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IntelliFlow RF2+ Service Guide 77-3165-3
- IntelliFlow RF2+ Service Guide 77-3165-3 [ English ]
77-3165-3
IntelliFlow™ RF2+™
®
www.binks.com77-3165-3 R1.0 (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:
RF2+
Obey local or municipal regulations for product recycling and disposal.
www.binks.com 77-3165-3 R1.0 (05/2025)
EN INTRODUCTION
i / iv
ABOUT THIS MANUAL
ITS PURPOSE
The purpose of this manual is to help you get the most
value from your Binks IntelliflowTM system. It can help you
to determine how to install, operate, maintain, and repair
your equipment. It provides information and procedures
for routine maintenance and servicing and offers
diagnostic and repair procedures to follow when trouble
occurs.
ITS CONTENTS
This manual is divided into Chapters, each of which is
divided into consecutively numbered Sections.
Chapters will contain text, images, tables, or a
combination of them.
Pages with images will have paragraphs and sentences
with callout numbers that refer to their respective images,
steps, and parts.
Procedures, once described in the text, are not normally
repeated. When it is necessary to refer to another
Chapter or Section, the reference will be given as
Chapter and Section number. Cross references given
without the use of the word Chapter apply to Sections or
paragraphs in the current Chapter.
Chapter 02. Table of Contents.
Chapter 03. Safety–Safety, hazard, and warning rules.
Chapter 04. Servicing–Material purge, inspection, and
frequency schedule.
Chapter 05. Maintenance–Maintenance and general
servicing information.
Chapter 06. Troubleshooting–Tracing and correcting
mechanical, electronic, programming, and fluid delivery
faults.
Chapter 07. Manual Change Summary–The revisions and
changes made to this manual.
Chapter 08. Warranty–Your equipment’s warranty.
WHO SHOULD USE THIS GUIDE
This guide is intended for users with different levels of
knowledge and experience with this system:
Installers: The person(s) who will locate and install this
equipment.
Users: The person(s) who will learn how to operate this
equipment.
Servicers: The person(s) who will service and maintain
this equipment.
This guide assumes all persons who will install, use,
operate, and service this equipment have some
knowledge of the product and its operating system.
For information on the installation of this equipment, refer
to RF2+ Installation Manual 77-3165-1.
For information on the operation of this equipment, refer
to RF2+ Operation Manual 77-3165-2.
For information on accessory kits and spare parts of this
equipment, refer to RF2+ Kit Instructions & Spare Parts
Manual 77-3165-4.
For programming information of this equipment, refer to
RF2+ Programming Manual 77-3165-5.
MANUAL DISCLAIMER
All current and applicable certifications shown in this
manual confirm Binks adherence to the strict standards
met to obtain the required regulatory compliances.
This manual was prepared with the most accurate
information current at the time of publishing. Binks does
not accept responsibility for errors in, or omissions from,
the information contained herein.
Please get in touch with your distributor or Binks
Customer Service for additional service information and
assistance.
