651

14GA WHT

GREEN/WHITE

109

10K OHM POT

363

DCC

CCW

324

RED

+24VDC

3

4

2

1

323

24DC

359

319

DCC TO 340

358

318

362

357

317

DISPENSE MOTOR DIRECTION

356

316

3461

355

315

346

354

314

322

353

313

39K

352

312

+24VDC

351 B-

AB+

350

GND

MC 340

311 GND

DIR 0

4865-01-02A

P2

DCC

DCC

STEP

310

348

347

346

345

P15

P14

0

A+

3581 BLACK

MOTION SENSOR

BOTTOM PRESSURE TRANSDUCER

344

343

PIN#

MC 340 P1

1061 14GA RED

349

358

308

3561 WHITE

1521

TOP PRESSURE TRANSDUCER

342

109

309

356

152

307

306

305

304

303

302

341

CONTROLLER BOARD A MEZZANINE CB 160

340

FROM 339 24DC

301

FROM 274 DCC(1082)

300

FROM 279 24DC

3561

308

307

M

SM 349

322

165

GND

L2

1062

GND

N

L1

MC 340

DCC

DCC

DCC

2

3 4

5

6

7

8

S2

O 1 N

2

3

4

5

6

7

STEPPER DRIVER DIP SWITCHES 8

RES= 2000

LIGHT STACK (OPTIONAL)

POSITION SENSOR

DISPENSER STEPPER MOTOR

DISPENSER STEPPER MOTOR DIRECTION

S1

O 1 N

DISPENSER STEPPER MOTOR STEP

STEPPER MOTOR CONTROL

FROM 339 DCC

17.1 Electrical Diagrams (cont.)

55

WARRANTY This product is covered by Binks’ 1 Year Limited Warranty.

Binks Sales and Service: www.binks.com U.S.A./Canada Customer Service 195 Internationale Blvd. Glendale Heights, IL 60139 630-237-5000

Toll Free Customer Service and Technical Support 800-992-4657 Toll Free Fax 888-246-5732

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