- QuickHeat Hose Manual 341164 EN [ English ]
- QuickHeat Hose Manual 341164 CH [ Chinese ]
- QuickHeat Hose Manual 341164 FR [ French ]
341164
IntelliSpray QuickHeat Hose
®
www.binks.com341164 REV E (05/2025)
ENADDITIONAL RESOURCES
For additional information or copies of your QuickHeat Hose 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.
https://carlisleft.com/en/product/is40-proportioner/
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EN INTRODUCTION
i / iv
ABOUT THIS MANUAL
ITS PURPOSE
The purpose of this manual is to help you get the most
value from your IntelliSpray QuickHeat Hose 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.
The digital PDF version of this manual contains
bookmarks and links to referenced sections and chapters.
Tap on a referenced chapter/section to jump to that
reference.
Chapter 02. Table of Contents.
Chapter 03. EU Declaration of Conformity - A mandatory
document the manufacturer signs to declare the product
complies with the EU requirements.
Chapter 04. Safety - Safety, hazard, and warning rules.
Chapter 05. Isocyanate Information - Information about
the safe handling and characteristics of Isocyanates
Chapter 06. Introduction - Overview of the QuickHeat
hose system.
Chapter 07. Installation - Procedures of installing the
QuickHeat hose onto an IS30 or IS40 proportioner and
ST1 spray gun.
Chapter 08. Troubleshooting - Procedures for identifying
and correcting issues users might experience.
Chapter 09. Maintenance - QuickHeat hose maintenance
procedures.
Chapter 10. Manual Change Summary - The revisions
and changes made to this manual.
Chapter 11. 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.
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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ENINTRODUCTION
ii / iv
RELATED MANUALS & PUBLICATIONS
Part Number Description
347492 IS30 User Manual
347493 IS30 Quick Start Guide
341162 IS40 User Manual
343064 IS40 Quick Start Guide
336742 ST1 User Manual
336741 ST1 Quick Start Guide
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EN 02. TABLE OF CONTENTS
iii / iv
02. CONTENTS
03. EU DECLARATION OF CONFORMITY 1
04 SAFETY 3
04.1 SAFETY PRECAUTIONS..................................................................................................................................3
04.2 ADDITIONAL SAFETY INFORMATION..........................................................................................................10
05. IMPORTANT ISOCYANATE INFORMATION 11
05.1 GENERAL HANDLING GUIDELINES.............................................................................................................11
05.2 MATERIAL SELF IGNITION............................................................................................................................12
05.3 KEEP COMPONENTS A & B SEPARATE.......................................................................................................12
05.4 EXPOSURE TO MOISTURE...........................................................................................................................12
05.5 FOAM RESINS WITH 245 FA BLOWING AGENTS.......................................................................................12
05.6 CHANGING MATERIALS.................................................................................................................................12
05.7 ELECTRICAL GROUND..................................................................................................................................12
06. INTRODUCTION 13
06.1 SYSTEM OVERVIEW......................................................................................................................................13
06.2 PRODUCT FEATURES....................................................................................................................................13
06.3 HOSE TERMINOLOGY....................................................................................................................................13
06.5 SYSTEM COMPONENTS................................................................................................................................14
06.6 HOSE LAYERS.................................................................................................................................................14
06.4 HOSE SPECIFICATIONS................................................................................................................................14
06.8 HOSE SET CONFIGURATIONS.....................................................................................................................16
07. INSTALLATION 19
07.1 PROPORTIONER TO HOSE CONNECTION................................................................................................19
07.2 HOSE-TO-HOSE CONNECTIONS.................................................................................................................21
07.2.1 MASTER HOSE TO MID HOSE CONNECTION.................................................................................21
07.3 HOSE-TO-GUN CONNECTIONS....................................................................................................................22
07.4 HOSE USAGE..................................................................................................................................................23
07.5 FIBER OPTIC CABLE LED INDICATORS......................................................................................................23
08. TROUBLESHOOTING 25
09. MAINTENANCE 27
09.1 REGULAR MAINTENANCE PROCEDURES AND RECOMMENDATIONS................................................27
09.2 STORAGE.........................................................................................................................................................27
09.3 SPARE PARTS & REPAIR KITS......................................................................................................................28
09.4 HOSE SECTION REPLACEMENT.................................................................................................................31
09.4.1 SINGLE HOSE SEGMENT: REMOVAL...............................................................................................31
09.4.2 SINGLE HOSE SEGMENT REINSTALLATION..................................................................................31
09.4.3 HOSE SECTION REMOVAL (TWO SIDES)........................................................................................32
09.5 HOSE CONNECTION DIAGRAM....................................................................................................................33
09.6 WRAPPING NEW HOSE SECTIONS.............................................................................................................34
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EN02. TABLE OF CONTENTS
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09. MAINTENANCE 27
09.7 FLATS METHOD..............................................................................................................................................34
09.8 CLAMP LOCATION MAPPING........................................................................................................................34
09.9 CABLE TERMINATION....................................................................................................................................35
09. MANUAL CHANGE SUMMARY 37
10. WARRANTY 39
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EN 03. EU DECLARATION OF CONFORMITY
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.
Low Voltage Assessment
Executive President: Engineering and
Operations, Shoreview, MN, 55126.
USA
F. A. Sutter
6-3-25
Signed for and on behalf of
Binks US LLC:
Document Part No.
Product Description / Object of Declaration:
Fast Set Polyurethane Foams and PolyureasThis Product is designed for use with:
QuickHeat Hose No.34XXXX
Suitable for use in hazardous area:
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
Protection Level: Not Applicable
This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:
Notified body details and role:
President @. Binks France SAS
5 Place Pierre Semard, 94130 Nogent sur Marne , Paris,
France
Machinery Directive 2006/42/EC
Low Voltage Directive 2014/35/EU
RoHS Directive 2011/65/EU
by complying with the following statutory documents and harmonised standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN 63000: 2018 Technical documentation for the assessment according to REACH
EN 60204-1:2018 Safety of Machinery. Electrical equipment of machines
EU Declaration of Conformity
Representative authorised to compile the technical
file
03. EU DECLARATION OF CONFORMITY
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EN03. EU DECLARATION OF CONFORMITY
This page intentionally left blank.
