- Low Pressure Pneumatic Color Change Manual 77-3119 [ English ]
SPECIFICATIONS
Maximum air inlet pressure: 7 bar [105 psi]
Air requirements (operating pressure): 4.8-6.9 bar [70-100 psi]
Air inlet connection: 1/4 OD tubing
Valve actuation speed (ON/OFF cycles): 55 cycles/min
Number of colors: 1 to 5 (main box);
up to 10 additional per add-on box
LOW PRESSURE PNEUMATIC COLOR CHANGE SELECTORS
MODELS:
240-5002 MAIN BOX (COLORS 1-5)
240-5003 ADD-ON BOX (COLORS 6-15)
EN
SERVICE MANUAL
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LOCK OUT / TAG-OUT
Failure to de-energize, disconnect, lock out and tag-out all power
sources before performing equipment maintenance could cause
serious injury or death.
OPERATOR TRAINING
All personnel must be trained before operating finishing
equipment.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture,
malfunction, or start unexpectedly and result in serious injury.
PROJECTILE HAZARD
You may be injured by venting liquids or gases that are released
under pressure, or flying debris.
PINCH POINT HAZARD
Moving parts can crush and cut. Pinch points are basically any
areas where there are moving parts.
INSPECT THE EQUIPMENT DAILY
Inspect the equipment for worn or broken parts on a daily basis.
Do not operate the equipment if you are uncertain about its
condition.
In this part sheet, the words WARNING, CAUTION and NOTE are used to
emphasize important safety information as follows:
Hazards or unsafe practices which
could result in minor personal injury,
product or property damage.
! CAUTION
Hazards or unsafe practices which
could result in severe personal
injury, death or substantial property
damage.
! WARNING
Important installation, operation or
maintenance information.
NOTE
Read the following warnings before using this equipment.
READ THE MANUAL
Before operating finishing equipment, read and understand all
safety, operation and maintenance information provided in the
operation manual.
WEAR SAFETY GLASSES
Failure to wear safety glasses with side shields could result in
serious eye injury or blindness.
NEVER MODIFY THE EQUIPMENT
Do not modify the equipment unless the manufacturer provides
written approval.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE OPERATOR OF THE EQUIPMENT.
FOR FURTHER SAFETY INFORMATION REGARDING THIS EQUIPMENT, SEE THE GENERAL EQUIPMENT SAFETY BOOKLET (77-5300).
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT
IN CASE OF AN EMERGENCY
PRESSURE RELIEF PROCEDURE
Always follow the pressure relief procedure in the equipment
instruction manual.
NOISE HAZARD
You may be injured by loud noise. Hearing protection may be
required when using this equipment.
STATIC CHARGE
Fluid may develop a static charge that must be dissipated through
proper grounding of the equipment, objects to be sprayed and all
other electrically conductive objects in the dispensing area. Improper
grounding or sparks can cause a hazardous condition and result in
fire, explosion or electric shock and other serious injury.
WEAR RESPIRATOR
Toxic fumes can cause serious injury or death if inhaled.
Wear a respirator as recommended by the fluid and solvent
manufacturer’s Material Safety Data Sheet.
TOXIC FLUID & FUMES
Hazardous fluid or toxic fumes can cause serious injury or death if
splashed in the eyes or on the skin, inhaled, injected or
swallowed. LEARN and KNOW the specific hazards or the fluids
you are using.
KEEP EQUIPMENT GUARDS IN PLACE
Do not operate the equipment if the safety devices have been
removed.
! WARNING
AUTOMATIC EQUIPMENT
Automatic equipment may start suddenly without warning.
FIRE AND EXPLOSION HAZARD
Improper equipment grounding, poor ventilation, open flame or
sparks can cause a hazardous condition and result in fire or
explosion and serious injury.
MEDICAL ALERT
Any injury caused by high pressure liquid can be serious. If you
are injured or even suspect an injury:
• Go to an emergency room immediately.
• Tell the doctor you suspect an injection injury.
• Show the doctor this medical information or the medical alert
card provided with your airless spray equipment.
• Tell the doctor what kind of fluid you were spraying or
dispensing.
GET IMMEDIATE MEDICAL ATTENTION
To prevent contact with the fluid, please note the following:
• Never point the gun/valve at anyone or any part of the body.
• Never put hand or fingers over the spray tip.
• Never attempt to stop or deflect fluid leaks with your hand,
body, glove or rag.
• Always have the tip guard on the spray gun before spraying.
• Always ensure that the gun trigger safety operates before
spraying.
EN
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:
4-3191R-3
Executive President: Engineering and
Operations, 3760 Victoria St N
Shoreview, MN 55126. USA
F. A. Sutter
4/8/25
Signed for and on behalf of Binks
US LLC:
Document Part No.
