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77-2985-R0.5

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

Summary of Contents for GEMS

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

Page 2: ...ance 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 Procedur...

Page 3: ...ZARD You may be injured by loud noise Hearing protection 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 fluid into your WEAR RESPIRATOR Toxic fumes can caus...

Page 4: ...he 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 ...

Page 5: ... 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 measuremen...

Page 6: ...ixer 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 dispe...

Page 7: ...x 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 Com...

Page 8: ...nt to understand the names and locations of various compo nents for use during operation and maintenance Major components are shown below Color Stack Section 4 1 Ethernet Port Section 4 1 B Pump Section 10 1 Flow Meter Section 9 1 Mix Manifold Section 7 1 AC Lock Out Switch Section 4 1 Alarm Buzzer Section 4 1 Control and atomizing air connections Section 4 1 4 2 AC Inlet and Ground Stud Section 4...

Page 9: ...r 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...

Page 10: ...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 ...

Page 11: ... 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 ...

Page 12: ...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 ...

Page 13: ...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 ...

Page 14: ...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 liqu...

Page 15: ...n 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 rem...

Page 16: ...16 38 77 2985 R0 5 EN 6 Color Stack 5 Color 240 3230 5 Thread Sealant ...

Page 17: ...ings 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 ...

Page 18: ...955 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 ...

Page 19: ... 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...

Page 20: ...l 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 ...

Page 21: ...art with screwdrivers etc Rather replace the bolts and only thread them in a few turns then tap the top of the bolts with a soft mallet while holding the top half of the body 3 Clean and replace worn parts as necessary 4 Install new gasket Install all parts in the order they were removed Install flatted portion of shafts away from gears as shown 5 Push the two covers together aligning the pins and...

Page 22: ...22 38 77 2985 R0 5 EN ...

Page 23: ...tio With very low speed capability and true positive displacement the catalyst pump can accurately provide ratios from 1 1 to 100 1 depending on flow rate At a low ratio such as 10 1 flow rates should not exceed 1000cc min so as to not overspeed the pump Linear Potentiometer ACME Shaft Stepper Linear Actuator Bearing Position Indicator Pressure Transducer Oil Reservoir Pump Fluid Inlet Pump Fluid ...

Page 24: ...24 38 77 2985 R0 5 EN 10 1 Drive Assembly Note Loctite 242 must be applied when reinstalling items 4 and 14 Note Lubricate the shaft of item 3 using Dupont Krytox GPL 206 as needed ...

Page 25: ...2C 1 4 20 x 1 SHCS 2 6 240 3048 MOTOR MOUNT ASSEMBLY 1 7 20 6952 O RING 1 8 SS 6505 CD 1 4 20 FLAT WASHER 2 9 SS 1505 CD 1 4 20 LOCK WASHER 2 10 SS 655 ZN 1 4 20 NUT 2 11 240 3218 SWIVEL NUT 1 12 240 3216 LOCK NUT 1 13 240 3217 MOTOR ROD ADAPTER MP 1 14 77578 16C 1 4 20 x 1 2 BHCS SS 2 15 240 3014 PUMP COUPLING 1 16 A12772 01 10 24 x 1 2 SHCS SS 4 NOTE Stepper motor and lead screw item 3 are sold ...

Page 26: ...26 38 77 2985 R0 5 EN 10 2 Fluid Assembly 240 3208 Gun Lubricant Thread Sealant Torque to 10ftlbs 14Nm Use anti seize ...

Page 27: ...3 237 729 RETAINING RING 1 24 240 2012 AC COLOR VALVE 4 25 240 3016 1 BOTTOM BLOCK 1 26 240 3018 200 CYLINDER 200CC 1 27 240 3029 TOP BLOCK ASSEMBLY 1 28 240 3084 SEAL HOLDER 1 29 240 3117 OIL RESERVOIR ASSEMBLY 2 30 240 3211 ROD SEAL 2 31 240 3212 200 PISTON SEAL 2 32 240 3219 PUMP ROD ADAPTER 1 33 240 3224 200 200CC ROD AND PISTON ASSEM 1 34 240 3235 4 JIC HIGH PRESSURE HOSE 2 35 240 3238 ELBOW ...

Page 28: ...aded rod 3 Move the pump to a clean workbench 6 Unscrew the four clamping screws 37 from the bottom block Remove the bottom block 25 7 Remove the cylinder 26 to access the piston Remove the pump rod adapter 32 and jam nut 16 to slide the rod out of the top block 19 8 Thoroughly inspect all parts for damage especially the running surfaces of the rod and cylinder Carefully and thoroughly clean all p...

Page 29: ...ng in linear motion of the dispense pump The threaded shaft should be lubricated periodically with a small amount of Dupont Krytox GPL 206 to prevent shaft and nut wear The position sensor and potentiometer bracket must be removed to replace the stepper motor The stepper motor may be removed by removing its bolts and disconnecting from pump fluid end Motor and lead screw are sold as a matched pair...

Page 30: ...value in the center of the screen indicates the current rod position 3 To set the upper limit the last command used must have been JOG UP If this is the case simply press the save button to set the upper limit This value should be about 85 it will show on the left side of the screen 4 To set the lower limit use the JOG DOWN button When the middle value shows about 3 8 press JOG DOWN again to stop ...

Page 31: ...77 2985 R0 5 31 38 EN 17 1 Electrical Diagrams ...

Page 32: ...32 38 77 2985 R0 5 EN ...

Page 33: ...77 2985 R0 5 33 38 EN ...

Page 34: ...34 38 77 2985 R0 5 EN ...

Page 35: ...77 2985 R0 5 35 38 EN ...

Page 36: ...38 77 2985 R0 5 EN ACO GIB2 GIB1 TRG1 TRG2 A5 A4 A3 A2 A1 A0 A7 AE B4 B3 B2 B1 As Viewed from Front inside Enclosure 17 2 Pneumatic Diagrams AIR CUT OFF ACO OR PRESSURE SWITCH 2 GIB2 PRESSURE SWITCH 1 GIB1 ...

Page 37: ...77 2985 R0 5 37 38 EN TRG2 TRG1 GIB1 ACO GIB2 A2 A3 A4 A5 AE A7 A0 A1 B1 B2 B3 B4 As Viewed from Back Side of Enclosure ...

Page 38: ...ormation please contact the closest Finishing Brands location listed below Standard 1 year warranty Binks products are covered by Finishing Brands five year materials and workmanship limited warranty The use of any parts or accessories from a source other than Finishing Brands will void all warranties For spe cific warranty information please contact the closest Finishing Brands location listed be...

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