RF2 & RM2 Gun Flush Kit 77-3160

INSTALLATION MANUAL EN

77-3160

IntelliFlow™ GUN FLUSH BOX KIT

®

www.binks.com77-3160-R6.0 (05/2025)

ENADDITIONAL RESOURCES

For additional information or copies of your service manual, please visit us online at:

binks.com/en/library

Or use this QR code with your mobile device:

Obey local or municipal regulations for product recycling and disposal.

RM2 RF2+™

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EN 02. TABLE OF CONTENTS

i / ii

02 CONTENTS

03 EU DECLARATION OF CONFORMITY 1
04 SAFETY 3
04.1 SAFETY PRECAUTIONS ��3
04.2 ADDITIONAL SAFETY INFORMATION ��10
05 PRODUCT OVERVIEW 11
05.1 GUN FLUSH BOX ��11
05.2 GUN FLUSH BOX PARTS LIST ��11

06 INSTALLATION 13
06.1 MOUNTING INSTRUCTIONS ��13
06.2 GUN FLUSH BOX AIR CONNECTIONS ��14
06.3 CONNECTING TO THE RM2 ��15
06.4 ENABLE RM2 USER INTERFACE (LOW PRESSURE & MEDIUM PRESSURE)........................................16
06.5 RM2 CONNECTIONS DIAGRAM ��17
06.6 CONNECTING TO THE RF2 AND RF2+ ��18
06.7 ENABLE THE RF2 AND RF2+ USER INTERFACE ��19
06.8 RF2 AND RF2+ CONNECTIONS DIAGRAM ��20
06.9 GUN SADDLE ADJUSTMENT ��21
06.10 SADDLE ADJUSTMENT STEPS ��22

07 OPERATION 23
07.1 OPERATION GUIDE ��23

08 TROUBLESHOOTING 25
08.1 TROUBLESHOOTING GUIDE ��25

09 PARTS IDENTIFICATION 27
09.1 GUN SADDLES PARTS LIST ��27
09.2 GUN FLUSH BOX COMPONENTS (FRONT & LEFT SIDE VIEW) 28
09.3 GUN FLUSH BOX PARTS LIST ��29
09.4 GUN FLUSH BOX COMPONENTS (FRONT & RIGHT SIDE VIEW)............................................................30
09.5 GUN FLUSH BOX PARTS LIST ��31

10 MANUAL REVISIONS 33
11 WARRANTY 35

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EN02. TABLE OF CONTENTS

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EN 03. EU DECLARATION OF CONFORMITY

EN

This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:

EU Declaration of Conformity

Representative authorised to compile the technical file

Suitable for use in hazardous area: Zone 1/Zone 2

This Declaration of Conformity / Incorporation is issued
under the sole responsibility of the manufacturer:

Binks US LLC.
3760 Victoria St N
Shoreview, MN 55126. USA

Element Materials Technology Rotterdam B.V. (2812)

President @. Binks France SAS
5 Place Pierre Semard, 94130 Nogent sur Marne
Paris, France

Machinery Directive 2006/42/EC
ATEX Directive 2014/34/EU
by complying with the following statutory documents and harmonised standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN ISO 80079-36:2016 Explosive Atmospheres- Part 36:Non Electrical equipment for explosive atmospheres-Basic
methods and requirements.
EN ISO 80079-37:2016 Explosive Atmospheres- Part 37: Non Electrical equipment for explosive atmospheres -
protection by methods c, b and k.
EN 1127-1:2019 Explosive atmospheres - Explosion prevention - Basic concepts

Product Description / Object of Declaration:

Solvent & Waterbased MaterialsThis Product is designed for use with:

Gun Flush Boxes - 240-3179-K

Providing all conditions of safe use / installation stated within the product manuals have been complied with and also installed in
accordance with any applicable local codes of practice.

Notified body details and role:

II 2 G X/Ex h II Gb XProtection Level:

Lodging of ATEX Technical file

4-3192R-1

Executive President: Engineering and
Operations, 3760 Victoria St N

Shoreview, MN 55126. USA

F. A. Sutter

18/8/25

Signed for and on behalf of Binks
US LLC:

Document Part No.



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EN03. EU DECLARATION OF CONFORMITY

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EN 04. SAFETY

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04 SAFETY
04.1 SAFETY PRECAUTIONS
Before the operation, maintenance, or servicing of this
Binks system; fully read and understand all technical
and safety literature for your product. This manual
contains information that is important for you to know and
understand.
This information relates to USER SAFETY and the
PREVENTION OF EQUIPMENT PROBLEMS.
To help you understand this information, we use
recognizable ANSI Z535 and ISO warning boxes and
symbols throughout this manual. Please obey these
safety sections.

Careful study and continued use of this manual will
provide a better understanding of the equipment functions
and procedures.
This understanding will result in improved operation,
efficiency, and longer, trouble-free service with faster and
easier troubleshooting. If you need the necessary safety
literature for your specific system, contact your local Binks
representative or Binks directly.