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 IntelliSpray has an emergency stop (E-Stop) pushbutton on the main operator panel. During an emergency, all
operations for the IntelliSpray 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. ISOCYANATE INFORMATION
05. IMPORTANT ISOCYANATE
INFORMATION
05.1 GENERAL HANDLING GUIDELINES
Isocyanates (ISO) are catalysts used in two component
materials.
Fluids with isocyanates that are sprayed or dispensed
creates potentially harmful mists, vapors, and atomized
particulates. Workers exposed to isocyanates can
develop a range of short and long-term health problems.
Read and understand the fluid manufacturer’s warnings
and Safety Data Sheet (SDS) for specific hazards and
precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous
procedures. Do not spray with this equipment
unless you are trained, qualified, and have read and
understood the information in this manual and in the
fluid manufacturer’s application instructions and SDS.
• Use of incorrectly maintained or adjusted equipment
may result in unsatisfactory cured material which
can off-gas and make offensive odors. Refer to the
instruction in the manual to correctly maintain and
operate the equipment.
• To prevent inhalation of isocyanate mists, vapors
and atomized particulates, everyone in the work
area must wear applicable respiratory protection.
Always wear a correctly fitted respirator that includes
a supplied-air respirator. Refer to the instructions in
the fluid manufacturer’s SDS for correct work area
airflow.
• Avoid all skin contact with isocyanates. Everyone in
the work area must wear chemically impermeable
gloves, protective clothing, and foot cover
recommended by the fluid manufacturer and local
regulatory authorities. Follow all fluid manufacturer
recommendations, to include the discard of
contaminated clothing. Do not eat or drink after
equipment use until hands and face have been
washed.
• Hazard from exposure to isocyanates continues after
spray use. Anyone without correct personal protective
equipment must stay out of the work area during and
after the application, and for the time period specified
by the fluid manufacturer. This time period is usually a
minimum of 24 hours.
• Warn others who may enter work area of hazard
from exposure to isocyanates. Follow the
recommendations of the fluid manufacturer and local
regulatory authority.
• It is recommended to post a sign outside the work as
the one shown below:
WARNING
DO NOT ENTER UNTIL AFTER:
DO NOT ENTER DURING SPRAY
FOAM APPLICATION OR FOR ─
HOURS AFTER APPLICATION IS
COMPLETE
TOXIC FUME HAZARD
DATE: TIME:
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EN EN05. ISOCYANATE INFORMATION
05.2 MATERIAL SELF IGNITION
Some materials may become self-igniting if applied too
thick. Read material manufacturer's warnings and Safety
Data Sheet
05.3 KEEP COMPONENTS A & B
SEPARATE
Prevent cross contamination of A and B materials. Cured
material in fluid lines and passages can cause serious
personal injury or equipment damage.
Never interchange the wetted parts of components A and
B.
Never use solvent on one side that is contaminated with
fluid from the other side.
05.4 EXPOSURE TO MOISTURE
ISO will start to cure and form small, hard, abrasive
crystals when exposed to moisture and humidity.
These crystals become suspended in the fluid and can
cause equipment damage. Over time, a film will form on
the surface and the ISO will get thicker with increased
viscosity.
Take the following steps to prevent damage to spray gun
components due to cured ISO:
• A sealed container with a desiccant dryer in the vent,
or a nitrogen atmosphere in the empty head space of
the container must be used.
• ISO must not be stored in an open container.
• The ISO pump reservoir must be kept filled with
applicable lubricant. The lubricant creates a barrier
between the ISO and the atmosphere.
• Only ISO compatible moisture-proof hoses must be
used.
• Reclaimed solvents, which may contain moisture,
must not be used.
• Solvent containers must be closed when not in use.
• Assemble threaded parts only with the correct
lubricant.
05.5 FOAM RESINS WITH 245 FA BLOWING
AGENTS
Some materials may become self-igniting if applied too
thick. Read material manufacturer's warnings and Safety
Data Sheet (SDS).
05.6 CHANGING MATERIALS
Prevent equipment damage and downtime during material
changes and flushes for service or storage.
• Flush equipment multiple times to make sure it is fully
clean.
• The fluid strainers must be cleaned after all flushes.
Speak with the material manufacturer for information
on chemical compatibility.
• When there is a change between epoxies, urethanes,
or polyureas, all wetted parts must be disassembled
and cleaned, and the hoses changed.
05.7 ELECTRICAL GROUND
Examine the local electrical code and Proportioner
manual for instructions on how to correctly ground the
equipment.
Ground the spray gun through a connection to a Binks
approved grounded fluid supply hose.
ISO that has started to cure will reduce the life and
performance of all wetted parts.
EN 06. INTRODUCTION
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06. INTRODUCTION
The Binks IntelliSpray™ Spray Polyurethane Foam
(SPF) system consists of the IS40 or IS30 Proportioner,
QuickHeat™ Hose, and ST1™ Spray Gun. The
IntelliSpray system has been designed for ease of use,
increased productivity, best in class process control,
easy service, and real-time ratio control.
06.1 SYSTEM OVERVIEW
The QuickHeat hose system is designed to be used
with the Intellispray IS30 and IS40 proportioners.
They are specifically designed to use Binks QuickHeat
Hoses. These hoses contain high-power internal electric
heating cables, ensuring that all of the heating energy is
transmitted directly to the fluid.
QuickHeat hoses are available in:
• 50, 100, 150 or 200 foot (15, 30, 45, or 60m) lengths
for the master hose.
• 100 or 150 foot (30 or 45m) lengths for the mid
section.
• 20, 25 or 40 foot (6, 7 or 12m) lengths for smart ends,
with the 25ft length a hi-flex version.
• Insulated whips are available as 3,4,6,10 (1, 1.5, 2 or
3m) with the 4ft version being the hi-flex option.
Each length of a heated hose begins with a fluid manifold
or modem that contains pressure and/or temperature
sensors, heater cable connectors, and electronics used
to send information over the hose to the proportioner
control module. With this approach, no sensor power or
communication cables are required, which are a common
source of hose failures in other systems. It also provides
the proprietary architecture for two way communication
between the hose, proportioner and remote devices.
