Binks GEMS Operating instructions

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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

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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