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EN02. TABLE OF CONTENTS
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RF2+ RELATED MANUALS & PUBLICATIONS
Part Number Description
77-3150 Coriolis Flow Meter Service Guide
77-3154 Flow Meter Kit
77-3155 Remote Fluid Panel Kit-Barrier and F.O. Transceiver Box
77-3156 Flow Meter Sensor Battery Replacement Kit
77-3157 Flow Sensor Kit
77-3158 Color Change Kit
77-3159 Touchscreen Protector Kit
77-3160 Flush Box Kit
77-3164 Flow Meter Replacement Head Kit
77-3165-1 RF2+ Installation Manual
77-3165-2 RF2+ Operation Manual
77-3165-4 RF2+ Kit Instructions and Spare Parts
77-3165-5 RF2+ Programming Manual
LN-9112-00 Weeping MVR Service Guide
LN-9225-00 Weepless MVR Service Guide
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EN 02. TABLE OF CONTENTS
iii / iv
02 CONTENTS
03 SAFETY 1
03.1 SAFETY PRECAUTIONS..................................................................................................................................1
03.2 ADDITIONAL SAFETY INFORMATION............................................................................................................8
04 REGULAR SERVICING PROCEDURES AND RECOMMENDATIONS 10
04.1 MATERIAL PURGE .........................................................................................................................................10
04.2 REGULAR INSPECTION ................................................................................................................................10
05 RF2+™ MAINTENANCE 12
05.1 COMMON RF2+ PROBLEMS..........................................................................................................................12
05.2 PREVENTATIVE MAINTENANCE..................................................................................................................12
05.3 GENERAL.........................................................................................................................................................12
05.4 PRELIMINARY PROCEDURES .....................................................................................................................12
06 TROUBLESHOOTING 14
06.1 ALARM LIST .....................................................................................................................................................14
06.2 DISPENSE PUMP............................................................................................................................................19
06.3 FESTO VTEM PRESSURE REGULATOR MANIFOLD.................................................................................20
06.4 SOLENOID CONNECTION REFERENCE–COLOR STACK (310-3920 SHOWN) .....................................23
06.5 SOLENOID CONNECTION REFERENCE–DISPENSE PUMP (310-3920 SHOWN) .................................25
06.6 STANDARD FLOW METER TROUBLESHOOTING......................................................................................27
06.7 MAINTENANCE PROCEDURES ...................................................................................................................27
06.7.1 CLEANING OF HOSES........................................................................................................................27
06.7.2 CCV AND PULSE VALVE MAINTENANCE.........................................................................................27
06.7.3 CLEANING THE ENCLOSURE EXTERIOR AND HMI.......................................................................27
06.8 PREVENTIVE MAINTENANCE ......................................................................................................................28
07 MANUAL REVISIONS 30
08 WARRANTY 32
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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.
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.
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, 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 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.
03.2 ADDITIONAL SAFETY INFORMATION
The IntelliFlow™ RF2+™ 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 03. SAFETY
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EN EN04. SERVICING
04 REGULAR SERVICING PROCEDURES AND RECOMMENDATIONS
04.1 MATERIAL PURGE
After a job is completed, remember to purge the system thoroughly. Failure to do so can cause clogs, leaks, or cross-
contamination of colors and material when the system is disassembled.
04.2 REGULAR INSPECTION
Regular inspections help prevent RF2+™ system malfunctions. Refer to the table below for the recommended
frequency, description, and method for each inspection task.
FREQUENCY DESCRIPTION INSPECTION METHOD
Daily System flushed with solvent Visual
Daily Check for leaks Visual
Daily Clean spray guns Visual
Daily Check alarm history Visual
Daily Check for material supply Visual
Monthly Check static mixer for clogs Visual
Monthly Check all hoses for kinks and wear Visual
Monthly Perform flow meter calibration check Test with beaker
Monthly Check CCV operation Trigger manually or from HMI
Monthly Clean mix manifold and check valves Disassemble
Monthly Check fluid hoses for material buildup Disassemble
As needed Clean flow meter Disassemble
As needed Rebuild color change valves Disassemble
As needed Rebuild MVR valve Disassemble
As needed Replace static mixer assembly Disassemble
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EN EN 04. SERVICING
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EN05. MAINTENANCE
05 RF2+™ MAINTENANCE
05.1 COMMON RF2+ PROBLEMS
1. Improperly filtered fluids cause the most common
operation problems with the RF2+.
Particulates and residue in the system can plug the
fluid ports and cause sluggish valve operation. Use a
100-mesh (149 Micron) filter for proper filtration. If the
system is repeatedly disassembled and cleaned for
the removal of solids and residue, examine the entire
fluid supply system.
2. Fluid backup, known as reverse flow, can cause
reacted or catalyzed material to enter the fluid panel
components. The machine will detect reverse flow
and shut down. Clean or immediately flush the
system to prevent fluid set-up. If the equipment needs
to be cleaned repeatedly, examine the check valves
and correctly adjust the Reverse Flow Volume in
Global Setup.