The QuickHeat hose has roughly double the heating
power compared to most other SPF hoses and directly
heats the fluid from inside the hose, which results in fast
and efficient fluid heating, even in cold climate conditions.
QuickHeat hoses have embedded temperature and
pressure sensors, independent A & B hose heating,
and up to six independent heating zones to improve
temperature control. QuickHeat hoses provide sensor
power and signal communication without cables or
connectors, providing high reliability while reducing failure
points. QuickHeat hoses include a snag and abrasion
resistant outer hose wrap that is sealed with industrial
grade Hook & Loop material to allow individual A or B side
hose replacement.
06.2 PRODUCT FEATURES
• Fast and reliable heat: Independent A & B embedded
heater wire submerged in hose fluid achieving >100˚F
(37˚C) DeltaT in under 15 minutes on average.
• Real-time system control: Pressure and temperature
data communicated and controlled within hose to
spray gun to maximize control and accuracy.
• Cut service costs: Reduced need for service with fully
potted electronics/sensors and the ability to replace A
& B side
independently when needed.
• Reduced electrical connections
• Resulting in less maintenance issues.
• More heat control and less risk: Independent heat
sensors allow system to adjust temperature.
• Lighter and more flexible hoses for less sprayer
fatigue.
06.3 HOSE TERMINOLOGY
• Hose Segment: Describing one side (one fluid path)
of a hose section
• Hose Section: A pair of hose segments (e.g. a Master
section, Mid section, or Smart End section)
• Hose Set: Combined hose sections needed for a fully
functional IntelliSpray™ system
EN06. INTRODUCTION
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06.5 SYSTEM COMPONENTS
The QuickHeat hose has the following components:
• Potted modem (2 halves per hose section) - Part of
material hose assembly (non-removable)
• Material Hoses (2 per hose section)
• Heater wires (2 per hose section) - Part of material
hose assembly (non-removable)
• Heater power cables (2 per hose section) - Provide
power to the internal heater wire (Replaceable).
• Master hose low voltage (24 VDC) power cable - Part
of master modem (not replaceable)
• Master hose EtherCAT cable (green) - Part of master
modem (not replaceable)
• M8 communication cable (black) - Connects modem
halves together (not replaceable)
• Fiber Optic status light cable - Part of each material
hose assembly (not replaceable)
• Air hose (1 per hose section) - Replaceable
06.6 HOSE LAYERS
1. Santoprene
2. Proprietary communication layer
3. Thermoplastic Urethane (TPU)
4. Fiber braid
5. Nylon core
06.4 HOSE SPECIFICATIONS
Dimensions (Length)
Master Hose: 50, 100, 150, or 200 ft length (15, 30, 45, or 60m)
Mid hose: 100 or 150ft length (30 or 45m)
Smart-end: 20, 25 or 40ft length (6, 7.5 or 12m)
Whip: 3, 4, 6, or 10ft length (1, 1.5, 2, or 3m)
Dimensions (Diameter) The hose has an internal diameter of 3/8 in (Master, Mid, and Smart-end) and 1/4
in ID for the insulated whip
Weight 150-250lb (68-113kg) (depending on configuration and length).
Temperature differential >100˚F (37˚C) DeltaT (over full length of hose system)
Maximum working pressure 2,250 PSI (155 BAR)
Maximum operating temperature 200˚F (93˚C)
Minimum bend radius 8 in (20cm) (entire hose bundle)
NOTICE
The Santoprene and proprietary communication layers
are not included in the Smart-End or whip assemblies.
1
2
3
4
5
EN 06. INTRODUCTION
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06.7 POTTED MODEM STRUCTURE
Each hose segment has a potted modem half at the start
of the segment (one hose section contains 2 modem
halves). The modems may differ depending on whether
they are part of a master, mid or smart-end segment. The
differences are explained in the installation section of this
manual. The modem diagram below is shown without the
B-side modem shell for reference.
The QuickHeat hose structure and connections vary
depending on the configuration selected.
Benefits
• Fully ruggedized potted electronics
• Fully sealed set of fluid fittings
• Built-in multi-colored LED and fiber optic feedback for
system status
• High-resolution process control and communication
electronics
• Independently-replaceable A and B side design
• Minimized connections
• Independent pressure and temperature sensing
control
1. Material A input (upstream)
2. Material B input (upstream)
3. Material temperature probes (A & B) (hidden in
diagram) - Mid and Smart End only
4. Integrated modem power cable connections
5. Fluid pressure sensors (Smart End only)
6. Circuit boards (1 per hose segment)
7. Material A output
8. Fiber optic status cable (A side only)
9. Material B output
5
7
6 3
2
4
8
1
9
EN06. INTRODUCTION
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06.8 HOSE SET CONFIGURATIONS
The following figures show how the Master, Mid, and
Smart-End hose sections are assembled into either 4 or 6
Zone sets.
The difference between a 4 or 6 zone set configuration
is the presence of a Mid Hose with an integrated Y
power splitter. Both the IS30 and IS40 are sold as 6 zone
proportioners, which can accommodate either 4 or 6 zone
hose sets.
Depending on the total length needed for the entire hose
system, the hose sections can be assembled in 2 different
configurations. The hose length cannot exceed 350ft for
either the IS30 or IS40 systems.