WARNING
WARNING!: Indicates a hazardous situation that, if not

avoided, could result in death or severe injury.

CAUTION
Caution!: Indicates a hazardous situation that, if not
avoided, could result in minor or moderate injury, or

equipment damage.

NOTICE
Notice: Indicates information considered important but

not hazard related.

DANGER
DANGER!: Indicates a hazardous situation that, if not

avoided, will result in death or severe injury.

SAFETY
Safety: Indicates a type of safety instruction, or a

separate panel on a safety placard, where specific
safety-related instructions or procedures are described.

WARNING
The hazards shown on the pages that follow can occur

during the normal use of this Binks equipment, but
not all listed hazards will be applicable to your product

model or equipment.

Repairs may only be performed by personnel
authorized by Binks.

WARNING
The user MUST read and be familiar with the Safety

Section in this manual and the safety literature therein
identified.

Only trained personnel can operate this equipment.

All personnel who operate, clean, or maintain this
equipment MUST fully read and understand this

manual! To operate and service the equipment, follow all
WARNINGS and safety requirements.

The user must be aware of and adhere to ALL local
building and fire codes and ordinances, as well as NFPA

33 AND EN 16985 SAFETY STANDARDS, LATEST
EDITION, or applicable country safety standards, before
the installation, operation, or servicing of this equipment.

NOTICE
This manual lists standard specifications and service

procedures. Differences can occur between this
literature and your equipment.

Differences in local or municipal codes, manufacturer
or plant requirements, material delivery requirements,

and more can make variations unpreventable. To
find these differences, compare this manual to your

system installation drawings and other applicable Binks
equipment manuals.

EN04. SAFETY

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AREAS
Indicate possible

hazard occurrences.

HAZARDS
Indicate possible hazards.

SAFEGUARDS
Prevention of possible hazards.

Spray Areas Fire Hazards
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire
hazard.
If the safety interlocks are
disabled during operation,
protection against accidental
arcing is shut off and can cause
a fire or explosion.
Frequent Power Supply or
Controller shutdown identifies a
problem in the system. For this
occurrence, a correction will be
necessary

Fire extinguishing equipment must be present in the
spray area. Periodically run a test to make sure the
equipment stays usable.
Keep spray areas clean to prevent the build-up of
combustible residues.
Do not smoke in the spray area.
The high voltage supplied to the atomizer must be
turned off before the equipment is cleaned, flushed
or maintained.
Spray booth ventilation must be kept at the rates as
set by NFPA-33, OSHA, country, local, and municipal
codes.
If flammable or combustible solvents are used to
clean the equipment, ventilate the area.
Prevent electrostatic arcing. Maintain spark-safe
work distance between the parts that get coated and
the applicator. A span of one inch for every 10KV of
the output voltage is necessary.
Do an equipment test only in areas free of
combustible material. The test may necessitate the
high voltage to be on, but only as instructed.
Non-factory replacement parts or unauthorized
equipment modifications can cause a fire or injury.
The key switch bypass is used only during setup
operation.
Do no production work with disabled safety
interlocks.
Set up and operate the paint procedure and
equipment under NFPA-33, NEC, OSHA, local,
municipal, country, and European Health and Safety
Norms.

EN 04. SAFETY

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AREAS
Indicate possible

hazard occurrences.

HAZARDS
Indicate possible hazards.

SAFEGUARDS
Prevention of possible hazards.

Spray Areas

General Use and
Maintenance

Explosion Hazard
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire or
explosion hazard.
If the safety interlocks are
disabled during operation,
protection against accidental
arcing is shut off and can cause
a fire or explosion.
Frequent Power Supply or
Controller shutdown identifies a
problem in the system. For this
occurrence, a correction will be
necessary.

Improper or unsatisfactory
operation and maintenance
procedures will cause a fire
hazard.
Personnel must be correctly
trained in the operation and
maintenance of this equipment.

Prevent electrostatic arcing. Maintain spark-safe
work distance between the parts that get coated and
the applicator. A span of one inch for every 10KV of
output voltage is necessary.
Unless specifically approved for use in hazardous
locations, put all electrical equipment outside of
Class I or II, Division 1 or 2 hazardous areas in
accordance with NFPA-33, or outside of Zone 2 or
Zone 22 in accordance with EN standards.
If equipped, set the current overload sensitivity as
described in the related section of the equipment
manual. If incorrectly set, the current overload
sensitivity for protection against accidental arcing is
turned off and can cause a fire or explosion.
Frequent power supply shutdown indicates a
problem in the system, which requires correction.
Always turn off the control panel power before the
system is flushed, cleaned, or servicing the spray
system equipment. Make sure no objects are within
the spark-safe work distance before the high voltage
is turned on.
The control panel must interlock with the ventilation
system and conveyor in accordance with NFPA-33,
EN 50176.
Fire extinguishing equipment must be present in the
spray area. Periodically run a test to make sure the
equipment stays usable. Do an equipment test only
in areas free of combustible material.

