Binks GEMS Operating instructions

77-2985-R0.5 1/38
EN
GLOBAL ELECTRONIC MIX SOLUTIONS
PLURAL COMPONENT MIXING SYSTEM FOR ACID CATALYST
MAINTENANCE & REPAIR MANUAL

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Table of Contents
1: System Depressurization Procedure………...4
2: Cleaning and Maintenance……...……………..5
2.1: Preventive Maintenance…………….6
2.2: Maintenance Schedule……………...7
3: Component Names and Locations……........8
3.1: Component Descriptions…...…..….9
4: Control Enclosure ………………………………...10
4.1: Control Enclosure Interior………….11
4.2: Control Board Detail………………….12
4.3: Solenoid Manifold Detail…………….13
Assembly Lubricant Note……………………………14
5: Color Change Valve (CCV)...………………….15
5.1: Valve Troubleshooting……………...15
6: Color Stack–5 Color………………….……..…. 16
6.1: Color Stack Parts List…………….….17
6.2: Color Stack Rebuild…………………..17
7: Mix Manifold………………………...……..……...18
7.1: Mix Manifold Maintenance………...19
7.2: Injector Assembly……..………….….19
7.3: Injector Assembly Repair………..…19
8: Fluid Panel Components………………………..20
9: Flow Meter Guide………………….................21
9.1: Disassembly and Servicing ……….21
10: Dispense Pump…………………………………..22
Pump Operation………………………10.2
Drive Assembly…………………………10.3
Fluid Assembly…………………………10.4
Dispense Pump Parts List………....10.5
Dispense Pump Flow Sensor………10.6
Flow Sensor Calibration…...10.7
Flow Sensor Installation……10.8
Dispense Pump Removal……………10.9
Seal Replacement Procedure………10.10
Limit Set Procedure………………….10.11
Pump Troubleshooting Checklist..10.12
Pressure Transducer Electrical….10.13
Reassembly Callouts……………………………..4.1
Solenoid Stacks………………11.4
Alarm Guide…………………………………….13.1
Power Outage Cleaning Procedure…….14.1
Trigger Line Connection Reference.14.2
Enclosure Air Plumbing ……………………..15.1
Connecting Direct Power…………………..16.1
Electrical Diagrams………………………….17.1
Pneumatic Diagrams…….………………….17.2

77-2985-R0.5 3/38
EN
It is the of the to this to the of the
For see the
READ THE MANUAL
read and all safety, and
TRAINING
EQUIPMENT HAZARD
can cause the to or start
LOCK OUT / TAG-OUT
Failure to de-energize, disconnect, lock out and tag-out all power sources before
performing equipment maintenance could cause serious injury or death.
PRESSURE RELIEF PROCEDURE
Always follow the pressure relief procedure in the equipment instrucon manual.
AUTOMATIC EQUIPMENT
Automac equipment may start suddenly without warning.
KEEP EQUIPMENT GUARDS IN PLACE
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT IN CASE OF AN EMER-
GENCY
WEAR SAFETY GLASSES
Failure to wear safety glasses with side shields could result in serious eye injury or
INSPECT THE EQUIPMENT DAILY
Inspect the equipment for worn or broken parts on a daily basis. Do not operate the
NEVER MODIFY THE EQUIPMENT
Do not modify the equipment unless the manufacturer provides wrien
STATIC CHARGE
Fluid may develop a stac charge that must be dissipated through proper grounding
of the equipment, objects to be sprayed and all other electrically conducve objects
in the dispensing area. Improper grounding or sparks can cause a hazardous condi-
on and result in re, explosion or electric shock and other serious injury.
ELECTRIC SHOCK / GROUNDING
Improper equipment grounding, poor venlaon, open ame or sparks can cause hazard-
ous condions and result in re or explosion and serious injury.
PROJECTILE HAZARD
You may be injured by venng liquids or gases that are released under
PINCH POINT HAZARD
Moving parts can crush and cut. Pinch points are basically any areas where there are
NOISE HAZARD
You may be injured by loud noise. Hearing protecon may be required when using
PROP 65 WARNING
WARNING: This product contains chemicals known to the State of California
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 uid into your
WEAR RESPIRATOR
Toxic fumes can cause serious injury or death if inhaled. Wear a respirator as recom-
mended by the uid and solvent manufacturer’s Safety Data Sheet.
TOXIC FLUID & FUMES
Hazardous uid 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 specic
FIRE AND EXPLOSION HAZARD
Improper equipment grounding, poor venlaon, open ame or sparks can cause a
Plural Component Materials Hazard
Because of the vast number of chemicals that could be used and their varying chemi-
cal reacons, the buyer and user of this equipment must determine all facts relang
to the materials used, including any of the potenal hazards
Halogenated hydrocarbon solvents can cause an explosion when in contact with
aluminum components of a pressurized or closed uid system.
READ THE MANUAL
read and all safety, and
All must be before equipment.
EQUIPMENT HAZARD
can cause the to or start
PRESSURE RELIEF PROCEDURE
Always follow the pressure relief procedure in the equipment instrucon manual.
KEEP EQUIPMENT GUARDS IN PLACE
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT IN CASE OF AN EMER-
GENCY
WEAR SAFETY GLASSES
Failure to wear safety glasses with side shields could result in serious eye injury or
In this manual, the words WARNING, CAUTION and NOTE are used to emphasize important safety informaon as follows:
NOTE
or in
! WARNING
! CAUTION
Read the following warnings before using this equipment
! WARNING