50, 100, 150 or 200ft
(15, 30, 45 or 60m)
Master Hose (heated)
20, 25 or 40ft
(6, 7.5 or 12m)
Smart End
(heated)
20, 25 or 40ft
(6, 7.5 or 12m)
Smart End
(heated)
50, 100, 150 or 200ft
(15, 30, 45 or 60m)
Master Hose (heated)
3, 4, 6 or 10ft
(1, 1.5, 2 or 3m)
Insulated End
Whip
3, 4, 6 or 10ft
(1, 1.5, 2 or 3m)
Insulated End
Whip
100 or 150ft
(30 or 45m)
Mid Hose
(heated)
EN 06. INTRODUCTION
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Low Voltage Power Cable (24V)
Hose Fluid, Air, and Power Connections
1. Proportioner Control Module (IS30 or IS40)
2. Material A Fluid Module
3. Material B Fluid Module
4. Zone 1A and 1B Heater Wire Power Cable (4 and 6 zone)
5. Zone 2A and 2B Heater Wire Power Cable (4 and 6 zone)
6. Zone 2A and 2B Heater Wire Power Cable (6 zone)
7. Hose Segment Modem
8. Power Splitter (integrated into Mid Modems)
9. Material A & B Circuit board Power Cable
1
1
2
7
7
8
7
7
4-Zone Configuration
6-Zone Configuration
9
3
7
9 9
2
3
4
5
4
5
6
EN06. INTRODUCTION
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EN 07. INSTALLATION
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07. INSTALLATION
Refer to the IS30 and IS40 manual for instructions
on hose setup, pairing modems and selecting
communication frequency.
Before operating the QuickHeat Hose, ensure all of the
following installation steps in this chapter have been
completed.
REQUIRED TOOLS AND HARDWARE
• Open ended wrenches: two 11/16 in, two 5/8 in, one
9/16 in, and one 15mm wrench
• 5/16 Allen wrench
• Utility knife and/or scissors
• Roll of 2 in wide black vinyl tape (provided)
• Spare insulation and wrap material (provided)
• Black permanent marker (for installation)
• 3mm allen wrench
• #1 Phillips screwdriver
Also required supplies for depressurized wetted systems:
• Safety glasses and/or face shield
• Nitrile gloves
• Plastic sheeting 10x10 foot minimum recommended
• Absorbent pads and/or paper shop towels
• Recommended four stainless steel caps and plugs
(JIC5 and JIC6)
07.1 PROPORTIONER TO HOSE
CONNECTION
The first phase of the installation is connecting the master
hose modem to the proportioner system. To achieve this:
1. Identify the Master Hose module through the serial
number on the product. The master module is the
only one that contains a green EtherCAT cable (a)
and a thin grey low voltage (24 VDC) power cable (b).
2. Remove the modem area guard from the proportioner
system (c)
• IS40: Remove the two screws (d) using a 3mm
Allen wrench. Be careful not to drop the screws
into the fluid modules below (e).
• IS30: Pull out and up on cover.
a
b
*IS30 model shown
d
e
c
d
WARNING
You should only disconnect and reconnect hoses for
maintenance or replacement procedures. Please refer
to the Hose Replacement section in Maintenance
NOTICE
Prior to assembly, uncoil hoses to remove any twists.
EN07. INSTALLATION
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3. For easier installation and to minimize torsion, place
the hose on top of the proportioner system and
feed the modem into the guarded area through the
top of the hose guard bar (f) - (IS40 only). Loosen
the cabinet clamp screws using a 15mm wrench if
needed.
4. Position the modem and place into the top clamp (g)
loosely, while being careful not to pinch the fiber optic
cable in the clamp.
5. Connect the jumper hose fittings (h) to the bottom
modem inputs (i) and tighten using the Flats method
(see section 09.7). Remove plugs from the modem
JIC fittings.
6. Locate the power connectors (j) to the left (IS40) or to
the right (IS30) of the modem.
7. Connect each heater power cable on the cabinet to
their corresponding cables on the hose. (refer to
cable labels). Six connections will need to be made
on a 6 zone hose, (two at the mid/master connection,
four at the proportioner cabinet) and four connections
will need to be made on a 4 zone hose (all at the
cabinet). Be careful to match material colors (A: Red,
B: Blue) and zones for each connection (i.e. red
Zone 1A to red Zone 1A). Refer to section 09.9 Cable
Termination for instructions on making the cable
connections in the hose.)
8. Connect the etherCAT and low voltage power cables
to their corresponding inputs (k) & (l), respectively.
9. Connect the air hose to main air supply (quick
disconnect).
10. Tighten both the bottom and top clamps (referenced
in step 4) using a 15mm wrench.
11. Reinstall the modem area guard. (Ensure that fiber
optic is in a visible location.)
k l
NOTICE
The QuickHeat Hose assembly is compatible ONLY
with IntelliSpray Systems
f
g
h
i
j
EN 07. INSTALLATION
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07.2 HOSE-TO-HOSE CONNECTIONS
Depending on the configuration purchased, a hose-to-
hose installation may be required. For the installation
procedure, please refer to the details below:
• 4-Zone configuration: No hose-to-hose installation
required. Hoses will arrive connected within the box.
• 6-Zone configuration: There is one hose-to-hose
connection needed. Master Segment will arrive in Box
1 out of 2 and Mid Hose will arrive connected to the
Smart End in box 2. To connect Master to Mid, please
follow the steps detailed below.
07.2.1 MASTER HOSE TO MID HOSE
CONNECTION
1. Remove temp probe sheaths on the Mid hose that
are shipped attached to the Mid modem. These
sheaths protect the temp probes from damage during
shipping.
2. Tip the last 3ft of the Master Hose (male fitting end)
towards the ground and gently shake it. This allows
the Isolator to drop to the closest fitting for an easier
probe install.
3. Lay the last 3ft of the Master Hose (male fitting end)
and the first 3ft of the Mid Hose (female fitting end)
including the modem in a straight line in front of each
other.
4. Lightly straighten the temperature probe wires
coming from the Mid Modem (a).
5. Carefully, slide the temperature probes into the
corresponding A and B hoses of the Master Hose
simultaneously.
6. Tighten the fluid fittings using the Flats method
(see section 09.7).
7. Loosen the two centering clamp bolts using a 3mm
Allen. Remove the bolts.
8. Connect the power cables from the master hose to
their matching cables in the mid modem. (Refer to the
Cable Termination section of this manual).
9. Insert both assembled cables from modem into the
center hole of the of the centering clamp, and reinstall
bolts. Tighten clamp around cables with a 3mm Allen
wrench. BE CAREFUL NOT TO PINCH CABLES!
10. Lay the air hoses coming from the Master and the
Mid separate from the power cables and make the
swivel connection using a 5/8 open end wrench, and
a 9/16 open end wrench to tighten.