Train all personnel in accordance with the
requirements of NFPA-33, EN 60079-0.
Before equipment operation, personnel must read
and understand these instructions and safety
precautions.
Obey appropriate local, municipal, state, and
national codes governing ventilation, fire protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms, and your
insurance company requirements.

EN04. SAFETY

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AREAS
Indicate possible

hazard occurrences.

HAZARDS
Indicate possible hazards.

SAFEGUARDS
Prevention of possible hazards.

Spray Area High
Voltage Equipment

Electrical Discharge
This equipment contains a
high-voltage device that can
cause an electrostatic induction
on ungrounded objects. This
electrical charge is capable of
igniting coating materials.

Insufficient ground will cause a
spark hazard. A spark can ignite
many coating materials and
cause a fire or explosion.

Operators in the spray area and the parts to be
sprayed must be sufficiently grounded.
All conductive objects inside the spray area must be
grounded.
Hold the parts that get sprayed on conveyors or
hangers that are correctly grounded. The resistance
between the parts and the earth-ground must not be
more than 1 MΩ. Refer to: NFPA-33.
Before the equipment is operated, ground all
operators. They cannot wear rubber-soled insulated
shoes. Wear ground straps on wrists or legs for
sufficient ground contact.
Operators must not wear or carry ungrounded metal
objects.
When used, operators must make complete contact
with the applicator handle and electrostatic gun. Use
conductive gloves or gloves with the palm section cut
out.
Operators must wear grounded footwear.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES FOR GUIDANCE TO
CORRECTLY GROUND THE OPERATOR.
Except for objects needed for the high-voltage
process, all electrically conductive objects in the
spray area are to be grounded. Supply a grounded
conductive floor in the spray area.
Always turn off the applicator voltage before the
system is flushed, cleaned, or when servicing the
spray system equipment.
Unless specifically approved for use in hazardous
locations, put all electrical equipment outside of
Class I or II, Division 1 or 2 hazardous areas in
accordance with NFPA-33, or outside of Zone 2 or
Zone 22 in accordance with EN standards.
Do not install an applicator into a fluid system if the
solvent supply is ungrounded.
Do not touch an energized applicator electrode.

EN 04. SAFETY

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AREAS
Indicate possible

hazard occurrences.

HAZARDS
Indicate possible hazards.

SAFEGUARDS
Prevention of possible hazards.

Spray Areas

Spray Area and
Equipment Use

Toxic Fluid or Fumes
Toxic fluids or fumes can cause
severe injury or death if splashed
in the eyes or on the skin, or if
inhaled or swallowed.

High-pressure fluid sprayed
from the gun, hose fittings, or
ruptured/damaged components
can pierce the skin.
While this injury can appear as
cut skin, this is a severe injury
that can result in the amputation
of the affected area.

Read the Safety Data Sheet (SDS) for instructions
to know and understand how to handle the specific
hazards of the fluids used, and the effects of long-
term exposure.
During the spray, clean, or servicing of equipment,
or when in the work area, keep the work area fully
ventilated.
Always wear personal protective equipment (PPE)
when in the work area or during equipment operation.
Refer to the Personal Protective Equipment warnings
in this manual.
Store hazardous fluid in approved containers and
refer to local, municipal, state, and national codes
governing the disposal of hazardous fluids.

Do not point or operate the spray gun at the body
part of a person.
Do not put your hand or fingers over the gun fluid
nozzle or fittings in the hose or Proportioner.
Do not try to stop or deflect leaks with your hand,
glove, body, or shop rag.
Do not blowback fluid, as the equipment is not an
air spray system.
Relieve pressure in the supply hoses, Proportioner,
and QuickHeat™ hose before the equipment is
inspected, cleaned, or serviced.
Use the lowest possible pressure to recirculate,
purge, or troubleshoot the equipment.
Examine the hoses, couplings, and fittings every day.
Service or immediately replace parts that leak, are
worn, or are damaged. Replace high-pressure hose
sections. They cannot be recoupled or serviced.

EN04. SAFETY

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AREAS
Indicate possible

hazard occurrences.

HAZARDS
Indicate possible hazards.

SAFEGUARDS
Prevention of possible hazards.

Equipment
and Fluids

Pressurized
Aluminum Parts

Skin and Clothing Burns
Equipment surfaces and fluids
can become very hot during
operation.

The use of certain solvents and
chemicals can cause equipment
damage and severe personal
injury.

Do not touch hot fluid or equipment during operation.
Do not let clothing touch the equipment during
operation or immediately after the equipment is
stopped.
Let the equipment fully cool before the examination
or servicing of the component.

