BINKS EMS Plural Component Mixing System Maintenance and Repair Manual

ElEctronic Mix SolutionS

Plural component Mixing System

Maintenance and Repair Manual

Replaces

Part Sheet

77-0000

Part

Sheet

77-2981

2

table of contents

ComPonent nameS and LoCationS

Component Descriptions

Preventive maintenanCe

Maintenance Schedule dePreSSurization

System Depressurization Procedure

CLeaning and maintenanCe

PoPPet vaLve

Poppet Valve Repair Instructions

Poppet Valve Operation

Poppet Valve Troubleshooting Procedure

Sealing Properties air FLow SwitCh

Air Flow Switch Function Check

Air Flow Switch Repair Instructions mix maniFoLd

Manual Flush Mix Manifold

Programmable Flush Mix Manifold

Multicolor Mix Manifold

Mix Manifold Parts List

Mix Manifold Maintenance Instructions

High Ratio Mix Kit

High Ratio Mix Kit Maintenance

Hose & Static Mixer Assemblies

CoLor StaCk

Color Stack – 5 Color

Color Stack Parts List

Color Stack Repair Instructions

FLow meter

Flow Meter Configuration

Flow Meter Calibration

Maintenance Guide

3.1

3.2

4.1

5.1

5.2

5.3

5.4

5.5

6.1

6.2

6.3

1.1

1.2

2.1

2.2

8.1

8.2

8.3

9.1

9.2

9.3

7.1

7.2

7.3

7.4

7.5

7.6

7.7

7.8

diSPenSe PumP

Pump Operation

Drive Assembly

Fluid Assembly

Dispense Pump Parts List

Dispense Pump Flow Sensor

Flow Sensor Calibration

Flow Sensor Installation

Dispense Pump Removal

10.7

10.8

10.9

Seal Replacement & Pump Rebuild Procedure 10.10

Potentiometer Gear Calibration Procedure 10.11

Pump Troubleshooting Checklist

Flow Sensor Cable Wiring

10.12

10.13

10.1

10.2

10.3

10.4

10.5

10.6

ControL enCLoSure

Control Enclosure Exterior

Control Enclosure Interior

Control Enclosure Parts List

Solenoid Stacks gun Box

Gun Box Gun Holder Adjustment

Gun Box Air Connections

Gun Box Mounting Information

Gun Box Parts List

Gun Box Trigger Lines

Gun Box Pneumatic Diagram aLarm guide

Power outage CLeaning ProCedure

Trigger Line Connection Reference enCLoSure air PLumBing

13.1

14.1

14.2

15.1

12.1

12.2

12.3

12.4

12.5

12.6

12.7

11.1

11.2

11.3

11.4

ConneCting direCt Power eLeCtriCaL diagramS

16.1

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.

wear SaFety gLaSSeS

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

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.

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.

oPerator training

All personnel must be trained before operating finishing equipment.

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.

PinCh Point hazard

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

know where and how to Shut oFF the equiPment in CaSe oF an emergenCy

equiPment miSuSe hazard

Equipment misuse can cause the equip ment to rupture, malfunction, or start unexpectedly and result in serious injury.

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.

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.

ProjeCtiLe hazard

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

Ca ProP 65 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.

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

ACME

Lubricant

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 to the corresponding part number label on exploded view drawings.

This icon indicates the need for

Lubricant

Lubricant

Use Petroleum Gel to lubricate

AL

ACME

Lubricant

Gun

Lubricant

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

TS

TS

Petroleum

Petroleum

Gel

Thread

Thread

Sealant 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,

Petroleum

Gel friction is expected upon assembly.

This material will be washed away easily by solvent, but will allow adequate lubrication of parts.

add a bead of sealant around entire 2nd male thread before tightening into female thread. Do not loosen sealed parts.

Thread

Sealant

1.1 component names and locations

TS

Thread

Sealant

Zener Barrier Dispense Pump This Maintenance and Repair

Pendant

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)

Flow Meter

Resin Enable Valve

(Poppet Valve)

Air Flow Switches

4 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.

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.

