Resource Library
Ransburg – MCV Series – Product Manual – CS-11-02.2
- Ransburg - MCV Series - Product Manual - CS-11-02.2 [ English ]
carefully read SAFETY PRECAUTIONS, starting on
page 1, and all instructions in this manual. Keep
this Service Manual for future reference.
MODEL: A12846-XX
PRODUCT MANUAL
CS-11-02.2
Inline/Piggable
Dual Modular Color Changer
Product Manual Price: $50.00
2
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
3
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
CONTENTS
Section 1: SAFETY 5-9
Safety Precautions
Hazards / Safeguards
Section 2: INTRODUCTION 10-15
General Description
Pre-Engineered Color Changer Assemblies
Color Changer Assembly Model Identification
Identification / Parts List
Section 3: INSTALLATION 16-17
Color Changer Installation Procedures
Section 4: OPERATION 18-20
Color Changer Schematics
Grounding of the Color Changers
Fluid Inlet and Outlet Fittings
Air Pilot Hose
Fluid Output Hose
Assembly with Purge Block
Assembly with No Purge Block
Section 5: MAINTENANCE 21-25
Micro-Valve and Valve Seat Replacement
Test and Checkout Procedure for Color Changer
Tools and Optional Equipment
Recommended Spare Parts
Section 6: WARRANTY POLICIES 26
Limited Warranty
4
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
5
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
Section 1: SAFETY
Before operating, maintaining or servicing any Binks coating system, read and understand all of the technical and safety
literature for your Binks products. This manual contains information that is important for you to know and understand.
This information relates to USER SAFETY and PRE-
VENTING EQUIPMENT PROBLEMS. To help you
recognize this information, we use the following sym-
bols:
CAUTION - states information that tells
how to prevent damage to equipment
or how to avoid a situation that might
cause minor injury.
WARNING - states information to alert
you to a situation that might cause se-
rious injury if instructions are not fol-
lowed.
While this manual lists standard specifications and service
procedures, some minor deviations may be found between
the literature and your equipment. Differences in local codes
and plant requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this manual with
your system installation drawings and appropriate Binks
equipment manuals to reconcile such differences.
Careful study and continued use of this manual will provide a
better understanding of the equipment and process, resulting
in more efficient operation, longer trouble-free service and
faster, easier troubleshooting. If you do not have the manu-
als and safety literature for your Binks system, contact your
local Binks representative or Binks.
WARNING
• The user MUST read and be familiar with the Safety Section in this manual and the Binks safety literature
therein identified.
• This manual MUST be read and thoroughly understood by ALL personnel who operate , clean or maintain
this equipment! Special care should be taken to ensure that the WARNINGS and safety requirements for
operating and servicing the equipment are followed. The user should be aware of and adhere to ALL local
building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD, 2009 EDITION, prior to
installing, operating, and/or servicing this equipment.
• The hazards shown on the following pages may occur during normal use of this equipment. Please read
the hazard chart beginning on page 6.
6
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
AREA HAZARD SAFEGUARDS
Spray Area Fire Hazard
Improper or inadequate operation and
maintenance procedures will cause a fire
hazard.
Protection against inadvertent arcing that is
capable of causing fire or explosion is lost if
any safety interlocks are disabled during
operation. Frequent power supply shut-
down indicates a problem in the system
requiring correction.
Follow These Guidelines
Fire extinguishing equipment must be present in the
spray area and test periodically.
Spray areas must be kept clean to prevent the accumu-
lation of combustible residues.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing or maintenance.
When using solvents for cleaning:
• Those used for equipment flushing should have
flash points equal to or higher than those of the
coating material.
• Those used for general cleaning must have flash
points above 1000F (37.80C).
Spray booth ventilation must be kept at the rates re-
quired by NFPA 33, 2009 Edition, OSHA and local
codes. Ventilation must be maintained during cleaning
operations using flammable or combustible solvents.
Electrostatic arcing must be prevented.
Non-factory replacement parts or unauthorized equip-
ment modifications may cause fire or injury.
If used, a key switch bypass is intended for use only
during setup operations. Production should never be
done with safety interlocks disabled.
Never use equipment for use in waterborne installa-
tions to spray solvent based materials.