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Disconnect and De-energize!
1 : System Depressurization Procedure
With air and pressurized working fluids, the GEMS system is constantly under various states of fluid
pressure. To perform maintenance and repair or shut down for extended periods the system should be
completely depressurized. Follow the instructions below to depressurize and prevent the sudden
unexpected release of fluid or air from the system.
1. Close all material supply valves for paint resin (component A) and hardener (B). Relieve material
pressure from all A+B sources. Do not shut off solvent or flushing air at this time.
2. Shut off atomizing air to the gun(s).
3. From the home screen press the Prime button on the touchscreen. While triggering the gun(s)
into a grounded metal waste container use the Prime function to open all CCVs for the A
components available.
4. Run the Prime function for the B pump for at least one full stroke and direction change.
5. Press the color change button on the HMI. Enter Color 0 (Solvent) and press GO.
6. 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 Continuous Flush mode as long as
required to clear any debris from the fluid lines. Always end with a color 0 load to remove air
pockets from the fluid lines.
6. Close flushing air and solvent supply valves. Relieve pressure.
7. While triggering gun(s) return to Prime mode and open valve 0.
8. Shut off the system using the AC lockout switch.
9. Disconnect atomizing and system air pressure.
10. Trigger gun to relieve any pressure remaining in the material line.
11. If disassembling any part of the machine, be sure to verify it is disconnected and locked out from
all power sources.
Before attempting any maintenance or repair it is necessary to ensure the system is
depressurized and disconnected from power. Follow all lockout / tag out procedures
applicable to this machine. The GEMS system uses electrical and pressurized fluid (air
and liquid) power and material sources. Make sure all energy sources are disconnected
and the machine has been de-energized before attempting work of any kind.
WARNING