3. Kinks or tight bends in the control air line will restrict
airflow to the system. Periodically examine the
condition of exposed tubing and check the fitting
connection at the fluid panel components.
05.2 PREVENTATIVE MAINTENANCE
1. Examine the fluid fittings for leakage. Repair the
fittings if leakage is evident.
2. Examine the exposed fluid and air tubing for kinks,
tight bends, leaks, and other defects.
05.3 GENERAL
1. Work on a clean, dry bench.
2. Always install new O-rings, gaskets, and diaphragms
as recommended when fluid components are
disassembled for service.
3. Use only lint-free wipes or cloths to clean the
equipment.
4. To order replacement parts, refer to the model
number of the components or the respective
assembly service manual.
05.4 PRELIMINARY PROCEDURES
Before the removal of components for servicing or
repair, do the following:
1. Flush the components with the system purge mode.
2. Remove all pressure from the affected fluid lines.
3. If equipped, close all shut-off valves.
4. Clean the exterior of the components before removal.
5. Disconnect the control air lines from the components
and cap the exposed hose ends to prevent system
contamination.
6. Remove the components from the fluid lines.
7. If the fluid lines remain open during servicing, cap
them to prevent system contamination.
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EN 05. MAINTENANCE
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EN EN06. TROUBLESHOOTING
ALARM
DESCRIPTION DETAILS AND TROUBLESHOOTING TIPS
E-Stop Pushbutton
Pressed
The E-Stop on the front of the RF2+ control enclosure has been pressed.
Pull the emergency stop pushbutton to reset the alarm
Festo VTEM Pressure
Regulator Module (x)
Fault
The indicated module (x) on the Festo pressure regulator manifold is at fault.
This alarm usually occurs at the same time as all other pressure regulator modules and is
caused by a lack of input air pressure being fed to the manifol
• Make sure the main air pressure is turned on.
• Press the Reset button on the main HMI.
• If the fault persists, troubleshoot the pressure regulator manifold further.
PLC Has Suffered a
Critical Fault
The PLC has suffered a critical fault and must be rebooted.
Contact Binks support for further assistance.
Comm Loss with Aux.
Communications
Gateway
The AnyBus gateway is installed, and communications between it and the RF2+ controller
have been interrupted.
• Power cycle the RF2+.
• Examine the cable between the RF2+ and the AnyBus gateway.
Station (x)-Recipe
Update Failed
The indicated station (x) failed to load a recipe (timeout occurred).
• Try loading the recipe again.
• Power cycle the RF2+.
• Contact Technical Support.
Station (x)-Fluid
Sequence Failed
The indicated station (x) has experienced a failed (incomplete) fluid sequence.
Material may not be properly loaded or purged from the system.
This occurs when an interlock is lost during a sequence.
• Examine all the wired interlocks to ensure they will not turn on at inappropriate times.
• Examine other alarms that can occur in conjunction with this for more detailed cause
analysis.
• Try to run the fluid sequence again.
06 TROUBLESHOOTING
Although the RF2+™ is a complex machine, troubleshooting the unit is straightforward, with a few basic steps.
06.1 ALARM LIST
The alarm dialog is the first indication that something may be wrong with the RF2+ control processes. Below is a list of
alarms and troubleshooting steps.
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EN EN 06. TROUBLESHOOTING
ALARM
DESCRIPTION DETAILS AND TROUBLESHOOTING TIPS
Station (x)-Solvent
Flow Low
The indicated station (x) has run a sequence and detected not enough solvent flow
compared to the solvent.
• Examine the settings.
• Make sure the solvent supply is adequate and not restricted.
• Examine the Solvent Flow Meter.
• Examine the timing of the fluid sequence to make sure that solvent flow occurs for
enough time to flush the system.
Pot Life Expired
The material pot life for the indicated gun/mixer has elapsed.
• If it is safe to do so, trigger the gun/mixer in order to let fresh material into the system.
• Or flush the system.