11. Insert the Mid hose modem into the protective boot
(provided). Align the pattern on the inside of the
boot with pattern on the modem.
a
Power cables not
shown for clarity
NOTICE
The Mid hose sections come with temp probe sheaths
installed on the modem fluid fittings, to protect the
probes from damage. You need to remove those in
order to install any mid to a master segment. Keep the
temperature probe sheaths, caps and plugs in case it is
ever necessary to seal that section separately.
NOTICE
When inserting the probes, if you encounter resistance
that is causing them to bend, back up a few inches,
straighten the hoses and the probes and try again.
The probes are tip sensitive and will not be damaged
by light bends.
NOTICE
No PTFE tape is needed.
WARNING
Ensure that the system is powered down before
continuing. Allowing fittings (A&B) to touch while the
system is energized (SELV 24Vdc) will cause a fault
condition that will require a system reboot. Bridging
fittings with a metal tool will also generate the same
fault.
NOTICE
The entire IS30/IS40 Proportioner and hose system
are factory tested using an inert oil and subsequently
blown out. Some residual oil may be noticed in the lines
once the caps and plugs are removed, but there are no
chemical reaction concerns upon the initial installation.
WARNING
DO NOT REMOVE the temperature probe tips.
EN07. INSTALLATION
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12. Insert the air hose and the heater wire power cables
into the protective modem boot through the outside
center gap and tape (b).
13. Close up the hose wrap from each section and cover
the modem boot with the provided joint wrap piece.
Secure with 2 wide electrical tape for 4 on both
sides of the joint.
07.3 HOSE-TO-GUN CONNECTIONS
Once all connections between the hoses are completed,
the final step is to connect the End Whip hose to the
spray gun. To install:
1. Identify the insulated hose whip.
2. Connect the material hose ends of the whip to the
gun manifold (a) of the ST-1 spray gun.
3. Tighten the fittings using the Flats Method (see
section 09.7).
4. Screw the air hose connector into the Quick
Disconnect adapter
5. Connect the newly installed adapter to the air inlet (b)
in the ST-1 spray gun.
b
a
NOTICE
DO NOT TAPE POWER CABLES inside the bundle.
Allow the cables and air hose to move as freely as
possible for strain relief. Flex hose on either side of the
modem zone to a approximately 8in (20cm) radius to
ensure the cables and hose enough slack.
NOTICE
The QuickHeat Hose is specially designed for use with
the Binks ST1 Air Purge Spray Gun. If you need to
use other equipment, we recommend using only Binks
approved Spray Guns or guns designed solely for the
same purpose.
b
NOTICE
Smart end connection to a Master or Mid is very similar
to the connection between a Master and Mid, with only
2 power, 2 fluid, and one air connection per connecting
point. The mid hose has an additional 2 power.
EN 07. INSTALLATION
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07.4 HOSE USAGE
Key operational requirements:
• All air must be purged from system before use to
avoid system malfunction (pressure imbalance errors,
chemical solidification, hot spots in hose)
• Do not heat hose without fluid to avoid damaging the
hose and causing leaks
• Remove entire hose from hose rack in rig before
heating to avoid overheating and temperature
variations
• Remove tight loops in hose prior to pulling hose into
position to avoid hose kinking
• On initial startup, straighten sections of hose near
modems to allow best temperature feedback to unit
• Do not pull on hose sections that are not in line-of-
sight to prevent tight loops and kinking
• Leave hose under positive pressure when not in use
to avoid reacting with the ambient environment
07.5 FIBER OPTIC CABLE LED
INDICATORS
Fiber optic status lights (5Hz Frequency) are provided at
the inlet end of each heated hose section. Each light color
and state reflects on a different status:
• Flashing Green: Hose status OK, but no color
status setting from HMI
• Flashing Yellow: HoseLink communication is
marginal - warning level
• Flashing Purple: Hose pairing error or possible
crosstalk - warning level
• Flashing White: Hose firmware updating
(informational)
• Flashing Red: Hose internal error
• Flashing Blue: Bluetooth connection to modem
(informational)
EN07. INSTALLATION
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EN 08. TROUBLESHOOTING
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08. TROUBLESHOOTING
The following table contains information on troubleshooting the QuickHeat Hose system. It list possible issues a user
may experience, the probable cause(s), and the solution(s).
CAUTION
To prevent cross contamination of wetted parts, do not interchange A component (ISO) and B component (RESIN)
parts.
WARNING
Be sure that the Safety stop is engaged and the manual shut-off valves are closed before performing maintenance.
WARNING
Relieve pressure before cleaning or repairing the QuickHeat Hose.
TROUBLESHOOTING PROCEDURES
PROBLEM IDENTIFICATION SOLUTION
Leak between hose
sections at JIC fitting
A or B material leaking
out of jacket or loss of
pressure
1. Power down the system. Trace down source of leak.
Start by opening jacket 3ft (1m) before and after joint to
determine direction and extent.
2. If wet, open joint, clean up residual fluid and inspect fittings.
Tighten (1.0 to 1.25 flats for JIC5) on A side, (1.25 to 1.5
flats for JIC6) on B side.
3. Check that clamps are tight enough to constrain hose.
Make sure insulation is taped into position while still
allowing power cable slack loops to move freely.
4. Close up hose wrap. Check the clamps for tightness. Check
fittings for cracks (over torqued)
Loss of communication
between A & B side on
a particular modem
Error message on screen
and yellow light at a
modem
1. Inspect modem optical fiber lights.
2. If any of the lights are flashing yellow or red, open that joint
section.
3. Power down the system.
4. Inspect the jumper connection between the two halves.
5. Remove any debris or chemical residue from the
connection with IPA. Allow to dry.
6. Put the connection back together. Power up the unit.
Confirm green light at the modem.
7. Put insulation and joint wrap back in place.
(An additional step for the master modem is to unroll the hose
at least one full zone (not just the Smart End). If there is still
no green light at master modem, run a frequency scan (on the
HMI) and try selecting a new frequency channel.)
EN08. TROUBLESHOOTING
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TROUBLESHOOTING PROCEDURES
PROBLEM IDENTIFICATION SOLUTION
A or B Side Hose run
over, cut or kinked
Known incident or evident
damage
1. Inspect the system. Tracing the source of a leak is not
always easy.