7
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
AREA HAZARD SAFEGUARDS
Spray Area Explosion
Improper or inadequate operation and
maintenance procedures may cause an
explosion.
Protection against inadvertent arcing that is
capable of causing fire or explosion is lost if
any safety interlocks are disabled during
operation. Frequent power supply shut-
down indicates a problem in the system
requiring correction.
Follow These Guidelines
Electrostatic arcing MUST be prevented.
All electrical equipment must be located outside Class I
or II, Division 1 or 2 hazardous areas, in accordance
with NFPA 33, 2009 Edition.
Test only in areas free of flammable or combustible
materials.
The current overload sensitivity (if equipped) MUST be
set as described in corresponding section of the equip-
ment manual. Protection against inadvertent arcing
that is capable of causing fire or explosion is lost if the
current overload sensitivity is not properly set. Fre-
quent power shutdown indicates a problem with the
system which requires correction.
Always turn the control panel off prior to flushing, clean-
ing, or working on spray system equipment.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance with
NFPA 33, 2009 Edition.
Have fire extinguishing equipment readily available and
tested periodically.
Explosion - Incompatible Materials
Halogenated hydrocarbon solvents for ex-
ample: methylene chloride and 1,1,1,-
Trichloroethane are not chemically compati-
ble with the aluminum that might be used in
many system components. The chemical
reaction caused by these solvents reacting
with aluminum can become violent and lead
to an equipment explosion.
Spray Area Follow These Guidelines
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators, trig-
gering valves, etc. Halogenated hydrocarbon solvents
must never be used with aluminum equipment during
spraying, flushing, or cleaning. Read the label or data
sheet for the material you intend to spray. If in doubt
as to whether or not a coating or cleaning material is
compatible, contact your coating supplier. Any other
type of solvent may be used with aluminum equipment.
8
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
AREA HAZARD SAFEGUARDS
Spray Area / High Volt-
age Equipment
Electrical Discharge
There is a high voltage device that can in-
duce an electrical charge on ungrounded
objects which is capable of igniting coating
materials.
Inadequate grounding will cause a spark
hazard. A spark can ignite many coating
materials and cause a fire or explosion.
Follow These Guidelines
Parts being sprayed must be supported on conveyors
or hangers and be grounded. The resistance between
the part and ground must not exceed 1 mega ohm.
All electrically conductive objects in the spray area, with
the exception of those objects required by the process
to be at high voltage, must be grounded.
Any person working in the spray area must be ground-
ed.
Unless specifically approved for use in hazardous loca-
tions, the power supply and other electrical control
equipment must NOT be used in Class I, Division 1 or 2
locations.
Electrical Discharge
High voltage equipment is utilized. Arcing
in areas of flammable or combustible mate-
rials may occur. Personnel are exposed to
high voltage during operation and mainte-
nance.
Protection against inadvertent arcing that
may cause a fire or explosion is lost if safety
circuits are disabled during operation.
Frequent power supply shutdown indicates
a problem in the system which requires
correction.
An electrical arc can ignite coating materials
and cause a fire or explosion.
Electrical Equipment Follow These Guidelines
All electrical equipment must be located outside Class I
or II, Division 1 or 2 hazardous areas. Refer to NFPA
33, 2009 Edition.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of flammable or combustible
material.
Testing may require high voltage to be on, but only as
instructed.
Production should never be done with the safety cir-
cuits disabled.
Before turning the high voltage on, make sure no ob-
jects are within the sparking distance.
9
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
AREA HAZARD SAFEGUARDS
Robot Work Area Mechanical Hazard
Improper use or maintenance can lead to
hazardous conditions, particularly from un-
expected robot manipulator movement.
Follow These Guidelines
Applicator adjustments or maintenance should be done
after the robot is taken out of service. Do not adjust or
repair the applicator if the robot is operating or standing
ready to start.
Refer to robot operating instructions for the procedures
to take a robot out of service.
Follow all OSHA Lockout / Tagout procedures when
performing any maintenance.
Improper / Inadequate Training
Improper operation or maintenance may
create a hazard.
Personnel must be properly trained in the
use of this equipment.
All Areas Follow These Guidelines
Personnel must be given training in accordance with
the requirements of NFPA 33, 2009 Edition.