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2: Cleaning and Maintenance
If material leaks occur, be sure to correct the problem and maintain a clean work area. To avoid hardening of
paint inside the fluid lines, the system must be cleaned by a complete flushing procedure at the end of
operations. See the Operations Manual 77-2984 for more information regarding flushing.
Cleaning of Hoses
If gun 1 and gun 2 flush sequences are correct the mixed material line(s) will remain clean and ready for the
next use. Always finish spraying operations with a “color 0 load” that removes all air from the fluid lines. If
pot life is greatly exceeded, it is recommended the static mixer and mixed material hose be replaced and the
mix manifold disassembled and cleaned.
Maintenance of CCVs
If a color change valve (CCV) has not been used for a prolonged period, it is recommended to remove the
valve and clean the corresponding passageway. Paint material may collect inside the valve or manifold
passages. If the valves do not operate properly or if fluid leaks occur the valve must be repaired. Check the
valves for proper operation regularly.
Maintenance of Flow Meters
If the flow rate graph or dispense pump movement appears erratic the flow meter should be inspected for
proper operation. Paint solids may collect in and around the gears, bearings, and shafts, interfering with the
motion of the gears and resulting in incorrect flow measurement. The use of abrasive or pigmented fluids will
lead to wear which influences the accuracy of the flow meter. Routinely calibrate the flow meter for all paints
used with the system.
Cleaning The Enclosure Exterior and HMI
The control enclosure’s exterior painted surfaces must only be cleaned with a soft damp cloth and household
cleaners. Cleaning of the touch-screen-display with solvents is not allowed. If contamination of the display is
expected, use disposable screen cover starter kit 240-3187. For refills, order 240-3199.
Read and understand all operating manuals for connected equipment. Failure to properly follow the
operating instructions could result in personal injury or damage to equipment.
CAUTION
Never expose electrical equipment to flammable liquids or gases including solvents.
WARNING

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2.1: Preventive Maintenance
The GEMS system requires periodic inspection and regular maintenance for optimum performance and the
least possible down time. 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 sprayed.
Daily / Each Shift:
 Ensure mixed material is properly flushed with solvent at the end of the shift. Verify there is no mixed
material or air pockets in the fluid lines.
 Identify and correct air and fluid leaks on the system including fluid hoses, flow meter, dispense
pump, and mix manifold locations.
 Ensure spray guns are functioning properly and air is not leaking from the air valve.
 Check Alarm History and review errors with operator. Verify that any issues have been corrected.
 Ensure material supplies are filled and pressures are correct.
Monthly
 Examine B pump oil reservoir tubes for presence of hardener.
 Check all air and fluid lines for kinks, cuts, or wear.
 Perform Resin + Hardener calibration to ensure flow meter and dispense pump are working properly.
 Inspect static mixer assembly at mix manifold outlet. If static mix elements become clogged,
disassemble and replace the mix elements as needed. Balancing alarms or increasing outlet pressure
may indicate clogging.
• Ensure all CCVs are opening and closing properly. Remove valves and clean or repair if needed.
• Disassemble and inspect flow meter for excessive wear or buildup of material. Clean as needed. Verify
smooth dispense pump movement after reassembly.
• Clean and reassemble the mix manifold and check valves.
 Check fluid hoses for buildup of material. Replace if needed. With plural component coatings, buildup
of material is common around the hose fittings. This is a potential source for contamination of the
finished product.
As Needed
 Rebuild mix manifold –replace O-Rings and parts within the injector assembly.
 Rebuild B pump –required if “B” material begins to leak from the oil reservoirs, or if the A Only
Calibration is correct, but the A+B Calibration is inaccurate.
 Rebuild Color Change Valves –monitor valves for air leaks or slow response time when triggering.
Improper pump operation may be attributed to failing color change valves.
 Set limits of B Pump or replace Pot Wiper and/or Bracket assembly if damaged.
NOTE:
Fluid properties vary greatly. If a material clogs any component more frequently than expected, adjust the
maintenance schedule accordingly.

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Binks GEMS Monthly Inspection
Description Inspection Completed By Date
Examine oil reservoir Visual
Check all hoses for kinks and wear Visual
Perform flow meter calibration check Test with Beaker
Check static mixer for clogs Disassemble
Check CCV operation. Remove valves
and clean. Disassemble
Clean flow meter Disassemble
Clean mix manifold and check valves Disassemble
Check fluid hoses for material buildup Disassemble
Binks GEMS As Needed Inspection
Description Inspection
Method Completed By Date
Clean and rebuild injector assembly Disassemble
Clean and rebuild B pump Disassemble
Rebuild color change valves Disassemble
Set B pump limits Visual
2.2: Maintenance Schedule
Binks GEMS Daily Inspection
Description Inspection Completed By Date
System flushed with solvent Visual
Check for leaks Visual
Clean spray guns Visual
Check alarm history Visual
Check material supply Visual