Ratio Out Of Tolerance
The RF2+ has calculated that the ratio of mixtures A:B or %C has deviated by more than
the permitted tolerance.
• Determine if the fluid delivery is ok, if the fluid pressures are correctly set, etc.
• Examine for restrictions in any of the fluid channels.
• Examine the material's viscosity for abnormalities.
• Examine the recipe settings for ratio tolerance.
Flow Rate Out Of
Tolerance
The RF2+ has calculated that the overall flow rate is out of tolerance.
• Determine if the fluid delivery is ok, if the fluid pressures are correctly set, etc.
• Examine for restrictions in any of the fluid channels.
• Examine the material viscosity for abnormalities.
• Examine the recipe settings for flow tolerance.
Ratio Shutdown
A Ratio Out Of Tolerance fault has been generated, shutting down the station.
• Determine if the fluid delivery is ok, fluid pressures are correctly set, etc.
• Examine for restrictions in any of the fluid channels.
• Examine the material viscosity for abnormalities.
• Examine the recipe settings for ratio tolerance.
• See the alarm-masking instructions to disable the shutdown of the system for this
fault.
Flow Rate Shutdown
A Flow Rate Out Of Tolerance fault has occurred and shut down the station.
• Determine if the fluid delivery is ok, fluid pressures are correctly set, etc.
• Examine for restrictions in any of the fluid channels.
• Examine the material viscosity for abnormalities.
• Examine the recipe settings for flow tolerance.
• See the alarm-masking instructions to disable the shutdown of the system for this
fault.
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EN EN06. TROUBLESHOOTING
ALARM
DESCRIPTION DETAILS AND TROUBLESHOOTING TIPS
Channel (x)-Outlet
Underpressure
The indicated channel (x) has detected low pressure on its outlet pressure sensor
(applicable only for gear-pump controlled channels).
• Determine if the fluid delivery is ok, fluid pressures are correctly set, etc.
• Examine for restrictions in the tubing feeding this channel.
• Examine the material viscosity for abnormalities.
• Examine the settings for low pressure.
• Examine the pressure sensor scaling/operation.
Channel (x)-Outlet
Overpressure
The indicated channel (x) has detected high pressure on its outlet pressure sensor
(applicable only for gear-pump controlled channels). This event will cause a spray
shutdown.
• Determine if the fluid delivery is ok, fluid pressures are correctly set, etc.
• Examine for restrictions in the tubing downstream from this channel.
• Examine the material viscosity for abnormalities.
• Examine the settings for high pressure.
• Examine the settings for trigger timing.
• Examine the pressure sensor scaling/operation.
Channel (x)-Inlet
Underpressure
The indicated channel (x) has detected low pressure on its inlet pressure sensor
(applies only to the gear-pump controlled channels).
• Determine if the fluid delivery is ok, fluid pressures are correctly set, etc.
• Examine for restrictions in the tubing feeding this channel.
• Examine the material viscosity for abnormalities.
• Examine the settings for low pressure.
• Examine the pressure sensor scaling/operation.
Channel (x)-Inlet
Overpressure
The indicated channel (x) has detected high pressure on its inlet pressure sensor
(applicable only for gear-pump controlled channels).
• Determine if the fluid delivery is ok, fluid pressures are correctly set, etc.
• Examine for restrictions in the tubing feeding this channel.
• Examine the material viscosity for abnormalities.
• Examine the settings for high pressure.
• Examine the pressure sensor scaling/operation.
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EN EN 06. TROUBLESHOOTING
ALARM
DESCRIPTION DETAILS AND TROUBLESHOOTING TIPS
Channel (x)-Low Flow
The RF2+ has determined that the flow rate for this channel is low.
• Determine if the fluid delivery is ok, fluid pressures are correctly set, etc.
• Examine for restrictions in any of the fluid channels.
• Examine the material viscosity for abnormalities.
• Examine the recipe settings for flow tolerance.
• Examine the Flow Sensor Calibration/Operation.
Channel (x)-High Flow
The RF2+ has determined that the flow rate for this channel is high.