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 5

6

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

n Ensure 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 Identify and correct air and fluid leaks on the system including fluid hoses, flow meter, dispense pump, and mix manifold. n Ensure spray guns are functioning properly and air is not leaking from the air valve. n Check Alarm History and review errors with operator.

Verify the issue has been addressed.

n Ensure material supplies are filled.

Monthly

n Check 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 Examine oil reservoir for hardener material.

n Check 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 Check 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.

AS nEEDED

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

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

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

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.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

2.2 Binks EMS Maintenance Schedule

System Flushed with Solvent description

Check for Leaks

Clean Spray Guns

Check Alarm History

Check for Material Supply

BinkS emS daiLy inSPeCtion inspection method Completed By

Visual date

Visual

Visual

Visual

Visual

Check Static Mixer for clogs description

BinkS emS monthLy inSPeCtion inspection method Completed By

Visual date

Examine Oil Reservoir Visual

Check All Lines For Kinks and Wear

Perform Flow Meter Calibration Check

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

Clean Flow Meter

Clean Mix Manifold and Check Valves

Check Fluid Hoses for Material Buildup

Visual

Test with Beaker

Disassemble

Disassemble

Disassemble

Disassemble description

BinkS emS aS needed inSPeCtion inspection method Completed By

Clean and Rebuild Mix Manifold Disassemble date

Clean and Rebuild Dispense Pump

Inspect and Rebuild Air Flow Switch

Disassemble

Disassemble

Rebuild Poppet Valves

Perform Potentiometer Calibration

Disassemble

Set Limits

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 7

8

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.

6. Press 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.

2. Press the color button on the pendant. Load Color

0 (Solvent) and press F3 (Go).

7. Next, 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. Turn 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.

9. Next, 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.

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.

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.

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

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.

MAintEnAncE oF Flow MEtErS

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.

10 item no. Part numBer deSCriPtion

12

13

14

15

8

9

10

11

16

17

18

3

4

1

2

5

6

7

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

* Items included in repair kit E21-0006 qty.

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

AL

ACME

Lubricant

GL

Gun

Lubricant

PG

Petroleum

Gel

TS

Thread

Sealant

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. First depressurize the system before taking any component of the EMS apart. See 3.2 System

Depressurization Procedure.

2. Disconnect 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. Now that the air line is out of the way, use a

7/8” wrench to unscrew the entire Poppet Valve assembly.

4. Once 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. With the Cap removed, both ends of the Valve

Shaft are visible. Unscrew the Locking Nut

Indicator (10) and set it aside.

6. Unscrew the Piston Retaining Nut (9) from the

Valve Shaft.

7. Slowly pull the Plunger End (5) away from the

Body (3), and remove it from the assembly.

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.

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 recessed indicator oPEn/EnErgizED

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.

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.

3. Depressurize the Binks EMS using 3.2 System

Depressurization and unscrew the Poppet Valve in question.

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

5. Pull apart Poppet Valve and inspect Piston O rings.

Replace if damaged.

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)

12 open valve Closed valve

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

6.1 Air Flow Switch

E21-0015

5

6

14

8

4

10

9

2

3

1

7

7

13

12

15 note 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. Part numBer deSCriPtion

13

14

15

9

10

11

12

7

8

5

6

1

2

3

4

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

* Items included in repair kit E21-0016 qty.

2

1

4

1

1

1

4

2

1

1

1

1

1

1

1

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

18

28

PG

25 9

10

11

21

6

PG

27

AL

1

ACME

Lubricant

2

GL

Gun

Lubricant

PG

Petroleum

Gel

TS

Thread

Sealant

16

18

15 note

*See 7.6 high ratio Mix Kit for more information.

17

15

TS

32

PG

13

11

20

10

4

9

5

26

PG

33

23

TS

7

13

9

32

GL

22*

8

19

12

24

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 15

7.2 Programmable Flush Mix Manifold

E21-0023 / E21-0023-hr*

28

PG

31 30 29

28

19

TS

15 ft-lbs

4

9

5

26

PG

3

20

10

13

25

2

9

10

21

33

11

PG

27

1

AL

ACME

Lubricant

6

GL

Gun

Lubricant

PG

Petroleum

Gel

TS

Thread

Sealant

PG

28

3

13

11

9

GL

22*

12

19 note

*See 7.6 high ratio Mix Kit for more information.