2. Dry off areas, inspect for source. Very minor ‘wicking’
A-side leaks may seal on their own if allowed to dry. If the
leak is major, replace A or B hose section.
Leak from inside the
potted section of the
modem
Leak not coming from JIC
fittings. Watch for a leak
from a modem connection
1. Inspect the system. Tracing the source of a leak is not
always easy.
2. Dry off areas, inspect for source. Very minor ‘wicking’
A-side leaks may seal on their own if allowed to dry. If the
leak is major, replace A or B hose section.
No heat Front Panel
1. Inspect material hose and power cables and connectors for
damage.
2. Check heater wire breakers.
3. Check for system error codes.
4. Make sure power cable clamps, strain relief loops and
slack loops are in the correct locations and that tape is not
impeding the ability of cables to pull from slack loops when
under tension.
Fluid temperature over
setpoint upon startup
As given on control panel
or observed at spray gun
1. Remove all hose from hose rack.
2. Lay house straight for a three feet upstream of modem.
3. Spray for a few seconds to move fluid past probes as the
fluid temp is within 15F (8.3C) degrees of setpoint.
Fluid temperature
variation while spraying
As given on control panel
or observed at spray gun Remove all hose from hose rack
No air pressure Insufficient flow at gun or
audible air leak
1. Inspect hose, open section near modem (on the
downstream side of the joint).
2. Inspect swivel fitting. Reconnect or tighten fitting as
required. A cut air hose can be spliced with a 1/4 inch barb
to barb fitting.
Hose insulation
separation
Exposed hose or notably
thin section inside wrap
Splice in replacement insulation with 2 inch wide black
electrical tape.
Cut hose wrap Evident tear
Close up with 2 or 3 inch wide black electrical tape. Wrap
as loosely as possible to not compress insulation or impede
power cables from moving freely inside the bundle.
Temp overshoots once
material starts spraying
As seen on HMI or
observed at spray gun
Check for condition of insulation upstream form each modem.
Lack of insulation will cause temp crossovers and inconsistent
temperature readings.
NOTICE
For other system-level issues and more in-depth troubleshooting, refer to proportioner manuals.
(IS30: 347492, IS40: 341162)
EN 09. MAINTENANCE
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09. MAINTENANCE
09.1 REGULAR MAINTENANCE
PROCEDURES AND RECOMMENDATIONS
Continuous use or lack of use of the system may both
lead to system malfunctioning. Please conduct regular
inspections to the system according to the frequency
table below.
09.2 STORAGE
To maximize the life of the material and hoses, please
store the unused equipment in spaces where the ambient
temperature is 60˚F and 100˚F (15 to 37˚C)
For storage, wrap hoses in a minimum of a 3ft (1m)
diameter to avoid tight bends that may damage the
equipment.
After completing a job, power down the system and allow
positive pressure to remain in the fluid lines to minimize
the chance of the A and B chemicals interacting with the
ambient environment.
Frequency Inspection
After every use Leak inspection in hose fittings and hose modules.
After every use Visual inspection of damage to each hose section (excessive bending, breaks or scratches on the
external hosing).
Weekly
If unit has not been used, bleed A side of system from gun manifold to remove any residual/
crystallizing Isocyanate from hose. Bleed until fluid appears normal. Doing so will eliminate
possibility of clogging hose due to Isocyanate crystallization. If in climate of high humidity, conduct
step more often.
Monthly
With system powered down, remove proportioner guard cover and visually inspect cable for any
connection issues. To minimize stress on pins, do not pull apart any electrical connectors if they
appear to be properly protected and there are no error codes.
Yearly Remove Modem boots and inspect modems for excessive wear, wire damage, and/or damaged/
cracked shell. Replace as necessary. If unit is used frequently, conduct step more often.
WARNING
Shut of all power and depressurize system before
servicing.
EN09. MAINTENANCE
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09.3 SPARE PARTS & REPAIR KITS
Part Number Description
340969 KIT MODEM JACKET
340970 KIT MODEM JACKET AND INSULATION
340971 6' 1/4 INSULATED WHIP
340972 3/8 20' SMART END WITH OPTICAL
340974 3/8 100' MASTER - 6 ZONE SYS
340976 3/8 150' MASTER - 6 ZONE SYS
340977 3/8 100' MID-Z5/6-6 ZONE SYS
340978 3/8 150' MID-Z5/6-6 ZONE SYS
341062 100FT AIR HOSE
341063 150FT AIR HOSE
341064 20FT AIR HOSE
341067 100FT BLACK SCUFF JACKET
341068 150FT BLACK SCUFF JACKET
341069 3/8IN 20FT SMART END A SEGMENT
341070 3/8IN 20FT SMART END B SEGMENT
341295 10' 1/4 INSULATED WHIP
341296 3/8 40' SMART END WITH OPTICAL
341556 40' AIR HOSE
341559 3/8 40' SMART END A SEGMENT
341570 3/8 40' SMART END B SEGMENT
347412 3/8 150' MASTER A SEGMENT
347413 3/8 150' MASTER B SEGMENT
347414 3/8 100' MASTER A SEGMENT
347415 3/8 100' MASTER B SEGMENT
347416 3/8 150' MID A SEGMENT
347417 3/8 150' MID B SEGMENT
347418 3/8 100' MID A SEGMENT
347419 3/8 100' MID B SEGMENT
347420 A HOSE CABLE 150FT - MASTER
347421 B HOSE CABLE 150FT - MASTER
347422 A HOSE CABLE 100FT - MASTER
347423 B HOSE CABLE 100FT - MASTER
347424 100' AIR HOSE - MID
347425 150' AIR HOSE - MID
EN 09. MAINTENANCE
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Part Number Description
347426 10' AIR HOSE
347427 6' AIR HOSE
347428 50' SCUFF JACKET
347431 HOSE CLAMP ASSEMBLY
347432 SUPPLY AB JUMPER HOSE KIT
347434 3/8 200' MASTER - 6 ZONE SYS
347439 3' 1/4 INSULATED WHIP
347515 MAXWRAP HD - 100FT
347516 MAXWRAP HD - 150FT
347517 MAXWRAP HD - 200FT
347518 MAXWRAP HD - 20FT