• Determine if the fluid delivery is ok, fluid pressures are correctly set, etc.
• Examine for restrictions in any of the fluid channels.
• Examine the material viscosity for abnormalities.
• Examine the recipe settings for flow tolerance.
• Examine the Flow Sensor Calibration/Operation.
Channel (x)-Flow
Feedback Loss
Zero flow is detected by the RF2+ for the indicated channel (x).
• Determine if the fluid delivery is ok, fluid pressures are correctly set, etc.
• Examine for restrictions in any of the fluid channels.
• Examine the material viscosity for abnormalities.
• Examine the recipe settings for flow tolerance.
• Examine the Flow Sensor Calibration/Operation.
Channel (x)-Spray
Shutdown
The indicated channel (x) has caused a spray shutdown, due to a flow or feedback fault
that has been configured to shut down the system.
• Address the other channel faults that occurred in conjunction with this fault.
• See the alarm-masking instructions to disable the shutdown of the system for this fault.
Channel (x)-Reverse
Flow Detected
The RF2+ has detected flow in the reverse direction that exceeds the reverse-flow volume
setting. This will cause a spray shutdown.
• Inspect the-valves on mix manifold and color stacks.
• Examine the wiring to flow meter.
• Examine the trigger timing settings.
• Examine the settings for reverse flow volume. It is normal to detect a small reverse
reading when triggering off, as the fluid may create a wave in the reverse direction
momentarily. This condition does not indicate fluid has passed beyond the check valve.
Channel (x)-Inlet
Pressure Loss of
Feedback
If an inlet pressure sensor is configured (gear-pump systems only), the RF2+ has detected
no feedback from the inlet pressure sensor.
Examine the pressure sensor scaling/operation.
Channel (x)-Outlet
Pressure Loss of
Feedback
If an outlet pressure sensor is configured (gear-pump systems only), the RF2+ has
detected no feedback from the outlet pressure sensor.
Examine the pressure sensor scaling/operation.
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EN EN06. TROUBLESHOOTING
ALARM
DESCRIPTION DETAILS AND TROUBLESHOOTING TIPS
Channel (x)-Flow Out Of
Range
The flow actuator (MVR or DR1) is operating at its maximum pilot pressure signal, but
the flow rate is low.
• Examine that the desired flow rate is attainable given the system flow restrictions
(gun tip settings, tubing size, and lengths, etc.).
• Examine the material viscosity for abnormalities.
Channel (x)-
Unconfigured Inlet
Pressure Pilot
The indicated channel has been configured with inlet pressure control, but no pressure
regulator has been assigned for this purpose.
Examine the System Configuration Settings.
Channel (x)-
Unconfigured Flow
Pressure Pilot
No flow rate pilot signal is assigned to a regulator.
Examine the System Configuration Settings.
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EN EN 06. TROUBLESHOOTING
06.2 DISPENSE PUMP
Use this checklist to help identify potential problems with the dispense pump to avoid unnecessary disassembly. If the
problem is still not corrected, it may be necessary to remove the dispense pump and clean it thoroughly after flushing it
with a solvent. Look for clogged passageways and evidence of fluid leaks.
DESCRIPTION PASS/FAIL
Verify that the system is not in an Alarm state. An Alarm can cause the pump to not run.
Verify there are no leaks anywhere on the pump fluid end.
Examine the Oil Reservoir. Look for overflowing or hints of hardener/catalyst material in the
reservoir.
Check for air in all fluid lines. There must be no air bubbles anywhere.
Visually inspect the threaded actuator rod; look for wear or damage. Check the rod for
adequate lubrication.
Verify that the ball plunger correctly contacts the linear potentiometer. The center value
changes on the Dispense Pump Limits screen during the jog-up or jog-down movement.
Go to the PRIME screen. Trigger the gun and dispense pump. Confirm the valve operation and
look for a constant stream of material exiting the gun.
Examine the stepper motor. Verify for smooth operation when the pump runs.