Do not use 1,1,1-trichloroethane, methylene
chloride or other halogenated hydrocarbon solvents
or fluids that contain such solvents.
These solvents can cause a severe chemical
reaction and equipment rupture that results in
equipment and property damage, serious bodily
injury, or death.

EN 04. SAFETY

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AREAS
Indicate possible

hazard occurrences.

HAZARDS
Indicate possible hazards.

SAFEGUARDS
Prevention of possible hazards.

Spray Areas Do Not Touch
The effect of paint flow rates
and formulations on the quality
of atomization can cause the
turbines to rotate at high speeds.

Do not use a rag or gloved hand against the bell
edge to stop or slow down a bell during rotation.
Do not try to clean the bell edge during rotation.

EN04. SAFETY

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If the operation of this equipment, sensors, switches, or other ancillary equipment occurs in the presence of flammable
gases and vapors, connect this equipment through intrinsic-safe or Zener barriers. Classify them as a ‘simple apparatus’
or approve them for use in these areas.

04.2 ADDITIONAL SAFETY INFORMATION
The IntelliFlow has an emergency stop (E-Stop) pushbutton on the main operator panel. During an emergency, all
operations for the IntelliFlow will halt when the E-Stop is engaged. The operator must disengage the E-Stop and reset
the system to recover from this state.
Observe all local or municipal safety measures and wear approved protective equipment when servicing this equipment.
Clean all spilled chemicals and materials and do all work in a clean and organized environment to prevent personal
injury and equipment damage.

NOTICE
During the initial commission of the equipment and at periodic times throughout equipment life, visually examine all

fluid fittings for leaks.

Periodically, it is necessary to visually examine all pieces of this equipment for signs of noticeable degradation due to
chemicals or other conditions in the equipment’s environment.

CAUTION
Only operate the equipment after you have read this section.

DANGER
To prevent injury or electrocution while the system is under power, do not contact, disconnect, or manipulate electrical
connections or devices. The main disconnect on the right side of the controller can be locked out. Follow the proper

Lockout–Tagout (LOTO) procedures for internal controller electrical work.

Only qualified electrical personnel can perform the work if diagnosis and troubleshooting are not possible during
working conditions.

WARNING
To prevent possible chemical spillage when personnel are not on site, air and fluid supplies for the equipment must be

disabled when the equipment idles for an extended period, such as an end-of-day shutdown.

SAFETY
Obey local or municipal regulations that require installed fire suppression for equipment operation.

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EN EN 05. PRODUCT OVERVIEW

05.1 GUN FLUSH BOX

Gun flush boxes operate with higher solvent and air
pressures. These pressures improve flush efficiency,
while gun flush boxes improve safety and minimize
solvent usage. They also save time compared to manual
spray gun flush procedures.

Up to two guns can be used on the IntelliFlow system.
The standard setup includes one flush box per gun
for optimal performance. In two-gun installations, the
system controller typically operates Gun #1 and Gun #2
with individual flush boxes for loading and flushing. A
single flush box can be used for both guns if configured
accordingly. This setup is not typical and should only be
used when specifically configured. Gun #2 can also be
disabled by the administrator if necessary.

The Gun Flush Box Kit operates with RM2, RF2 and
RF2+ systems. This manual has separate sections for the
pneumatic connections of the gun flush box to the RM2,
RF2 and RF2+.

All pneumatic connections to the gun flush box are
engineered for 5/32 (4mm) OD tubing.

The RM2 directly connects to the gun flush box, but it
is necessary to install Air Cut-Off Kit 310-3905-XX (sold
seperatly) before it can be connected to the gun flush box
kit. Installation instructions for the Air Cut-Off Kit-to-RF2
and RF2+ can be found in RF2 manual 77-3152-1 and
RF2+ manual 77-3165-1.

Gun Flush Box

GUN FLUSH BOX KIT - PARTS LIST
Part No. Description 240-5205-1 Qty. 240-5205-2 Qty.

240-3179-K Gun Flush Box 1 2

NHA-532BL 5/32 (4 MM) Tubing 100' 200'

NHA-532 5/32 (4 MM) Tubing Clear 100' 200'

05.2 GUN FLUSH BOX PARTS LIST

AIR CUT-OFF KIT - CONFIGURATIONS
Part No. Description

310-3905-L0 Air Cut-Off Kit, 1 Gun, LV

310-3905-LL Air Cut-Off Kit, 2 Guns, LV

310-3905-S0 Air Cut-Off Kit, 1 Gun, STD
310-3905-SL Air Cut-Off Kit, 1 Gun STD, 1 Gun LV
310-3905-SS Air Cut-Off Kit, 2 Guns, STD

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EN EN05. PRODUCT OVERVIEW

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EN EN 06. INSTALLATION

06 INSTALLATION
The Gun Flush Box Kit is designed to be used in a
hazardous area. It must be properly grounded before
operation.