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3: Component Names and Locations
Touchscreen HMI
Secon 4.1
A Enable Valve
This maintenance and repair manual provides part number, troubleshooting, and assembly infor-
mation for the Binks GEMS. It is important to understand the names and locations of various compo-
nents for use during operation and maintenance. Major components are shown below.
Color Stack
Secon 4.1
Ethernet Port
Secon 4.1
B Pump
Secon 10.1
Flow Meter
Secon 9.1
Mix Manifold
Secon 7.1
AC Lock
Out Switch
Secon 4.1
Alarm Buzzer
Secon 4.1
Control and atomizing
air connecons
Secon 4.1 & 4.2
AC Inlet and
Ground Stud
Secon 4.1
Stac Mixer
Secon 8.1

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3.1: Component Descriptions
Color Change Valve, also known as “CCV” — Pneumatic valve used to
open and close fluid passages on the dispense pump, mix manifold,
and color stack.
Mix Manifold—Continuously mixes paint resin (A) and catalyst (B). A
built-in check valve on the hardener side prevents back-up of resin into
the catalyst pump. Resin flow is controlled by a single CCV “AE”.
Color Stack—Manifold blocks and Color change valves for paint resin (A) material.
Multiple colors must use the same catalyst. Used as the location of flushing solvent
for cleaning of the fluid lines.
Dispense Pump—The device used to dispense hard-
ener or catalyst to the mix manifold. The system controls the pump’s step-
per motor to precisely dispense at the required ratio.
HMI—“Human-Machine Interface”. This is used to
operate and monitor the system. It has a 7” touch screen
and sends instruction to and receives data from the system
control main board.
Flow Meter—Measures and communicates the flow rate of resin to the system
control. Also used in the accessory solvent meter kit to measure solvent usage.

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4: Control Enclosure
ITEM NO. PART NO. DESCRIPTION QTY.
1 240-3054 ETHERNET BULKHEAD 1
2 240-3172 HMI DISPLAY, 7” 1
3 240-3173 HMI CABLE 1
4 240-3175 ETHERNET CABLE, ANGLED 1
5 A12464-00 FLASH DRIVE 1
6 240-3174 BUZZER 1
7 240-3052 AC INLET ASSEM 1
8 A12411-00 AC LOCKOUT SWITCH 1
9 240-3118 AIR CONTROL/ CUT OFF KIT (OPT.) 1
ITEMS 3-5 ON BACK OF DOOR

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4.1: Control Enclosure Interior
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 E21-0012 CONTROL BOARD 1
2 25766-106 PRESSURE SWITCH 2
3 240-3203 24VDC POWER SUPPLY 1
4 240-3204 48VDC POWER SUPPLY 1
5 240-3202-P STEPPER DRIVE 1
6 240-3205 STEP LINEAR ACTUATOR 1
7 240-3085-15 SOLENOID MANIFOLD ASSEMBLY 1

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4.2: Control Board Detail
ITEM NO. PART NO. DESCRIPTION QTY.
1 E21-0012 CONTROL BOARD 1
2 21643-411 SCREW 4
3 240-3074 TERMINAL BLOCK, 10 POSITION 4
4 240-3073 TERMINAL BLOCK, 2 POSITION 1
5 240-3077 TERMINAL BLOCK, 4 POSITION 1
6 240-3075 TERMINAL BLOCK, 16 POSITION 1
7 240-3076 TERMINAL BLOCK, 8 POSITION 1

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4.3: Solenoid Manifold Detail
240-3085-15
The solenoid manifold converts 24V electrical signals from the control board into pneumatic air signals for
CCV operation. Gaskets must be correctly seated for proper solenoid operation. Replacement gaskets and
screws may be ordered as part of a repair kit.
# PART NUMBER DESCRIPTION QTY.
1 240-3087 SOLENOID MANIFOLD BODY 1
2 240-3091 SOLENOID VALVE ASSEMBLY 15
3 54-4945 1/8” NPT x 1/4” OD TUBE FITTING 2
Part # Description Contains
240-3092 Solenoid Repair Kit 10 Screws
5 Gaskets

