Resource Library
IntelliFlow Air Manifold Manual 77-3162
- IntelliFlow Air Manifold Manual 77-3162 [ English ]
77-3162
IntelliFlow TM Air Manifold
®
www.binks.com77-3162-R1.0 (01/2025)
ENADDITIONAL RESOURCES
For additional information or copies of your service manual, please visit us online at:
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Or use this QR code with your mobile device:
RM2
Obey local or municipal regulations for product recycling and disposal.
www.binks.com 77-3162 R1.0 (01/2025)
EN INTRODUCTION
i / ii
02 CONTENTS
03 SAFETY ��������������������������������������������������������������������������������������������������������������������������������������1-8
03.1 SAFETY PRECAUTIONS AND HAZARDS ������������������������������������������������������������������������������������������������������1
03.2 ADDITIONAL SAFETY INFORMATION ����������������������������������������������������������������������������������������������������������������7
04 PRODUCT OVERVIEW ������������������������������������������������������������������������������������������������������������9-10
04.1 INTRODUCTION �������������������������������������������������������������������������������������������������������������������������������������������������9
04.2 KIT CONTENTS ��������������������������������������������������������������������������������������������������������������������������������������������������9
05 INSTALLATION FOR RM2 �����������������������������������������������������������������������������������������������������11-14
05.1 RM2 AIR MANIFOLD ����������������������������������������������������������������������������������������������������������������������������������������11
.
06 INSTALLATION FOR RE1 ������������������������������������������������������������������������������������������������������15-17
06.1 RE1 AIR MANIFOLD �����������������������������������������������������������������������������������������������������������������������������������������15
07 MAINTENANCE ����������������������������������������������������������������������������������������������������������������������18-20
07.1 AIR MANIFOLD ASSEMBLY ����������������������������������������������������������������������������������������������������������������������������18
08 MANUAL REVISIONS �����������������������������������������������������������������������������������������������������������������������21
09 WARRANTY ����������������������������������������������������������������������������������������������������������������������23
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EN02. TABLE OF CONTENTS
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EN 03. SAFETY
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03 SAFETY
03.1 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.
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, where specific safety-
related instructions or procedures are described.
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
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.
EN03. 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 03. 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.
EN03. 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, round 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 not 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 03. 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.
EN03. 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 03. 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.
EN03. 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.
EN 04 PRODUCT OVERVIEW
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04 PRODUCT OVERVIEW
04.1 AIR MANIFOLD INTRODUCTION
The BINKS 240-3900 air manifold distributes airflow from a single connected factory source to the controller air valve
and fluid stack assemblies. The maximum incoming working pressure is 1,000 psi (68.95 bar/6895 kPa) @ 100 °F (37.77
°C). It is recommended to use an inline air filter and dryer before the air manifold.
04.2 KIT CONTENTS
240-3900 BINKS AIR MANIFOLD ITEMS
Item Description
1 Manifold to Mast Hardware
2 Air Inlet Supply Line
3 Air Manifold, Aluminum Use With End Plug
3 21
EN04 PRODUCT OVERVIEW
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240-3900 BINKS AIR MANIFOLD ITEMS (cont.)
Item Description
4 Elbow Fitting to Color Change Box
5 Fitting Block-Off to Block an Unused Fitting
6 Push-In Fitting
7 Fitting Block-Off to Block an Unused Fitting
8 Push-In Y-Fitting to Air Push
9 Fitting Block-Off to Block an Unused Push-In Fitting
10 Fitting cap to Block an Unused Fitting
11 Fitting to Atomizing Air
5
4
7
6
11
10
9
8
11
10
7
6
EN 05 INSTALLATION FOR RM2
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05 RM2 AIR MANIFOLD
INSTALLATION
05.1 RM2 AIR MANIFOLD
1. Put the air manifold block (c) inside and against the
right side mast.
2. Put a washer (b) onto a screw (a) and into the drilled
hole in the mast and through the air manifold block.
Repeat with the second screw and washer.
3. Fasten the air manifold and screws to the mast with
the lock nuts (d).
4. Tighten the lock nuts to secure the air manifold to the
mast.
5. Remove and discard the air fitting caps (e) from the
fittings.
dc
ba
e
EN05 INSTALLATION FOR RM2
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6. Attach the ErgoFlex hoses (f) to the fittings and
tighten.
7. Attach the other end of the ErgoFlex hoses (g) to the
air inlet elbow fittings and tighten.
8. Remove and discard one of the air fitting plugs (h)
from the Y splitter push-in fitting. The second air
feed is reserved for future or optional peripheral
accessories.
NOTICE
These fittings are for optional equipment. Do not
remove these plugs unless optional equipment will be
attached at this time.
f
g
h
EN 05 INSTALLATION FOR RM2
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9. Insert in 5/32 air tubing (j) (not included) to supply
air to the optional Gun Flush Box (if equipped).
10. Remove and discard both air fitting plugs (k) from the
1/4 push-in fittings.
11. Insert one end of the green 1/4 air tube (m) to a
push-in fitting.