8

23

TS

7

24

16 BINKS EMS | MAINTENANCE AND REPAIR MANUAL

7.3 Multicolor Mix Manifold

E21-0024 / E21-0024-hr*

31 30 29

25 28

PG 14

13

11

20

10

4

28 PG

9

10

33

9

1

2

AL

27

ACME

Lubricant

PG

GL

Gun

Lubricant

PG

Petroleum

Gel

TS

Thread

Sealant

21

11

6

14

28

13

9

GL

22*

8

PG

19

12 note

*See 7.6 high ratio Mix Kit for more information.

5

26 PG

23

TS

7

24

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 17

7.4 Mix Manifold Parts list

item no.

Part numBer deSCriPtion

1 E22-1401

2 E22-1402

3 E22-1403

4 E22-1404

DISPENSE PUMP INLET PLATE

CHECK PLATE

FLUSH VALVE BLOCK

RESIN ENABLE VALVE BLOCK

5 E22-1405

6 E22-1406

7 E22-1407

E22-1408

8

E22-1408-HR

BLANK RESIN PLATE

MIX MANIFOLD BODY

RETAINING NUT

STANDARD MANIFOLD OUTLET

HIGH RATIO MANIFOLD W/

RESTRICTOR

9 E22-1409* SEALING O RING

10 E22-1410* CHECK VALVE O RING

11 E22-1411* MANIFOLD O RING

12 E22-1212* PTFE O RING (PART OF ITEM 19)*

13 E22-1413* BLANK PLATE O RING

14 E22-1414 BLANK AIR/SOLVENT PLATE

15 E22-1415

16 E22-1416

17 E22-1417

FLUSH CHECK VALVE

AIR SIDE BALL VALVE

SOLVENT SIDE BALL VALVE

* Items included in repair kit E21-0021 qty.

1

1

1

2

2

1

1

1

2

1

2

2

1

2

1

4

2 item no.

Part numBer

18 E22-1418

19 E21-0005

20 E21-0017

21 E21-0032

22 E22-1421

23 E22-1037

24 E22-1424

25 E22-1126

26 ----

27 ----

28 ----

29 ----

30 ----

31 ----

32 ----

33 E22-1020

34 E21-0031 deSCriPtion qty.

MANUAL FLUSH VALVE BLOCK

POPPET VALVE (INCLUDING O RING)

RESIN CHECK VALVE (#2046) 1

DISPENSE PUMP CHECK VALVE (#3624) 1

2

1

RESTRICTOR 1

3/8 COMP TO 1/8TH NPT 90 ELBOW 1

MANIFOLD OUTLET ELBOW

MOUNTING BRACKET

1

1

#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)

1

3

2

3

3

6

3

2

2

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).

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.

18 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

Back Side a

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

E21-1046

RESIN HOSE ASSEMBLY

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 E22-1601 TOP PLATE

2 E22-1602 PLUG

5 E22-1605

E22-1607

POPPET VALVE PLUG SEAT

THREADED ROD FOR 2 COLORS

1

1

3 E22-1603 COLOR BLOCK 2-4

4 E22-1604 POPPET VALVE PLUG WITH SEAT & O RING 1

0-1

2 6 E22-1608

E22-1609

THREADED ROD FOR 3 OR 4 COLORS

THREADED ROD FOR 5/6 COLORS

7 E22-1413 BLANK PLATE O RING

8 E22-1611 OUTLET BLOCK

9 E22-1612 COLOR STACK OUTLET FITTING

2-4

1

1 item no.

Part numBer deSCriPtion

10 E22-1613 MOUNTING BRACKET

11 E22-1614 ACORN NUT

12 E22-1415 FLUSH CHECK VALVE

13 E21-0005 POPPET VALVE

14 —

15 —

16 —

17 —

3/8” NPT PLUG

#10 WASHER

#10 LOCK WASHER

1/4-20 X 3/4” HHCS

18 E22-1616 REDUCER BUSHING

19 E22-1020 DOWEL PIN

20 E22-1617 ADAPTER 1/4 NPT(F) X 3/8 NPS(M) qty.

2-9

–

–

–

1

2

2

3-8

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. Load Color 0 to run Solvent through the Mix

Manifold and fluid lines to clear them of resin and particulates.