347520 MAXWRAP HD - 40FT
347522 MAXWRAP HD - 3FT
347523 MAXWRAP HD - 6FT
347524 MAXWRAP HD - 10FT
347526 CENTERING CLAMP ASSEMBLY
347527 3/8 200' MASTER A SEGMENT
347528 3/8 200' MASTER B SEGMENT
347534 A HOSE CABLE 200FT - MASTER
347535 B HOSE CABLE 200FT - MASTER
347536 HOSE POWER CONNECTOR KIT
347537 200' AIR HOSE - MASTER
347540 3' AIR HOSE
347547 A HOSE CABLE 150FT - MID
347548 B HOSE CABLE 150FT - MID
347549 A HOSE CABLE 100FT - MID
347550 B HOSE CABLE 100FT - MID
347556 CONNECTOR REPLACEMENT KIT - FULL HOSE (8 COUNT)
347557 INSULATION REPLACEMENT KIT
347559 HOSE POWER CABLE WYE KIT
347560 MASTER SEGMENT, 3/8 50'
347561 MASTER A SEGMENT, 3/8 50'
347562 MASTER B SEGMENT, 3/8 50'
347563 5/16 25' HIGHLY FLEXIBLE SMART END A
347564 5/16 25' HIGHLY FLEXIBLE SMART END B
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Part Number Description
347565 5/16 25' HIGHLY FLEXIBLE SMART END
347690 4' HIGHLY FLEXIBLE WHIP HOSE
347691 5/16 CLAMP ASSEMBLY
347692 50' MASTER AIR HOSE ASSEMBLY KIT
347693 CABLE ASSEMBLY, 50FT A - MASTER
347694 CABLE ASSEMBLY, 50FT B - MASTER
347695 25' AIR HOSE ASSEMBLY KIT
347696 25' SMART END INSULATION KIT
347698 TEAR RESISTANT HOSE INSULATION REPAIR KIT NEAR MODEMS
EN 09. MAINTENANCE
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09.4 HOSE SECTION REPLACEMENT
The following procedure is only needed in the case a
hose section needs to be replaced due to maintenance
procedures or damage.
Please refrain from disconnecting and reconnecting the
hose segments unless required.
Hose structure varies depending on the configuration
of the system and the process is different whether
connecting a Master, Mid or Smart End hose. Read the
following instructions thoroughly without skipping any step
to guarantee the system functions correctly.
Each hose section can be removed and replaced
independently. To do so, follow the next steps.
09.4.1 SINGLE HOSE SEGMENT: REMOVAL
1. Have the following items ready to use:
• Confirmed correct replacement hose section
• Hand tools, PPE
• Plastic sheeting and absorbent materials
• Caps and plugs as noted above in the
Installation section
2. Make sure the system is powered off and
depressurized.
3. Identify the hose segment you wish to replace.
4. Remove the hose wrap from the entire section,
remove modem jacket section and modem boot.
5. Take pictures of existing configuration for reference.
6. Remove any necessary clamps:
• For Master or Mid sections: use a 3mm Allen
wrench to remove the two bolts on each clamp
located on that hose section (one clamp on
Master, two clamps on Mid)
• For Smart End sections: Use a 3/16 allen
wrench to completely remove the white clamps.
7. Position plastic sheeting and paper towels to contain
dripping fluid.
8. Slowly crack open fittings to release any residual
pressure.
9. Disconnect the hose fittings on the furthest side of the
hose (next modem connection).
10. Plug and cap fittings when exposed to minimize
dripping. Be careful not to damage the temperature
probes (if present). Re-use probe covers to seal that
end.
11. Clean all residual/spilled chemical before proceeding.
12. Disconnect m8 cable between modem halves.
13. Separate modem halves by using a 5/16 Allen key to
remove modem bolts.
14. Remove the hose segment.
15. Follow safety precautions for handling chemicals as
given in material SDS.
09.4.2 SINGLE HOSE SEGMENT
REINSTALLATION
1. Position the new hose segment next to the other
material hose within the hose section.
2. Reconnect the fluid fittings and tighten using the
Flats Method (section 09.7) discussed further into the
maintenance section.
3. If any power cables have been disconnected, make
any necessary power cable connections. See section
09.9: Cable Termination.
4. Insert cables coming from modem into centering
clamp (Mid and Smart End modems only), and
tighten two bolts using 3mm Allen wrench. BE
CAREFUL NOT TO PINCH CABLES!
5. Reconnect M8 cable between modem halves - tape
over connection.
6. Install new insulation onto any bare hose.
7. Move new fluid through the entire hose section to
bleed out any air pockets immediately after assembly.
Check for leaks before covering fittings with wrap.
8. Follow the instructions in section 09.7 to reinstall the
hose wrap.
9. The final connections vary depending on what section
you are connecting. A diagram for each section is
included below.
WARNING
DO NOT REMOVE the temperature probe tips.
NOTICE
Do not route the fiber optic though the cable clamp
EN09. MAINTENANCE
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09.4.3 HOSE SECTION REMOVAL (TWO
SIDES)
If changing both sides of the hose (two people are
recommended for this operation), to prevent cross-
contamination:
1. Use plastic sheets to separate both sides.
2. Use separate gloves and wrenches for each side, or
thoroughly wash before contact with other material.
3. This would not require clamp removal and jacket
removal (length-wise)
4. Take pictures of existing configuration for reference.
Remove the jacket over modem, modem boot, air
hose connections, fluid connections, and power
connections for the hose segment.
5. Separate one side at a time and clean chemicals
between steps.
6. If easier to manage, remove necessary clamps to
splay hoses apart (keeping chemicals separate)
using 3/16 allen wrench (Smart Ends) or 3mm allen
wrench (Masters and Mids).
7. Have plugs and caps ready to plug hoses upon
removal.
8. If necessary to seal prior to scrapping, cut off
temperature probes on the hose section to be
removed to install plugs into modem.
9. Otherwise, a capped sheath is required to cover the
length of the temp probe.
10. Follow safety precautions of handling chemicals by
following material MSDS.