NOTICE
These fittings are for optional equipment. Do not
remove these plugs unless optional equipment will be
attached at this time.
CAUTION
To prevent kinks and breaks, the green air tube routing
must be positioned close to the controller box.
j
k
m
EN05 INSTALLATION FOR RM2
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12. Cut the green air tube with an air line cutter. The cut
end must be perpendicular (square) to the hose.
14. Insert the cut end of the green air tube into the VTUG
port (n) in the air solenoid stack.
15. Remove and discard the 3/8 air fitting plug (r) from
the 3/8 push-in elbow fitting.
16. Insert one end of the black 3/8 air tube (s) into the
push-in elbow fitting.
17. The black 3/8 air tube routing goes through the
right mast opening and attaches to the the air chop
regulator (not shown) if equipped.
NOTICE
The second green air tube (p) is for optional equipment
like the color change box. Do not remove this plug
unless optional equipment will be attached at this time.
NOTICE
The air chop regulator is only available on the Low
Pressure RM2 model.
For the Medium Pressure RM2, this hose and air manifold
fitting is available for future or optional equipment. Leave
the fitting plug in the push-in fitting if not used.
n
p
r
s
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EN EN 06 INSTALLATION FOR RE1
06 RE1 AIR MANIFOLD
INSTALLATION
06.1 RE1 AIR MANIFOLD
1. Put the air manifold block (c) inside and against the
right side mast.
2. Put a washer (b) onto a screw (a) and into the drilled
hole in the mast and through the air manifold block.
Repeat with the second screw and washer.
3. Fasten the air manifold and screws to the mast with
the lock nuts (d).
4. Tighten the lock nuts to secure the air manifold to the
mast.
5. Remove and discard the air fitting plug (e) from the
manifold. Keep plugs (f) in place, as fittings are not
used in RE1 configuration.
NOTICE
These fittings are for optional equipment. Do not
remove these plugs unless optional equipment will be
attached at this time.
a b c
d
f
e
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EN EN06 INSTALLATION FOR RE1
6. Remove and discard air fitting plug (g) from the 1/4
push-in fitting.
7. Insert one end of the green 1/4 air tube (h) to a push-
in fitting.
8. Cut green air tube with an air line cutter. The cut end
must be perpendicular (square) to the air tube.
9. Insert the cut end of the green air tube into the VTUG
port (j) in the air solenoid stack.
CAUTION
To prevent kinks and breaks, the green air tube routing
must be positioned close to the controller box.
g
h
j
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EN EN 06 INSTALLATION FOR RE1
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EN EN07 MAINTENANCE
AIR MANIFOLD ASSEMBLY 240-3900
2 3 4*1
8
7
13
12
9
10
12 13 7
8
5
6
17
16
15
22
TS
TS
TS
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EN EN 07 MAINTENANCE
AIR MANIFOLD 240-3900
Item No. Part No. Description Qty. Notes
1 - Air Manifold 1
2 - Flat Washer, M5, 18-8 2
3 - Socket Head Cap Screw, M5 x 0.8, 45 mm, 18-8 2
4 6T-4 3/8 NPT (M) x 1/4 NPS (M) 1 *Discard red cap
5 JML-38-4T Fitting, Elbow, 1/4 NPT (M) x 3/8 ODT 1
6 - Block-Off Fitting, Air Tube, 10 mm (not shown) 1 Remove to insert air
tube
7 20-7093 Push-In Fitting, 1/4 NPT X 1/4 OD 2
8 - Block-Off Fitting, Air Tube, (not shown) 2 Remove to insert air
tube as needed
9 20-7094 Push-In Y-Fitting, 1/4 NPT X 5/32 OD 1
10 - Block-Off Fitting, Air Tube, (not shown) 2 Remove to insert air
tube as needed
11 - Serrated Flange Locknut, M5 x 0.8, 18-8 2
12 4-CAP Cap, Fitting, 1/4 NPT (F) 2 Remove to insert air
tube as needed
13 4T-4 Fitting, 1/4 NPT (M) x 1/4 NPS (M) 2
14 - 3/8 Tubing, Black 2 ft Not shown to scale
15 72-2008 Connection, 1/4 Swivel x 3/8 ErgoFlex Hose 4 Parts create two (2)
hose assemblies (one
assembled hose shown)16 71-31000 ErgoFlex HVLP Bulk Hose, 3/8 ID x 41/64 OD 2
17 NHA-0403G 1/4 OD x .180 ID Nylon, .035 Wall, Green 6 ft Not shown to scale
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EN EN07 MAINTENANCE
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EN EN 08 MANUAL REVISIONS
MANUAL CHANGE SUMMARY
Date Description Version
01/07/2025 Initial release R1
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EN EN08 MANUAL REVISIONS
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EN 09 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 INDUSTRIAL/
AUTOMOTIVE
AUTOMOTIVE
REFINISHING
Americas Tel: 1-800-992-4657 Tel: 1-800-445-3988
Europe, Africa, Middle East Tel: +4401202571111
India marketingroa@binks.com
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