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Reassembly Lubricant Callouts
Refer to the icons below to avoid damage 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 assembly views.
Gun Lubricant
Use DeVilbiss SSL-10 gun lube to lubricate O-rings and sliding parts for assembly.
SSL-10 is silicone and petroleum-free and is easily washed away by typical paint solvents.
Petroleum Gel
Use Petroleum Gel to lubricate threads or other part surfaces to prevent galling or
other damage upon reassembly.
Thread Sealant
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 clockwise 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.
Follow all assembly procedures and lubricant
recommendations to ensure proper operation.
NOTE

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5 : Color Change Valve 240-2012-AC
The acid-compatible color change valve (CCV) is used throughout the GEMS system. State of the valve may
be quickly identified by an indicator on the end cap. If the red indicator is protruding from the surface, the
valve is open and fluid flow is permitted. Alternatively, if the red indicator is flush to the end cap, the valve is
closed. Paint material should not be present at the indicating holes. Immediately repair the valve if resin or
catalyst materials are present.
The valve is normally closed and a signal of 75~100 psi [5~7 bar]
pneumatic pressure opens the valve.
5.1: Valve Troubleshooting
1. Open Enclosure door and look for LED indicator light on solenoid responsible for valve operation. If the
red light is not on when valve is selected, the solenoid or wiring may be damaged. When actuated, the
CCV indicator should protrude, and no air leakage should be heard.
2. Verify pneumatic trigger signal is being sent through the 5/32” tubes with no air leaks or kinked tubing.
3. Depressurize the GEMS system using 1: System Depressurization Procedure and remove the CCV.
4. Visually inspect the valve for damage or wear. For repair, disassemble the valve by following 77-3128
CCV Service Manual instructions.
5. Inspect for damage or wear and replace any damaged or worn components. Reassemble valve or replace
as needed.
Fluid Inlet
Valve Indication
Seat and stem
Indicator
Needle Seals Indicang
Holes
See Binks part sheet 77-3128 for complete repair
instructions, including part numbers for repair kits and special
tools required for disassembly and reassembly.
NOTE

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6: Color Stack—5 Color
240-3230-5
Thread Sealant

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EN
6.2: Color Stack Disassembly / Reassembly
1. Color change using color 0 to flush the Color Stack.
2. Power down the system using the System Depressurization Procedure in 77-2984 Operation
Manual.
3. Disconnect all air, fluid, and solvent lines connected to the Color Stack.
4. Loosen the nut on tube fitting (3) to remove the Flow Meter from the bottom of the color stack. Remove
the Color Stack from the fluid panel.
5. Place the assembly on a clean work bench and remove the four nuts (14) and lock washers (13).
6. Slide lower bracket (12) and manifold blocks (7, 9) off the threaded rods (7). Do not remove the thread-
ed rods from the top block (8).
7. Use the pin tool CCV-7 to remove the CCVs from the Color Stack. Optionally, use a 1 1/16” [27mm]
wrench. See part sheet 77-3128 for CCV maintenance.
8. Replace o-rings (5). Inspect check valves for proper operation.
ITEM NO. PART
NUMBER DESCRIPTION QTY.
1 20-2848 ELBOW, 1/4 NPT SS 1
2 20-6955 ELBOW, 5/32” ODT 2-6
3 LSFI0033-00 3/8” JIC X OD TUBE CONNECTOR 1
4 240-2012-AC ACID COMPATIBLE COLOR VALVE 2-6
5 23165-430 O-RING 1-3
6 77578-16C 1/4-20 x 1/2” BHCS 4
7 CCV-16-SS CENTER MANIFOLD BLOCK 0-2
8 CCV-17-SS INLET MANIFOLD BLOCK 1
9 CCV-18-SS OUTLET MANIFOLD BLOCK 2
10 CCV-19 PLUG 1-2
11 CCV-21 HEX PORT 1-2
12 CCV-37 BRACKET 2
13 SS-1505-CD 1/4” LOCK WASHER 4
14 SS-655-ZN 1/4-20 NUT 4
15
SSF-6504-3”
SSF-6504-4.75”
SSF-6505-5.75”
1/4-20 x 3” THREADED ROD (for 1 color)
1/4-20 x 4.75” THREADED ROD (for 2-3 color)
1/4-20 x 5.75” THREADED ROD (for 4-5 color)
4
16 SSV-809 CHECK VALVE 1
6.1: Color Stack Parts List
Reassembly
1. When reinstalling the CCV torque the spanner nut to 132-156 in-lb [15~17.6 N-m].
2. Do not reuse o-rings (5). Reuse may cause leakage.
3. Torque the four nuts (14) to 110-130 in-lbs.
4. Use thread sealant on all tapered pipe threads. Avoid leaks by only turning clockwise.