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.

3. Power down the system using the 3.2 System

Depressurization Procedure.

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

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

6. Now it is safe to remove the color stack and

Mounting Bracket (13) from the fluid back panel.

7. Place 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.

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.

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.

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

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

12. Remount the assembly to the fluid back panel.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 21

1

4

3

2

7

9.1 Flow Meter configuration

8

5 10 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

3

2

7

FLOW

4

5

FLOW

10 9

8 item no.

Part numBer deSCriPtion

1 E22-1126 FLOW METER MOUNTING BRACKET

2 E22-1117** STANDARD FLOW METER

3

4

5

E21-0013 FLOW METER CONTACT

E21-0013-IS INTRINSICALLY SAFE CONTACT

E22-1122

E22-1123

FLOW METER OUTLET FITTING

3

FLOW METER INLET 1 COLOR SYSTEM

2

6 E22-1124

7 —

8 —

9 —

FLOW METER INLET MULTICOLOR SYSTEM

#10-32 X 1/2” SOCKET HEAD CAP SCREW

#10 WASHER

#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 note

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.

6 qty.

1

2

1

1

1

1

1

1

4

4

4

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. Ensure 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.

2. Navigate to the Set Up screen, and enter the

Advanced password. Press F4 to advance until the

Flow Meter Calibration - Resin+Hardener page is visible.

3. Make sure to shut off atomizing air so that an accurate volume can be measured in a beaker.

4. Place a beaker or other fluid measuring device under the output of the spray gun.

5. Press F2 twice to start the test. This will reset the values to zero. Manually trigger the gun into the beaker.

7. After 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.

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.

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.

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).

• 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.

• 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.

• Replace O-ring (5) if deformed.

• 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

8

9

2

8 item no.

6

7

4

5

—

1

2

3

Part no.

deSCriPtion

E22-1117

—

E21-1051

E21-1049

E21-1048

E21-1050

—

—

FLOW METER

LOWER HOUSING

LOCATING PIN

SHAFT

GEAR

O-RING

BODY

HEX BOLTS

JV-20KG w/IDH-8 Shown

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

qty.

1

1

6

2

2

1

2

7

6

5

4

3

1

24 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

200cc —E21 -0034

400cc —E21 -0035

Hardener

Fluid Inlet

Dispense

Fluid Outlet

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.

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 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.

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

13

4

11

37

41

39

40

10

9

38

43

7

6

42

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

26

AL

1 3

2

45

41

12

8

49

48

41

46

PG

40

39

44

39

40

5

AL

ACME

Lubricant

Gun

Lubricant

Petroleum

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

28 torque to 14nm/10ft-lbs

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

10.5 Dispense Pump Parts list

item no.

Part numBer deSCriPtion

3

4

5

6

1

2

E22-1001

E22-1002

E22-1003

E22-1004

E22-1005

E22-1006

7

8

E22-1007

E22-1008

9 E22-1009

10 E22-1010

11 E22-1011

POTENTIOMETER GEAR

POTENTIOMETER

POTENTIOMETER HOLDER

POTENTIOMETER BRACKET

BASE PLATE

SHAFT BUSHING

RETAINER

NON-SLOTTED MOTOR STANDOFF

SLOTTED MOTOR STANDOFF

LEAD SCREW COUPLING

INDICATOR

12 E22-1012

13 E21-0010

14

E22-1014

E22-1050

MOTOR MOUNT

STEPPER MOTOR

200cc PISTON HEAD

400cc PISTON HEAD

15 E22-1212 i w l s O-RING (PART OF ITEM 35)

16 E22-1016 PACKING GLAND

17 E22-1017

18 E22-1018

BASE PLATE STANDOFF

PACKING NUT

19 E22-1019 i w

20 E22-1020

21

E22-1021

E22-1052

PACKING SEAL ASSEMBLY

DOWEL PIN

200cc TOP DISPENSE BLOCK

400cc TOP DISPENSE BLOCK

22 E22-1022

23 E22-1023

24

25

E22-1024

E22-1053

E22-1025

E22-1057

FLUID TUBE

DISPENSE PUMP STANDOFF

200cc CYLINDER

400cc CYLINDER

200cc BOTTOM DISPENSE BLOCK

400cc BOTTOM DISPENSE BLOCK qty.