Product Description / Object of Declaration:
Solvent & Waterbased MaterialsThis Product is designed for use with:
Color Stacks - 240-35XX, 240-51XX, CCV-51XX; CCV-71XX;
Pneumatic Color Select Boxes - 240-5002, 240-5003, LPNE5002,
LPNE5003; Color Stack & Pneumatic Color Select Box Assembly
CCV-61XX
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
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)
EN
77-3119-R ( /20 ) / 16www. .com
EN
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.
Approved body details and role:
II 2 G X/Ex h II Gb XProtection Level:
Executive President: Engineering and
Operations, 3760 Victoria St N
Shoreview, MN 55126. USA
F. A. Sutter
4/8/25
Signed for and on behalf of Binks
US LLC:
Document Part No.
Product Description / Object of Declaration:
Solvent & Waterbased MaterialsThis Product is designed for use with:
Color Stacks - 240-35XX, 240-51XX, CCV-51XX; CCV-71XX;
Pneumatic Color Select Boxes - 240-5002, 240-5003,
LPNE5002, LPNE5003; Color Stack & Pneumatic Color Select
Box Assembly CCV-61XX
Supply of Machinery (Safety) Regulations 2008
Equipment and Protective Systems Intended for use in Potentially Explosive Atmospheres Regulations 2016
by complying with the following statutory documents and designated standards:
BS EN ISO 12100:2010 Safety of Machinery - General Principles for Design
BS EN ISO 80079-36:2016 Explosive Atmospheres- Part 36:Non Electrical equipment for explosive atmospheres-Basic
methods and requirements.
BS EN ISO 80079-37:2016 Explosive Atmospheres- Part 37: Non Electrical equipment for explosive atmospheres -
protection by methods c, b and k.
BS EN 1127-1:2019 Explosive atmospheres - Explosion prevention - Basic concepts
This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:
UKCA Declaration of Conformity
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 Warwick Ltd. UK. (0891)
77-3119-R ( /20 ) / 16www. .com
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240-5002 & 240-5003 INSTALLATION
Color Select Boxes Dimensions
Mounting Pattern
The Color Select Box have mounting brackets
for ease of mounting. The Color Select Boxes
may be mounted using the pattern at right.
Mounting hardware can be any type of a 6mm
[1/4 in] bolt with flat washers. A minimum of
150mm [6 in] should be left between the air
outlets on the box and the Color Change Stack
(240-51xx), to allow ample room for the air
tubing to be run later.
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240-5002 & 240-5003 INSTALLATION
240-5002 Control Box
Colors 1-5
Color #
1
Color #
2
Color #
3
Color Select / Run Input
O
perator panel for Flushbox
Solvent Push Valve
Color #
7
Color #
9
Color #
8
Color #
10
Color #
6
Color #
12
Color #
11
Color #
13
Color #
15
Color #
14
Solvent Push Valve
Air Push Valve
Color #
1
Color #
3
Color #
5
Color #
7
Color #
2
Color #
4
Color #
6
M
aterial outlet
M
aterial Inlets
Solvent Inlet
Air Push Kit
240-5004
Air in
77-3119
PAG
E
Typical Installation diagram
CCV Color Stack
240-5109 show
n
Service M
anual: 77-3118
240-5003 Add-on Box
Colors 6-15
Air in
Color #
5
Color #
4
O
N
from
Pow
er Supply
Air Push Valve
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240-5002 & 240-5003 INSTALLATION
Air Tubing Connections
For the proper connection locations on the Color Select
Box, refer to Figure 2. The main supply air must be
Diagram, Figure 9, the air tubing can be run to the
may be used only if a pneumatic control panel is being
used. In this case, HV6 is connected directly to HV6 on
the pneumatic control panel.
Coating Material Connections
Number the coating materials to correspond to the
numbers of the Color Select System. 3/8-inch OD tubing
is to be useda to connect the Color Change Valves to
the coating material. Connect the tubing from material
(#1) to CCV (#1), tubing from material (#2) to CCV
(#2), and so on, matching materials with the proper
CCV.
The coating material must be
pressurized for the Color Select System
to function properly.
NOTE
Solvent Connection
The solvent is connected in the same way as the
Coating Material, using 3/8-inch OD tubing. Installation
of the Color Select System is made simple by its ability
to be placed in a Class I, Division I environment. The
color change valves can be mounted as close to the
paint or the applicator as is desired. The color select
box can be mounted right on the wall of the spray
booth, allowing for fast color changes, since the
operator does not have to leave the booth.
The solvent must be pressurized for the
Color Select System to function properly.
NOTE
Overview
selecting the proper color number on the Color Select
Boxes corresponding to the Color Change Valve (CCV)
desired. If two Color Select Boxes are used, all Color
position. After the proper color number is selected, the
SELECT.
To select a new COLOR, the main switch
must be moved from the COLOR SELECT to
the OFF position.