06.1 MOUNTING INSTRUCTIONS
Mount gun flush boxes to a sturdy metal stand, a wall, or
a support connected to an earth ground.

Put a conductive metal flushing/solvent waste container
directly below the flush box.

Mount the box with four (4) each 1/4 (6 mm) diameter
screws at the dimensions shown on the right. Remove
the gun saddle from the box to make it easier to mount
the box.

WARNING
Gun flush box(es) will make paint and solvent vapors

and mists during use. Gun flush boxes must be
mounted in a spray booth or other Class 1 Division 1

[Zone 1] Hazardous Area.

The gun flush box and conductive metal waste flush
container must be bonded to an earth ground, and the

continuity must be measured with an ohmmeter.

Do not operate the gun flush box until it is correctly
grounded to true earth ground.

CAUTION
The gun flush box(es) must be enabled in the system

software configuration.

3.250
(83 mm)

5.375
(137 mm)

2.00
(51 mm)

4.00
(102 mm)

DANGER
After installation and before operation, make sure the gun flush box is grounded to a true earth ground.

The resistance to ground of metallic items on the outside and inside of the gun flush box must be less than 1 Megaohm
(MΩ).

Failure to correctly ground to earth can cause a fire and/or explosion.

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EN EN06. INSTALLATION

06.2 GUN FLUSH BOX AIR CONNECTIONS
AIR — Supplies necessary air to operate the gun flush box. 75-100 psi [5-7 bar] required.

GIB — Air signal sent to the controller (GIB1, GIB2) when the spray gun is in the gun flush box and the lid is closed.

ACO — Triggers the Air Cut Off (ACO) Valve at the Air Flow Switch. Enables/disables the spray gun’s atomizing air.

TRG — Air signal used to trigger the spray gun in the closed box. Receives signal from system controller (TRG1,
TRG2).

Underneath View Right Side View

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EN EN 06. INSTALLATION

06.3 CONNECTING TO THE RM2
1. Use 5/32 (4 mm) pneumatic tubing to connect the gun flush box bulkhead ‘AIR’ to the primary supply air and RM2

control. Adapt the length of the tubing as needed.

2. Use clear 5/32 (4 mm) tubing to connect the enclosure bulkhead for GIB1 (a) to gun #1 flush box bulkhead ‘GIB’,
or GIB2 (b) to gun #2 flush box bulkhead ‘GIB’.

3. Connect clear tubing from the ‘ACO’ bulkhead connector on the gun flush box to the elbow-mounted air cut-off
valve (c).

4. Use more tubing from the gun flush box TRG bulkhead connection to the related TRG1 (d) or TRG2 (e) bulkhead
on the back of the RM2 enclosure.

5. Make sure the tubings has no sharp bends and keep the tubing away from sharp edges or hot surfaces.

b

d

e

c

RM2 Enclosure

a

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EN EN06. INSTALLATION

06.4 ENABLE IN THE RM2 USER
INTERFACE (LOW PRESSURE & MEDIUM
PRESSURE)

1. To enable the gun flush box in the RM2 user
interface, first turn on the RM2.

2. On the RM2 screen, select menu from the top left
drop-down.

3. Select settings and then system configuration.

4. The box labeled Gun Flush Boxes has three
choices, as shown. If you use a single gun flush box,
check the box labeled single. If you use two gun
flush boxes, check the box dual.

Low Pressure Screen

Medium Pressure Screen

NOTICE
Refer to RM2 Operation Manual 77-3153-2 for detailed
instruction on setting up the System Configuration for

your Gun Flush Box(es)

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EN EN 06. INSTALLATION

06.5 RM2 CONNECTIONS DIAGRAM

R
M

2 Enclosure

G
un Flush B

ox

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EN EN06. INSTALLATION

06.6 CONNECTING TO THE RF2 AND RF2+

1. The black 5/32 pneumatic tubing connects the gun
flush box bulkhead labeled ‘AIR’ to the primary air
supply and RF2 and RF2+ IntelliFlow control. Adapt
the length of the tubing as needed.

2. Use clear 5/32 (4 mm) tubing to connect the
enclosure bulkhead for GIB1 (a) to gun #1 flush box
bulkhead ‘GIB’, or GIB2 (b) to gun #2 flush box
bulkhead ‘GIB’.

3. Connect clear tubing from the ‘ACO’ bulkhead
connector on the gun flush box to the elbow-mounted
air cut-off valve (c).

4. Use more tubing from the gun flush box TRG
bulkhead connection to the related TRG1 (d) or
TRG2 (e) bulkhead on the back of the RF2 and
RF2+ enclosure.