1

2

1

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

4

1

1 item no.

Part numBer deSCriPtion

26 E22-1028 ACME THREAD SHAFT

27 E22-1030 i w l s PACKING GLAND O RING

28

E22-1031

E22-1056 i l w s

200cc FLUID CYLINDER O RING

400cc FLUID CYLINDER O RING

29 E22-1032 i w l s FLUID TUBE O RING

30

E21-1054

E21-1055

31 E22-1034

32 E22-1035

33 E22-1036

34 E22-1038 i w

200cc PISTON O RING

400cc PISTON O RING

PLUG WASHER

PLUG SCREW

OIL RESERVOIR

1/8 NPT X 1/4 COMP ELBOW

35 E21-0005

36 E21-0011

37 —

38 —

39 —

40 —

41 —

42 —

43 —

44 —

45 —

46 —

47 —

48 —

49 —

50 E22-1058

51 E22-1059

POPPET VALVE

PRESSURE TRANSDUCER

SET SCREW

LOCKING NUT

1/4 LOCK WASHER

1/4 WASHER

10-32 X 1/2" SHCS

10-32 X 7/8" SHCS

10-32 X 1/2" MACHINE SCREW

1/4-20 X 1/2" HHCS

1-4-20 X 3/4" SHCS

1/4-20 X 3" HHCS

1/4-20 X 5.75" HHCS

#10 LOCK WASHER

#10 WASHER

1/8 STREET ELBOW

1/8 NPT X 3/8 NPS NIPPLE qty.

2

4

1

1

2

2

4

4

2

2

4

14

10

4

2

1

1

4

2

2

2

14

1

1

1

1 reBuiLd kit deSCriPtion

200cc dispense Pump rebuild kit

200cc dispense Pump

Seal kit

400cc dispense Pump rebuild kit

400cc dispense Pump

Seal kit

Packing Seal oil kit Part numBer

E21-0001

E21-0002

E21-0029

E21-0030 i l w s

0114-559433 itemS inCLuded

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

— qty.

4

2

1

1

2

4

2

4

1

4

1

2

4

2

1

4

4

4

1

2

550ml

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 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.

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

7. Remove the cover from the left vertical wire tray.

8. Place the free length of the cord in the wire tray, allowing the brown, blue, and black wires access to the PLC Board.

9. Connect the brown wire to 24v DC power from the power supply (36 on 11.2).

10. Connect the black wire to 2091 Cat Flow Switch

(Cat Flow Switch on 17.1).

11. Connect the blue wire to Analog Ground number 2 (Analog Ground on 17.1).

12. Contact your Binks representative or authorized distributor to configure the Binks EMS to enable the Dispense Pump Flow Sensor.

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. To 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.

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.

7. Use 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.

4. Disconnect all 5/32” air lines from the Poppet

Valves (35) in the assembly.

6. Unscrew 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.

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. Ensure 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. Using 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. Remove 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. Unscrew the Packing Gland (16) using a large adjustable wrench. The worn packings will be inside or underneath this fitting.

5. Using a spanner, unscrew the Packing Nut (18) to gain access to the various bit of packing.

6. Using Needle Nose Pliers, and other tools, remove and replace the Seal Assembly (19) in the same orientation as removed.

7. Once all the packings are correctly oriented on the Piston Shaft (15), slide the Packing Gland back in place, and screw it together.

8. Screw the Packing Nut back in place. Refill Oil

Resevoir with seal oil (0114-009433).

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.

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 e22-1019

Packing Seal assembly 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.

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.

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.

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

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

Pass/Fail

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

________

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.

________

________

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.

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 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

2

4

3

BLACK

BLUE

LOAD

–

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

Front Exterior View

32

31

43

42

Bottom Exterior View

30 61

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.