To flush the coating material from the coating
system, select the SOL position, which will
activate the solvent. The AIR position can
be used to blow the coating material or the
solvent out of the coating system.
NOTE
The coating material is supplied from the users
pressurized system that may be a pressure tank, paint
circulating system or other suitable pressure paint
supply system.
An air signal supplied to the CCV activates the paint
being delivered to the applicator. The air signal is
controlled by the Color Select Boxes. 1/4-inch OD air
tubing is recommended for use between the Color
Select Boxe(s) and the CCVs on the color stack.
240-5002 & 240-5003 OPERATION
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240-5002 & 240-5003 OPERATION
240-5002 Color Select Box (Master)
240-5003 Color Select Box (Add-on)
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240-5002 & 240-5003 OPERATION
SELECTOR SWITCH FUNCTIONS
POSITION DESCRIPTION 240-5002 240-5003
COLOR SELECT Supplies air to all color select switches X
OFF Stops all air flow X
AIR Supplies air to Air Push Valve X
SOL Supplies air to Solvent Push Valve X
COLOR OFF Off position for individual Color Select Valves (activates next valve) X
COLOR 1 - 5 Supplies air to corresponding Color Select Valve X
COLOR OFF Off position for individual Color Select Valves (activates next valve) X
COLOR 6 - 10 Supplies air to corresponding Color Select Valve X
COLOR OFF Off position for individual Color Select Valves (activates next valve) X
COLOR 7 - 15 Supplies air to corresponding Color Select Valve X
OUTPUT PORT FUNCTIONS
All ports are for 1/4 inch OD tubing.
POSITION DESCRIPTION 240-5002 240-5003
501 Main Air Supply Inlet X
CS2 Supply Air for Add-on Selector Box X X
C/R Run Input on Operator Panel of Flush Box X
MA1 Activation Air for Air Push Valve X
MS1 Activation Air for Solvent Push Valve X
HV6 High Voltage on Signal Air (to pneumatic control panel) X
CL1 - CL5 Activation air for corresponding individual Color Select Valves X
CL6 - CL15 Activation air for corresponding individual Color Select Valves X
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240-5002 & 240-5003 PARTS LIST
2
3x
1 5
1110
6
10x
3
4x
4
93
7x
12
2x
8
11x
7
2x
13
3
7x
1 6
11x
3
6x
2
1x
7
2x
8
11x
13
240-5002 Color Select Box (Master)
240-5003 Color Select Box (Add-on)
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240-5002 & 240-5003 PARTS LIST
COLOR SELECT BOXES
ITEM
NO. POSITION DESCRIPTION 240-5002 240-5003
1 LPNE0005-01 1 1
2 41-FP-1011 3 1
3 41-FTP-1023 11 13
4 41-BAS-1000 LOGIC BASE 1 –
5 41-VAP-1004 AIR PILOTED VALVE, NOT LOGIC (NO) 1 –
6 41-FTP-1015 10 11
7 41-VMC-1002 2 2
8 41-FBH-1000 11 11
9 LS0079 DIN RAIL, 6 LENGTH 1 –
10 LSMM0051-00 1 –
11 41-FTP-1050 1 –
12 41-PLG-1001 2 –
13 SSH-7739 1 1
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ACCESSORIES
LOW PRESSURE
PNEUMATIC COLOR CHANGE
VALVE STACKS
MODELS: 240-51XX
SERVICE MANUAL: 77-3118
1 TO 31 VALVES AVAILABLE
240-5131 Shown
31 Valves
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ACCESSORIES
LOW PRESSURE
PNEUMATIC COLOR CHANGE
VALVE
MODEL: CCV-503-SS
SERVICE MANUAL: 77-3117
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NOTES
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NOTES
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For technical assistance or to locate an authorized distributor,
contact one of our international sales and customer support locations.
Region Industrial/Automotive
Americas
Tel: 1-800-992-4657 Tel: 1-800-445-3988
Fax: 1-888-246-5732 Fax: 1-800-445-6643
Europe, Africa,
Middle East, India
Tel: +44 (0)1202 571 111
Fax: +44 (0)1202 573 488
China
Tel: +8621-3373 0108
Fax: +8621-3373 0308
Japan
Tel: +81 45 785 6421
Fax: +81 45 785 6517
Australia
Tel: +61 (0) 2 8525 7555
Fax: +61 (0) 2 8525 7575
WARRANTY POLICY
This product is covered by ’ materials and workmanship limited warranty. The use of any parts
or accessories, from a source other than ,
will void all warranties. Failure to reasonably follow any maintenance guidance provided
may invalidate any warranty.
DeVilbiss®, Ransburg®, and Binks®
are registered trademarks of
©20 .
All rights reserved.
For the latest information about our products, visit www. .com