5. Make sure the tubings has no sharp bends and keep
the tubing away from sharp edges or hot surfaces.

NOTICE
The air cut-off kit (sold separately) must be installed
before the gun flush box can be operated with the
RF2 and RF2+. The RF2 air cut-off kit installation

instructions can be found in the RF2 operation
manual 77-3152-2. The RF2+ air cut-off kit installation

instructions can be found in the RF2+ operation
manual 77-3165-2.

b a

c

d e

Air Cut Off Box: Right Side View

Air Cut Off Box: Left Side View

RF2 and RF2+ Enclosure

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EN EN 06. INSTALLATION

06.7 ENABLE IN THE RF2 AND RF2+ USER INTERFACE

1. Turn on the RF2.

2. From the home screen of the RF2 user interface,
select MENU, SETTINGS and System
Configuration.

3. Select Next until the interface screen with the
Station Configuration label (a) shows, as seen in
the image.

4. Select the number of enabled connected guns (b).

a

b

NOTICE
Refer to RF2 Operation Manual 77-3152-2 for detailed
instruction on setting up the System Configuration for

your Gun Flush Box(es).

RF2

RF2+
1. Turn on the RF2+.

2. From the home screen of the RF2+ user interface,
select MENU, SETUP and System
Configuration.

3. Use the scroll down button to select Custom (a)
then select Next.

4. Select Manual (b) as the control type and enter the
number of enabled connected guns (c).

NOTICE
Refer to RF2+ Operation Manual 77-3165-2 for detailed
instruction on setting up the System Configuration for

your Gun Flush Box(es).

RF2 Screen

RF2+ Screen

a

b

c

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EN EN06. INSTALLATION

06.8 RF2 AND RF2+ CONNECTIONS DIAGRAM

A
ir C

ut O
ff B

ox
R

ight Side

A
ir C

ut O
ff B

ox Left
Side

R
F2 and R

F2+ Enclo-

G
un Flush B

ox

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EN EN 06. INSTALLATION

06.9 GUN SADDLE ADJUSTMENT

The gun saddle is the plastic part inside the box that
cradles the spray gun’s front end to ensure proper box
operation. Install the gun saddle for the specific model of
spray gun to be used.

1. Insert two 5/16-18 screws through the spacer and
into the gun saddle to secure it to the side wall of the
gun flush box.

2. Put the gun in the saddle as shown. Try to shut the
lid. If the lid does not fully close, use the two screws
to adjust the height of the gun holder until the lid
correctly closes.

3. Make sure the gun trigger actuator pin engages the
finger side of the spray gun trigger when the lid is
closed. If it does not engage, the holder must be
adjusted.

4. The bottom of the gun saddle has 2 (50.8 mm) NPT
female threads for connection to a 2 (50.8 mm)
metal waste drain pipe with mating threads.

3/16 (5 mm)
saddle
movement when
gun is closed in
box

Adjustment
Locations

Adjustment Locations

1-1/2
(38.1 mm)
adjustment

Adjustment Locations

1/2
(12 mm)
adjustment

NOTICE
Gun flush box saddles are sold separately. See the gun

saddle chart on page 27 for applicable saddles.

CAUTION
Use the correct saddle for the spray gun that is

installed on the IntelliFlow system. An incorrect or
unsatisfactorily fitted saddle can cause faulty flush box
operation or paint and solvent blowback into the flush

box during the flush procedure.

Screws
Spacer

Gun Saddle

2 (50.8 mm)
NPT Female
Threads

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EN EN06. INSTALLATION

06.10 SADDLE ADJUSTMENT STEPS
1. To correctly adjust the gun saddle in the gun box, the

applicable saddle must be installed for the gun to be
used.

2. Remove the 5/16-18 cap screws on the right side to
put the gun saddle into the gun box.

3. Turn in the new gun saddle, and leave the screws
loose for adjustment.

4. Put the gun into the holder and bring the gun up to
the actuator pin. The pin must be under the gun
trigger.

5. Tighten the screws on the right side of the gun box.

6. Set the gun handle adjustment until it is clear of the
gun controls on the back of the gun.

7. Close the gun box lid. The box is ready to use if the
lid triggers the air output Gun in Box (GIB) signal. If
the lid does not trigger the air output Gun in Box
(GIB) signal, continue to steps 8-10 below.

8. Adjust the actuator pin location, pull it up, and tighten
its screws.

9. To access the screws to the actuator pin, remove the
four screws on the left side of the gun box and
remove the air connection enclosure part of the box.

10. Loosen the two screws on the actuator slide block
and move them up or down, dependent on the gun’s
size and shape. Tighten the screws.

11. Repeat steps (4 to 10) until the gun box GIB output
operates. The gun box is now ready to use.

Gun Trigger Actuator Pin

Cap Screws

Handle

Air Connection
Enclosure

Gun Handle
Adjustment

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EN EN 07. OPERATION

DANGER
The voltage must be turned off to clean and flush an electrostatic applicator. Failure to adopt and follow this procedure

can cause a fire and/or explosion.

CAUTION
The gun flush box must be enabled in the system software configuration.

The IntelliFlow system will NOT operate the gun flush box until software configuration is correct.