14

Part numBer deSCriPtion

1 E22-1101 120V FUSE HOLDER

2 E22-1102 24VDC FUSE HOLDER

3 E22-1103 24VDC POWER SUPPLY

4 E21-0012 PLC BOARD

5 E22-1105 STEPPER MOTOR CONTROL

6 E22-1106 WIRE TRAY

7 E22-1107 A6-A10 SOLENOID STACK

8 E22-1108 A11-A15 SOLENOID STACK

9 E22-1109 A16-A20 SOLENOID STACK

10 E22-1110 GUN 1 PRESSURE SWITCH

11 E22-1111 GUN 2 PRESSURE SWITCH

12 E22-1112 GUN 1 IN BOX PRESSURE SWITCH

13 E22-1113 GUN 2 IN BOX PRESSURE SWITCH

E21-0034

E21-0035

200cc DISPENSE PUMP FLUID ASSY.

400cc DISPENSE PUMP FLUID ASSY.

qty.

1

17

E22-1115 CORIOLIS FLOW METER

E22-1116 SMALL FLOW METER

E22-1117 STANDARD FLOW METER 1

E22-1118 4 FOOT FLOW METER CABLE 3 PIN (IS) 1

1

1

19

E22-1119 4 FOOT FLOW METER CABLE 6 PIN

E22-1120 25 FOOT FLOW METER CABLE 3 PIN (IS)

E22-1121 25 FOOT FLOW METER CABLE 6 PIN

22 E22-1122 FLOW METER OUTLET FITTING

1

1

1

1

23 E22-1123 FLOW METER INLET 1 COLOR

24 E22-1124 FLOW METER INLET MULTI-COLOR

25 E22-1125 COLOR STACK OUTLET FITTING

26 E22-1126 FLOW METER MOUNTING BRACKET

27 E22-1127 INTRINSICALLY SAFE BARRIORS

28 E22-1128 DISPENSE PUMP FLOW SENSOR

29 E22-1129 DISEPENSE PUMP FLOW SENSOR CABLE

30 E22-1130 ALARM LIGHT WITH HORN

1

1

2

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1 item no.

Part numBer deSCriPtion

31 E22-1131 ON OFF SWITCH

32 E22-1132 UTILITY SWITCH

34 E22-1134 ENCLOSURE

35 E22-1135 TERMINAL BLOCKS

36 E22-1136 DOUBLE HIGH TERMINAL BLOCK

37 E22-1137 GROUNDING TERMINAL BLOCKS

38 E22-1138 END ANCHORS

39 E22-1139 STEPPER MOTOR CONTROL BOARD

40 E22-1140 SOLENOID MOUNTING BRACKET

41 E22-1141 SOLENOID COVER PLATE

42 E22-1142 DISPLAY PENDANT

43 E22-1143 25 FOOT POWER CORD WITH GRIP

45 E22-1145 MAIN AIR BULKHEAD

46 E22-1146 TRANSDUCERS CORD GRIP

47 —

48 —

6-32 x 1/4" MACHINE SCREW

6-32 x 5/8" MACHINE SCREW

49 —

50 —

51 —

52 —

6-32 x 1" MACHINE SCREW

8-32 x 1/2" MACHINE SCREW

10-32 x 1/4" MACHINE SCREW

#10 LOCK WASHER

53 E22-1152 120V FUSE

54 E22-1153 24VDC FUSE

55 E22-1154 EXHAUST AIR BULKHEAD

56 E22-1155 SOLENOID MANIFOLD TEE

57 E22-1156 PRESSURE TRANSDUCER CABLE

58 E22-1157 CONTROL BOARD STANDOFF

61 E22-1160 DISPLAY PENDANT HOLDER

62 E22-1161 FLUID BACK PANEL

— E22-1162 OPTIONAL LIGHT BEACON (GREEN RED)

— E22-1163 LIGHT BEACON REPLACEMENT BULB qty.

1

1

2

4

–

–

1

1

1

0,2,4

8

8

6

2

4

4

1

1

1,2

1

1

1

4

1

4

2

1

2

1

1

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 39

4

40

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.

13 10

8

7

3

6

2

3

Air Inlet

Air Exhaust

1 item no.

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.

10

5

5

5

2

2

1

5

5

5

5

2

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. Verify the gun box lid needs adjustment. Typically due to the lid not closing, or the gun not being triggered automatically.