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Gun Lubricant
Thread Sealant
7: Mix Manifold
240-3240
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 20-6955 ELBOW FITTING 1
2 107-1449 DM NIPPLE, 1/8” NPT x #4 JIC 1
3 240-2012-AC HIGH PRESSURE COLOR VALVE 1
4 240-3047-1 INJECTOR ASSEMBLY 1
5 240-3049-1 MANIFOLD ASSEMBLY 1
6 240-3155 1/4-20 HEX STANDOFFS 3
7 240-3236 ADAPTER, 1/4 NPT x #4 JIC 1
8 77578-56C 1/4-20 BHCS 3
9 A12772-01 #10-24 x 1/2” SHCS 2
10 SSV-809 CHECK VALVE 1

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7.3: Injector Assembly Repair
1. After removing injector assembly from mix manifold, remove DM nipple (2), then use two screwdrivers to
disassemble the stem (4d) and spring retainer (4b).
2. Remove and discard spring (4c), and o-ring (4e). Clean stem and injector body (4a) thoroughly, inspecting
parts for nicks or scratches on sealing surfaces. Replace parts if damage is found.
3. Install new stem seal o ring (4e) on valve stem . Insert stem into body (4a). Drop new spring (4c) into
valve body, then use two screwdrivers to assemble spring retainer (4b) to stem. Push on spring retainer to
make sure the valve opens and closes freely.
4. Apply thread sealant to adapter (2) and tighten into injector body.
7.2: Injector Assembly
240-3047-1
* Items included in repair kit 240-3124
ITEM
NO.
PART NUMBER DESCRIPTION QTY.
4a 240-3042-1 INJECTOR BODY 1
4b 240-3044-1 SPRING RETAINER 1
4c 240-3045-1 SPRING 1*
4d 240-3136-1 VALVE STEM 1
4e 79001-04 VALVE STEM O-RING 1*
4f 79001-08 INJECTOR O-RING 1*
7.1: Mix Manifold Maintenance and Repair
Reduced flow through the mix manifold indicates dried or hardened paint buildup. Paint or solvent backing
into the hardener tube indicates a leak or malfunction of the injector assembly (see below). These items may
require disassembly and cleaning to restore mixing and flow performance.
1. Load Color 0 to run Solvent through the Mix Manifold and fluid lines to clear them of resin.
2. Power down and depressurize the system as described in 77-2984 Operations Manual.
Disconnect the resin and hardener fluid lines from the mix manifold. Remove adapting nipple (2) so
the injector assembly is visible.
3. Remove the Injector Assembly (4) by removing the screws (9) and pulling it out of the manifold (5).
If the body is stuck, thread the two screws into the threaded holes in the injector body and use them
to force the body away from the manifold.
4. Examine the Manifold Body, check valve (10), CCV (3), and injector assembly. Clean the mix manifold
and components with a compatible solvent, being sure to remove any debris or build up. If needed,
replace or repair the injector assembly.

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8: Fluid Panel Components
ITEM PART NUMBER DESCRIPTION QTY.
1 240-3276 FLOW METER 1
2 240-3114-A-6 FLOW METER CABLE (STANDARD 6 FT) 1
3 240-3213 ACCESSORY SOLVENT METER —
4 240-3241 RESIN HOSE 1
5 240-3231 STATIC MIX ASSEMBLY 1
6 240-3242 CATALYST HOSE 1