With the flush box mounted, the pneumatic tubing connected, and the saddle correctly adjusted for operation:

1. Open the valve or regulator to supply the AIR inlet of the flush box with 75-100 psi (5-7 bar) air.

2. Start the IntelliFlow system and adjust each gun’s flush time and load volume to optimize the flush and load
procedures.

3. Place the spray gun in the box and close the lid. Atomizing air will exhaust through the ACO valve, and the
actuator pin will extend to the front of the gun trigger.

4. Select the Color Change screen on the IntelliFlow system, then prepare the desired paint color load. The system
will do the applicable flush/load sequence. To change color, refer to RF2+ Operation Manual 77-3165-2 or RM2
Operation Manual 77-3153-2 for more detail.

5. When the paint load is complete, the system will return to the home screen and make a sound. The AE valve will
then close.

6. Open the gun flush box and remove the spray gun. Close the gun flush box lid. The gun is now ready to spray.

7. When the spray operation is complete, open the gun flush box lid. Put the gun back into the box, then close the lid.

8. If necessary, select the color change screen on the IntelliFlow system to flush or load the next color. Pot life will
continue to count down until it expires or a flush is done.

07.1 OPERATION GUIDE

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EN EN07. OPERATION

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EN EN 08. TROUBLESHOOTING

08.1 TROUBLESHOOTING GUIDE

GENERAL
PROBLEM POSSIBLE CAUSE SOLUTION

Flush and
Color Change
Faults

Gun not seated correctly in the box Check to make sure gun is seated correctly in saddle
Lid not closed Confirm gun lid is fully closed
Air pressure to the box not
between 75-100 psi (5-7) bar

Confirm air pressure supply is between 75-100 psi (5-7) bar to
box

Kinks in the air hoses or tubes Check air hoses and tubes for blockages
Gun saddle height not correctly
adjusted Check gun saddle height and adjust if necessary

Air switches not functioning
properly Check air switches and replace if necessary

Spray
Operation
Faults

Lid not closed Confirm gun lid is fully closed
Air pressure to the box not
between 75-100 psi (5-7) bar

Confirm air pressure supply is between 75-100 psi (5-7) bar to
box

Air switches not functioning
properly Check air switches and replace if necessary

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EN EN08. TROUBLESHOOTING

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EN EN 09. PARTS IDENTIFICATION

AVAILABLE GUN SADDLES - PARTS LIST
Part No. Description

240-3198-C Flush Box Saddle For Binks 2100 Gun
240-3198-D Flush Box Saddle For Binks Trophy Touch Up Gun
240-3198-E Flush Box Saddle For Graco Air Pro
240-3198-F Flush Box Saddle For Binks Trophy AA
240-3198-G Flush Box Saddle For DeVilbiss JGA & JGHV Gun
240-3198-H Flush Box Saddle For Ransburg Vector Gun
240-3198-J Flush Box Saddle For All DeVilbiss PROLite Models: Tekna, GTI, and PROLite
240-3198-K Flush Box Saddle For DeVilbiss Advanced HD Gun
240-3198-L Flush Box Saddle For Ransburg Ransflex Gun
240-3198-M Flush Box Saddle For Binks Trophy Gun
240-3198-X Flush Box Saddle For Binks DVX Gun

09.1 GUNS SADDLES FOR SPRAY GUNS
Different saddles are available to fit Binks, DeVilbiss, and Ransburg spray guns. See the table below for available gun
holders and their related part number.

CAUTION
Use the correct saddle for the spray gun that is installed on the IntelliFlow™ system. An incorrect or unsatisfactorily
fitted saddle can cause faulty flush box operation or paint and solvent blowback into the flush box during the flush

procedure.

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EN EN09. PARTS IDENTIFICATION

09.2 GUN FLUSH BOX COMPONENTS
240-3179-K

16

4
3

2

5

6 18

16

1 18

9 10

112019

12

8

232221

21

13

14

15 24

16

17

16

Front View Left Side View

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EN EN 09. PARTS IDENTIFICATION

GUN FLUSH BOX- PARTS LIST
Item No. Part No. Description Qty. Notes

1 E22-1533 PRESSURE INDICATOR 1

2 E22-1218 5/32 TUBE X #10-32 ELBOW 1

3 E22-1521 5/32 TUBE Y ADAPTER 1
4 E22-1517 TRIGGER CYLINDER 1
5 E22-1535 5/32 TUBE BULKHEAD 5
6 E22-1502 COVER 1
7 E22-1501 GUN BOX BODY 1 OUTER PANELS
8 E22-1503 LID ASSEMBLY 1
9 E22-1529 SS CHAIN LINK 4
10 E22-1530 SS CHAIN CONNECTOR 2
11 E22-1532-K2 1/4 X 1 SS DOWEL 1
12 E22-1525 AIR SWITCH 2
13 E22-1522 5/32 TUBE X 1/8 NPT TEE FITTING 1
14 E22-1528-K2 GROMMET 2
15 E22-1519 AIR PILOTED SWITCH VALVE 1
16 E22-1523 5/32 TUBE X 1/8 NPT ELBOW 5
17 E22-1520 AIR PILOT 1
18 E22-1552 #10-32 X 1/2 SHCS SS 4