2. Loosen the screws on the side of the unit so that the Gun Seat (8) is able to slide freely in the slot.

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

4. If the trigger is not being depressed, continue moving the gun seat upwards.

5. Tighten and test the actuation of the unit. If needed, begin the procedure again at step 1.

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

42

Left Side View Right Side View

BINKS EMS | MAINTENANCE AND REPAIR MANUAL

12.5 gun Box Parts list

item no.

Part numBer deSCriPtion qty.

1 E22-1501 GUN BOX BODY

2 E22-1502 COVER

3 E22-1503 LID ASSEMBLY

4 E22-1504 GUN IN BOX BRACKET

5 E22-1505 TOGGLE PLATE

6 E22-1506 BLOCK

7 E22-1507 ARM

8 E22-1508 GUN SEAT

9 E22-1509 HINGE

10 E22-1510 PUSH CAP

11 E22-1511 TRIGGER CAP

12 E22-1512 HANDLE

13 E22-1513 HANDLE ADAPTER

14 E22-1514 GUN SUPPORT

15 E22-1515 SPRING SPACER

16 E22-1516 SUPPORT SPACER

17 E22-1517 TRIGGER SOLENOID

18 E22-1518 PUSH SOLENOID

19 E22-1519 AIR PILOTED SWITCH VALVE

20 E22-1520 AIR PILOT

21 E22-1521 5/32" TUBE Y ADAPTER 1

22 E22-1522 5/32" TUBE x 1/8" NPT TEE FITTING 1

23 E22-1523 5/32" TUBE x 1/8" NPT ELBOW

24 E22-1218 5/32" TUBE x #10-32 ELBOW

5

1

25 E22-1525 AIR SWITCH

26 E22-1526 TORSION SPRING

2

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1 item no.

Part numBer deSCriPtion

27 E22-1527 COMPRESSION SPRING

28 E22-1528 GROMMET

29 E22-1529 S.S. CHAIN LINK

30 E22-1530 S.S. CHAIN CONNECTOR

31 E22-1531 SPRING PLUNGER

32 E22-1532 1/4" x 1" S.S. DOWEL

33 E22-1533 PRESSURE INDICATOR GREEN

34 E22-1534 5/32" TUBE TEES

35 E22-1535 5/32" TUBE BULKHEAD

36 E22-1536 AIR CUT OFF VALVE (NOT SHOWN)

37 E22-1537 #4-40 x 3/4" SHCS SS

38 E22-1538 #8-32 x 5/8" SHCS SS

39 E22-1539 #8-32 x 1" SHCS SS

40 E22-1540 #8-32 NUT SS

41 E22-1552 #10-32 x 1/2" SHCS SS

42 E22-1542 5/16" LOCK WASHER SS

43 E22-1543 5/16" WASHER SS

44 E22-1544 5/16"-18 x 1/2" BHCS SS

45 E22-1545 5/16"-18 x 3/4" BHCS SS

46 E22-1546 5/16"-18 x 3" BHCS SS

47 E22-1547 3/8" LOCK WASHER SS

48 E22-1548 3/8" WASHER SS

49 E22-1549 3/8" LOCK NUT SS

50 E22-1550 3/8"-16 x 1/2" BHCS SS

51 E22-1551 5/8" x 1-1/2" x 1/16" WASHER SS

52 E22-1552 HANDLE LINK qty.

4

4

4

4

1

2

5

1

1

1

1

1

4

2

1

1

1

2

1

2

2

2

2

2

4

2

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 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

(cont.)

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 45

12.7 gun Box Pneumatic Diagram

46 BINKS EMS | MAINTENANCE AND REPAIR MANUAL

12.7 gun Box Pneumatic Diagram

(cont.)