Verify that Signal 1A and Signal 1B (the top two LEDs on the rightmost card of the I/O block)
light up and flash when the material travels through the unit.
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EN EN06. TROUBLESHOOTING
06.3 FESTO VTEM PRESSURE
REGULATOR MANIFOLD
If an issue with the Festo VTEM Pressure regulator
manifold (310-6910 or 310-6911) occurs, the unit can
access more detailed troubleshooting.
First, locate the RJ45 port (1) used to configure the
VTEM module, and then connect a PC to this port.
Set the IP address of the connected PC to 192.168.4.1.
Open a web browser and enter 192.168.4.2 (a).
To troubleshoot a module, click the configuration tab (b).
1
a
b
192.168.4.2/cgi-bin/vtem-welcome
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EN EN 06. TROUBLESHOOTING
Click on any module to select it (c).
Select the monitor tab (d) to show a list of malfunctions
(e).
The example below shows that the supply pressure is too
low (f).
If the fluid panels for the RF2+ are installed too far from
the unit, tune the pressure regulators. To do this, press
the login key (g) and enter the password (h) to log into
the VTEM unit.
The factory default password is vtem. DO NOT change
this password.
d
c
e
f
h
g
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EN EN06. TROUBLESHOOTING
Once logged in, select the overview tab (i) and the module
(j) to edit. To make any changes, you must Take Write
Permissions from the PLC (k).
Changes are not permitted when the PLC is in
communication with the VTEM manifold, so the M12
Ethernet cable at the front of the manifold must be
unplugged to select the box below.
To change the tune, determine the labeled module port (4
or 2) to be connected to the tube type.
Select the small, medium, or large volume setting from
the drop-down menu to change the Characteristic (m)
parameter. The regulator can also be custom-tuned.
When edits are made, select Accept values for
configuration (n), then press Save Configurations (o).
If the configuration is not saved, the unit will revert to its
earlier settings upon start-up.
m
j
k
n o
i
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EN EN 06. TROUBLESHOOTING
06.4 SOLENOID CONNECTION
REFERENCE–COLOR STACK (310-3920
SHOWN)
A
1
7
15
17
19
27
14
16
18
8
6
2
0
26
4
12
10
20
22
24
28
30
9
11
13
21
23
25
31
29
3
5
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EN EN06. TROUBLESHOOTING
Use the reference below to reconnect the solenoid air lines to their bulkheads and CCVs. Units that are not fully
optioned may not have all solenoids.
# SOLENOID LOCATION DESCRIPTION BASIC OPTIONED
A INLET AIR MANIFOLD SOLENOID MAIN AIR INLET x
0 K1SS COLOR STACK 1 COMPONENT 1 SOLVENT FLUSH
VALVE x
1 K1SA COLOR STACK 1 COMPONENT 1 STACK AIR x
2 K2SS COLOR STACK 2 COMPONENT 2 SOLVENT FLUSH
VALVE x
3 SPARE EMPTY —
4 SPARE EMPTY —
5 SPARE EMPTY —
6 K1CAL CCV VALVE COMPONENT 1 CALIBRATION x
7 K2CAL CCV VALVE COMPONENT 2 CALIBRATION x
8 MBS FLUID MIX PANEL MIX BLOCK SOLVENT x
9 SPARE EMPTY —
10 TRG G1 SPRAY GUN 1 GUN 1 TRIGGER x