11. Refer to section 07.2 for instructions on reassembling
a hose section.
EN 09. MAINTENANCE
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09.5 HOSE CONNECTION DIAGRAM
The following diagram outlines the cable routing and
connection points for the Master to Mid hoses (6-
Zone configuration), Mid hose to Smart End (6-Zone
configuration), and the Master to Smart End (4-Zone
configuration).
1. Power cable slack
2. Power cable tension relief
3. Hose/Power cable clamp
4. Power cable splitter
Master Hose to Mid hose (6-Zone Configuration)
Mid hose to Smart End (6-Zone Configuration)
Master hose to Smart End (4-Zone Configuration)
3 5 6 3 2 7
1 1
2 4
5. Hose clamp
6. Air connection
7. Air hose slack
1 4 6 2 3 4 5
1 3 4 6 2 4 5
EN09. MAINTENANCE
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09.6 WRAPPING NEW HOSE SECTIONS
After completing the hose section replacement, wrap
the hose section at the fittings and modem. Hose jacket
should be re-installed around entire hose length with
coated side out. Make sure the Velcro along the hose
jacket is fully secured. If the jacket is excessively worn,
replace jacket section.
Cover boot with hose jacket section, making sure it
overlaps both jacket sections on distal and proximal hose
sections. Secure seams of jacket with 2 inch electrical
tape. Apply tape with light tension to allow inside cables
to move as freely as possible.
09.7 FLATS METHOD
To tighten the fittings using the Flats method:
• Hand tighten fittings, or tighten with wrenches until
resistance is felt.
• Mark starting position on the fitting with black
permanent marker to use as reference.
• Rotate each fitting to reach these final potions:
• A-side (JIC5): 1 to 1 1/8 hex flats past snug
(68° max)
• B-side (JIC6): 1 1/8 to 1 1/4 flats past snug
(75° max)
09.8 CLAMP LOCATION MAPPING
It is very important to place the clamps in the locations
specified in the diagram below. If clamps need to be
removed for maintenance, re-install according to the
diagram below. This protects electrical connections from
upstream and downstream cable tension caused by
pulling and bending the hose.
4 Zone Configuration
3 Zone Configuration
Master/Mid Hose Clamp
Smart End Clamp
Part Number 347526
Part Number 347691
(5/16 25' Smart End)
Part Number 347431
(Standard)
EN 09. MAINTENANCE
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09.9 CABLE TERMINATION
Use the following procedure for terminating the hose
heater power cables to the connectors.
1. Remove one side of the connector housing and nut
from the connector in need of termination.
2. Slide (1) connector nut, (1) sealing gasket, and (1)
housing onto cable that needs to be terminated as
shown:
3. Install conductors (with ferrules installed) into main
connector body, and tighten screws using screw
driver.
4. Screw connector housing to conductor body and
tighten until housing bottoms out.
5. Insert gasket into connector housing and tighten nut
over housing.
6. If necessary, repeat steps 1-5 for the other end of
connector.
7. Nest connector in hose bundle. Eliminate any tension
in the cable, and re-cover with hose wrap.
Nut Gasket
Housing
NOTICE
Install conductors completely into housing before
tightening.
One-1 (Black) Wire
(L Terminal)
Two-2 (Black) Wire
(N Terminal)
Green/Yellow Wire
(G Terminal)
NOTICE
Use image above for correct locations of each
conductor into connector body. DO NOT insert
conductors into the wrong location in the connector
body.
NOTICE
Nut should be tightened until nut bottoms out on
housing. Make sure gasket under connector nut grips
outer cable jacket. Make sure connectors match
(Ground wire, One-1 (Black), Two-2 (Black)) on both
ends of the same connector.
Match cables per side
NOTICE
Make sure A Cable (red heat shrink/tape) is connected
to A Cable (red heat shrink/tape), and B Cable (blue
heat shrink/tape) is connected to B Cable (blue heat
shrink/tape)
EN09. MAINTENANCE
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EN 10. MANUAL CHANGE SUMMARY
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MANUAL CHANGE SUMMARY
Date Description Version
02/17/2022 1st draft, initial release A
10/10/2022 2nd draft B
08/01/2023 3rd draft C
12/11/2024 Updated Format. D
04/14/2025 Updated manual to current Binks standard. Content and layout updates. E
09. MANUAL CHANGE SUMMARY
EN10. MANUAL CHANGE SUMMARY
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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.
www.binks.com 341164 REV E (05/2025) 39 / 39
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
10. WARRANTY
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.
03. EU DECLARATION OF CONFORMITY
04 SAFETY
04.1 SAFETY PRECAUTIONS
04.2 ADDITIONAL SAFETY INFORMATION
05. IMPORTANT ISOCYANATE INFORMATION
05.1 General HANDLING GUIDELINES
05.2 Material Self Ignition
05.3 KEEP COMPONENTS A & B SEPARATE
05.4 EXPOSURE TO MOISTURE
05.5 foam resins with 245 FA blowing agents
05.6 changing materials
05.7 electrical ground
06. INTRODUCTION
06.1 system overview
06.2 PRODUCT FEATURES
06.3 HOSE TERMINOLOGY
06.5 SYSTEM COMPONENTS
06.6 Hose layers
06.4 HOSE SPECIFICATIONS
06.8 Hose Set Configurations
07. INSTALLATION
07.1 proportioner to hose connection
07.2 HOSE-TO-HOSE CONNECTIONS
07.2.1 Master Hose to Mid Hose Connection
07.3 HOSE-TO-GUN CONNECTIONS
07.4 HOSE USAGE
07.5 Fiber optic cable LED indicators
08. TROUBLESHOOTING
09. maintenance
09.1 regular maintenance procedures and recommendations
09.2 storage
09.3 spare parts & repair kits
09.4 HOSE SECTION REPLACEMENT
09.4.1 Single Hose Segment: Removal
09.4.2 Single Hose Segment Reinstallation
09.4.3 Hose Section Removal (Two Sides)
09.5 hose connection diagram
09.6 Wrapping new hose sections
09.7 flats method
09.8 Clamp Location Mapping
09.9 cable termination
09. manual change summary
10. warranty