BINKS EMS | MAINTENANCE AND REPAIR MANUAL 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 low inlet

Pressure high outlet

Pressure

CauSe

Dispense pump input pressure is below the set limit

SuggeSted trouBLeShooting

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

Dispense pump outlet pressure is above the set limit

Check for pinched hoses leading to mix manifold

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 ratio Fault Current ratio is outside of tolerance

Ensure pressure transducers are functioning properly

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 is not spraying

Verify Resin Enable Valves is closed

Check Resin Enable Valve needle and seat for wear no hardener

Flow upper transducer

Fault

No Flow is detected through

Dispense Pump Flow Sensor when the dispense pump is running

Ensure flow meter is not detecting pulses of material—refer to

DIN0 LED on PLC Board

Check Hardener supply

Check Connection of Flow Sensor cable

Adjust Flow Sensor at minimum flow rate so display moves off red signal

Improper electrical signal from upper pressure transducer

Flow Sensor out of adjustment—see Flow Sensor Calibration procedure in section 10.6

Verify electrical connection and wiring

Ensure upper Pressure Transducer is functioning properly

48 BINKS EMS | MAINTENANCE AND REPAIR MANUAL

13.1 Alarm guide

(cont.)

FauLt lower transducer

Fault check Pump no resin

Flow

CauSe

Improper electrical signal from lower pressure transducer

Dispense pump output incorrect for Resin flow

SuggeSted trouBLeShooting

Verify electrical connection and wiring

Ensure lower Pressure Transducer is functioning properly

Check for air in the fluid lines

Reducer coating flow rate

Verify Dispense Pump Poppet Valve operation

Verify Potentiometer Gear engagement to ACME rod. Check pump for proper operation

Atomization air flow with no paint flow

Ensure no air leaks including spray gun and Air Flow switch

Ensure Blow Off Time has not been exceeded

Verify Resin Enable Valve opens when spray gun is triggered

Check connections on flow meter upper

Balancing

Fault lower

Balancing

Fault

Pot life color change

Fault

Dispense pump upper reversal not balanced

Air in upper chamber of dispense pump

Inadequate supply pressure– Inlet pump pressure should be greater than outlet pump pressure

Dispense pump lower reversal not balanced

Air in lower chamber of dispense pump .

Inadequate supply pressure– Inlet pump pressure should be greater than outlet pump pressure

Material at end of programmed pot life

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

If alarm repeats and material is flowing through spray gun, refer to Flow Meter Detail, section 9.1

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 high resin

Flow rate

Resin flow rate is above set limit

Restart color change with a color 0 (Solvent) flush

Ensure proper operation of Gun Flush Box

Check for air in fluid supply

Verify Max Resin Flow Rate on Advanced Settings setup screen component B

Flow Fault

Air Flow

Detected

Catalyst Flow is detected without pump operation

Adjust fluid regulator to ensure limit is not reached

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

Atomization air was detected during Color Change or when

Utility switch was in FLUSH or

STANDBY mode

Turn of atomization air

Ensure proper operation of Air Flow Switch

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 Flush Systems:

Air Flush: 255 and Open Air Ball Valve.

Solvent Flush: 255 and Open Solvent Ball Valve manual trigger Switch

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.

267

269

271

273

275

259

261

263

265

SoLenoid no.

247

249

251

253

255

257

LoCation

Dispense Pump

Dispense Pump

Dispense Pump

Dispense Pump

Mix Manifold

Color Stack/Mix Manifold

Color Stack/Mix Manifold

Color Stack

Color Stack

Color Stack

Color Stack

Color Stack

Color Stack or Gun Box

Gun Box

N/A deSCriPtion

Top In

Top Out

Bottom In

Bottom Out

Resin Enable Valve

Air On

Solvent On

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6 or Trigger 2

Trigger 1

Unused manuaL

FLuSh

X

X

X

X

X X

X

X

X

X

Prog.

FLuSh

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X muLti-

CoLor

X

X

50 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.

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Supply air exhaust note 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. Verify that all power at the source is turned off.

2. Open control enclosure door.

3. Use 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. Connect the electrical cord to the appropriate terminals as shown in fig. 6.

5. Close control box and turn on power at breaker.

6. Power 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.

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17.1 Electrical Diagrams

52 BINKS EMS | MAINTENANCE AND REPAIR MANUAL

17.1 Electrical Diagrams

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17.1 Electrical Diagrams

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54 BINKS EMS | MAINTENANCE AND REPAIR MANUAL

17.1 Electrical Diagrams

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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

4/13 © 2013 Binks All rights reserved. Printed in U.S.A.