11 TRG G2 SPRAY GUN 2 GUN 2 TRIGGER x
12 DUMP 1 — —
13 DUMP 2 — —
14 K1C1 COLOR STACK 1 COMPONENT 1 CCV VALVE 1 x
15 K1C2 COLOR STACK 1 COMPONENT 1 CCV VALVE 2 x
16 K1C3 COLOR STACK 1 COMPONENT 1 CCV VALVE 3 x
17 K1C4 COLOR STACK 1 COMPONENT 1 CCV VALVE 4 x
18 K1C5 COLOR STACK 1 COMPONENT 1 CCV VALVE 5 x
19 K1C6 COLOR STACK 1 COMPONENT 1 CCV VALVE 6 x
20 K1C7 COLOR STACK 1 COMPONENT 1 CCV VALVE 7 x
21 K1C8 COLOR STACK 1 COMPONENT 1 CCV VALVE 8 x
22 K1C9 COLOR STACK 1 COMPONENT 1 CCV VALVE 9 x
23 K1C10 COLOR STACK 1 COMPONENT 1 CCV VALVE 10 x
24 K1C11 COLOR STACK 1 COMPONENT 1 CCV VALVE 11 x
25 K1C12 COLOR STACK 1 COMPONENT 1 CCV VALVE 12 x
26 K2C1 COLOR STACK 2 COMPONENT 2 CCV VALVE 1 x
27 K2C2 COLOR STACK 2 COMPONENT 2 CCV VALVE 2 x
28 K2C3 COLOR STACK 2 COMPONENT 2 CCV VALVE 3 x
29 K2C4 COLOR STACK 2 COMPONENT 2 CCV VALVE 4 x
30 K1PV FLUID MODULE COMPONENT 1 PULSE VALVE x
31 K2PV FLUID MODULE COMPONENT 2 PULSE VALVE x
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EN EN 06. TROUBLESHOOTING
06.5 SOLENOID CONNECTION
REFERENCE–DISPENSE PUMP (310-3920
SHOWN)
A
1
7
15
17
19
27
14
16
18
8
6
2
0
26
4
12
10
20
22
24
28
30
9
11
13
21
23
25
31
29
3
5
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EN EN06. TROUBLESHOOTING
Use the reference below to reconnect the solenoid air lines to their bulkheads and CCVs. Units that are not fully
optioned may not have all solenoids.
# SOLENOID LOCATION DESCRIPTION BASIC OPTIONED
A INLET AIR MANIFOLD SOLENOID MAIN AIR INLET x
0 K1SS COLOR STACK
1
COMPONENT 1 SOLVENT FLUSH
VALVE x
1 K1SA COLOR STACK
1 COMPONENT 1 STACK AIR x
2 K2SS — —
3 SPARE EMPTY —
4 SPARE EMPTY —
5 SPARE EMPTY —
6 K1CAL CCV VALVE COMPONENT 1 CALIBRATION x
7 K2CAL — —
8 MBS FLUID MIX
PANEL MIX BLOCK SOLVENT x
9 SPARE — —
10 TRG G1 SPRAY GUN 1 GUN 1 TRIGGER x
11 TRG G2 SPRAY GUN 2 GUN 2 TRIGGER x
12 DUMP 1 — —
13 DUMP 2 — —
14 K1C1 — —
15 K1C2 — —
16 K1C3 — —
17 K1C4 — —
18 K1C5 — —
19 K1C6 — —
20 K1C7 — —
21 K1C8 — —
22 K1C9 DISPENSE
PUMP TOP INLET x
23 K1C10 DISPENSE
PUMP TOP OUTLET x
24 K1C11 DISPENSE
PUMP BOTTOM INLET x
25 K1C12 DISPENSE
PUMP BOTTOM OUTLET x
26 K2C1 — —
27 K2C2 — —
28 K2C3 — —
29 K2C4 — —
30 K1PV — —
31 K2PV — —
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EN EN 06. TROUBLESHOOTING
06.6 STANDARD FLOW METER
TROUBLESHOOTING
Particulates in the fluid can cause the gears to bind to
result in improper signals for the actual flow rate. To
maintain the fluid filters, refer to the filter manufacturer's
instructions.
If repeated disassembly and cleaning for removal of
solids and particulates occurs, inspect the entire fluid
supply system and evaluate the system cleaning cycle.
Fluid backup, that is, reverse flow, can cause reacted or
catalyzed material to enter the flow meter. The flow meter
(310-9010) should be cleaned immediately before the
fluid gels or hardens.
Under normal operation, the sensors or electrical
connections will not require replacement.
To service the flow meter, refer to Flow Meter Service
Manual 77-3154.