SOURCE
PARTS

LOCALLY

19 E22-1542 5/16 LOCK WASHER SS 4
20 E22-1544 5/16-18 X 1/2 BHCS SS 2
21 E22-1547 3/8 LOCK WASHER SS 1
22 E22-1548 3/8 WASHER SS 2
23 E22-1550 3/8-16 X 1/2 BHCS SS 2
24 E22-1537 #4-40 X 3/4 SHCS SS 1

09.3 GUN FLUSH BOX PARTS LIST

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EN EN09. PARTS IDENTIFICATION

09.4 GUN FLUSH BOX COMPONENTS
240-3179-K

25

Front View Right Side View

35

27

28

28
26

28

43 22

29

30

31

32
33 45

343644393837

40
12

46 47
41

42

45

44 20

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EN EN 09. PARTS IDENTIFICATION

GUN FLUSH BOX- PARTS LIST (cont.)
Item No. Part No. Description Qty. Notes

25 E22-1531-K2 SPRING PLUNGER 1

26 E22-1535 5/32 TUBE BULKHEAD 5
27 E22-1526-K2 TORSION SPRING 1
28 E22-1515 SPRING SPACER 3
29 E22-1511 TRIGGER CAP 1
30 E22-1510 PUSH CAP 1
31 E22-1506 BLOCK 1
32 E22-1518 PUSH CYLINDER 1
33 E22-1516 SUPPORT SPACER 1
34 E22-1512 HANDLE 1
35 E22-1513 HANDLE ADAPTER 1
36 E22-1505 TOGGLE PLATE 1
37 E22-1504 GUN IN BOX BRACKET 1
38 E22-1508 GUN SEAT 1
39 E22-1527 COMPRESSION SPRING 1
40 E22-1509 HINGE 1
41 E22-1507 ARM 1
42 SEE PAGE 27 GUN SUPPORT 1
43 E22-1549 3/8 LOCK NUT SS 1

SOURCE
PARTS

LOCALLY

44 E22-1545 5/16-18 X 3/4 BHCS SS 2
45 E22-1546 5/16-18 X 3 BHCS SS 2
46 E22-1540 #8-32 NUT SS 4
47 E22-1539 #8-32 X 1 SHCS SS 4
48 E22-1538 #8-32 X 5/8 SHCS SS (not shown) 2
49 E22-1534 5/32 TUBE TEES (not shown) 1
50 E22-1543 5/16 WASHER SS (not shown) 4

51 E22-1551 5/8 X 1-1/2 X 1/16 WASHER SS
(not shown) 2

52 E22-1536 AIR CUT OFF VALVE (not shown) 1

09.5 GUN FLUSH BOX PARTS LIST

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EN EN09. PARTS IDENTIFICATION

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EN EN 10. MANUAL REVISIONS

MANUAL CHANGE SUMMARY
Date Description Version

12/2022 Initial release R1.0
03/2023 Revised flush box mounting locations (manufacturer revision) R2.0
08/2023 Added new EU/ATEX Declaration of Conformity R3.0
082023 Added installation and safety information with earth ground specifications R4.0
9/2024 Updated to new template, updated steps and screenshot on page 19, added gun

saddle part numbers 240-3198-E, 240-3198-F and 240-3198-X. Added RF2+ to
the Table of Contents as well as pages 11, 18, 19 and 20.

R5.0

05/2025 Updated to latest Binks template. R6.0

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EN EN10. MANUAL REVISIONS

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EN 11. WARRANTY

WARRANTY POLICY

This product is covered by Binks’ materials and workmanship limited warranty.

The use of parts or accessories from sources other than Binks will void all warranties. Failure to follow reasonable
maintenance guidance provided can invalidate the warranty.

For specific warranty information, please contact Binks.

For technical assistance or to locate an authorized distributor, contact one of our international sales
and customer support locations listed below.

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REGION BINKS CONTACT

Americas Tel: 1-800-992-4657

Europe, Africa, Middle East Tel: +4401202571111

India marketingroa@binks.com

China Tel: +862133730108

Korea Tel: +82313663303

Japan Tel: +81457856421

Australia Tel: +61085257555

WARRANTY PAGE

EN

Binks is a global leader in innovative finishing technologies.
Binks reserves the right to modify equipment specifications without prior notice.

Binks®, DeVilbiss® and Ransburg® are registered trademarks of Binks US, LLC.

©2025 Binks US, LLC. All rights reserved.

RF2 & RM2 Gun Flush Kit 77-3160 [ English ]

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Email

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