A
NOTICE
The fiber optic pickup sensor PN 310-9012 (A) contains
a battery with a 15-month lifespan that starts at the
assembly date of your IntelliFlow system. For correct
signal readings, this battery is to be replaced every 15
months or sooner.
06.7 MAINTENANCE PROCEDURES
If the enclosure door is kept shut, no enclosure components
should require cleaning. If material seepage occurs, be sure
to correct the problem and maintain a clean work area.
Leftover paint can become hard in the fluid lines. To prevent
this occurrence, clean the system with a procedural flush at
the end of operations.
06.7.1 CLEANING OF HOSES
If flush sequences are correct, the mixed material line(s)
will remain clean and ready for the next use. Always finish
spraying operations with a solvent flush 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.
06.7.2 CCV AND PULSE VALVE
MAINTENANCE
If a color change valve or pulse valve has not been used
for a prolonged period, it is recommended that the valve
be removed and the fluid passages cleaned. Paint material
may collect inside the valve or manifold passages. If the
valve does not operate properly or if fluid leaks occur,
the valve must be repaired. Check the valve for proper
operation regularly.
06.7.3 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 protectors 310-8030.
WARNING
Never expose electrical equipment to flammable liquids
or gases including solvent fumes.
WARNING
Read and understand all operation manuals for
connected equipment. Failure to properly follow the
operating instructions could result in severe injury.
A
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EN EN06. TROUBLESHOOTING
06.8 PREVENTIVE MAINTENANCE
The RF2+ system requires periodic inspection and
regular maintenance. Follow the corresponding table as
a guide to perform routine maintenance at suggested
intervals. These intervals are recommendations and
largely depend on the material being sprayed.
Daily/Each Shift:
• Make sure mixed material is properly flushed at the
end of the shift. Verify there are no air pockets in
the fluid lines.
• Identify and correct air and fluid leaks on the system
to include the fluid hoses and dispense pump.
• Make sure the spray guns function correctly and that
air does not leak from the air valve.
• Examine the Alarm History and review errors with the
operator. Verify issues have been corrected.
• Make sure material supplies are filled and pressures
are correct.
Monthly:
• Examine the static mixer assembly at the dispense
pump outlet. If the static mixer elements are
clogged, replace them as needed. Balancing
alarms or an increase in outlet pressure indicate
blockage.
• If equipped: Make sure that the oil reservoir
tubes of the dispense pump have no hardener or
contamination.
• Make sure to keep sufficient lubricant levels at all
times.
• Examine all air and fluid lines for kinks, cuts, or wear.
• Perform a calibration to make sure the dispense
pump correctly operates.
• Make sure the CCVs open and close properly.
Remove and clean the valves if needed.
• Make sure all pulse valves open and close properly.
Remove and clean the pulse valves if needed.
• Clean, examine, and reassemble the valves.
• Examine fluid hoses for material buildup. Material
buildup is common around hose fittings and can be a
source of contamination for finished products.
As Needed:
• Rebuild the dispense pump. A pump rebuild is
required if there is material leakage from the
oil reservoirs, or if the calibration is incorrect or
inaccurate.
• Rebuild Color Change Valves – monitor the valves
for air leaks or slow response time when triggering.
• Rebuild Pulse Valves – monitor the valves for air
leakage or slow response time when triggering.
• Examine the dispense pump for excessive wear
or buildup of material. Verify that there is smooth
dispense pump movement.
• Set the limits of the dispense pump and calibrate it.
NOTICE
Reactive fluid properties greatly vary. If material
blockage occurs to any component, adjust the
maintenance schedule accordingly.
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EN EN 06. TROUBLESHOOTING
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EN EN07. MANUAL REVISIONS
MANUAL CHANGE SUMMARY
Date Description Version
05/2025 Initial Release R1.0
07 MANUAL REVISIONS
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EN EN 07. MANUAL REVISIONS
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EN 08. 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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WARRANTY PAGE
08 WARRANTY
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
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.