Instructions and safety precautions must understood
prior to using this equipment.
Comply with appropriate codes governing ventilation,
fire protection, operation maintenance, and housekeep-
ing. OSHA references are sections 1910.94 and
1910.107. Also refer to NFPA 33, 2009 Edition and
your insurance company requirements.
Toxic Substances Mechanical Hazard
Certain material may be harmful if inhaled,
or if there is contact with the skin.
Follow These Guidelines
Follow the requirements of the Material Safety Data
Sheet supplied by the coating manufacturer.
Adequate exhaust must be provided to keep the air free
of accumulations of toxic materials.
Use a mask or respirator whenever there is a chance of
inhaling sprayed materials. The mask must be compat-
ible with the material being sprayed and its concentra-
tion. Equipment must be as prescribed by an industrial
hygienist or safety expert, and be NIOSH approved.
10
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
Section 2: INTRODUCTION
The Inline / Piggable Dual Modular Color Changer assembly was designed for use with a pipe circulating system that
can also operate as a piggable fluid delivery systems. Made of stainless steel for corrosion resistance and built to stand
up under hard, continuous use. The PCC can be easily mounted and was designed for adaptability to the user’s needs.
SPECIFICATIONS - Environmental / Physical
Dual Valve Size: Single Valve (See Color Changer Schematics in the Operation section.)
Valve Block Assembly Weight: Dual Valve Assembly .45 lbs. (205 grams)
Assembly Weight with 3/4 Tube: Dual Valve Assembly 1.75 lbs. (793.8 Kg)
Purge Block Assembly Weight: .96 lbs. (435.4 grams)
Spacer Block Weight: .936 Block, .20 lbs. (91 grams)
.437 Block, .09 lbs. (41 grams)
Spacer Plate Weight: .936 Spacer Plate: .08 lbs. (36.2 grams)
.437 Spacer Plate: .04 lbs. (18.2 grams)
Operating Pressure: Fluid: 300 psi max. (20.68 bar)
Trigger Tube: 5/32 (4mm) OD
Micro-Valve Air Actuating Pressure: 75-120 psi (5.2-8.3 bar)
Average Flow Rate: 75 fl. oz./2200cc per min. @ 80 psi (50 centiposee) per side
Maximum Number of Colors: 20
Construction Materials:
Stainless Steel
UHMW
fluoropolymer elastomers
Acetal
11
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
PRE-ENGINEERED COLOR CHANGER ASSEMBLIES
The following is for Pre-Engineered Color Changer assemblies. Please reference selection chart for the changer as-
sembly number.
14
6 21
20
8
7
2
22
6
11
9 24 25 151 417 19
3
5
911
6
28
27
SHOWN WITH PURGE BLOCK ASSEMBLIES INSTALLED
12
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
COLOR CHANGER ASSEMBLY MODEL IDENTIFICATION
A12846-XX XX XX AS IDICATED IN TABLES A, B AND C
TABLE A- NUMBER OF COLOR BLOCKS
TABLE B- FLUID SUPPLY SIZE
TABLE C- PURGE BLOCK ASSEMBLY
When ordering, use A12846 - A, B, or C as indicated by Table A thru C. Four digits must follow the basic part number.
For example:
INLINE / PIGGABLE DUAL MODULAR COLOR CHANGER PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 Table A, Item Q Table B, Item E Pipe and Plate Assembly, Dual (Tabulated)
2 Table A, Item A A12739-00 Color Block (Piggable)
3 Table A, Item A 78949-00 Valve Assembly, Non-Repairable *****
4 Table A, Item A 79001-05 O-Ring, Solvent Proof *******
5 Table A, Item A 77367-00 Valve Seat Assembly ******
6 Table A, Item H 79001-06 O-Ring, Solvent Proof *******
7 Table A, Item A 79001-30 O-Ring, Solvent Proof *******
8 Table A, Item A 77516-04 Collet, 4mm
9 Table C, Item O A12847-00 Outlet/Inlet Block Assembly (Dual) **********
11 Table C, Item P A12853-00 Outlet/Inlet Block Assembly (Dual) **********
13 Table A, Item A A12727-00 Shut-off Valve Assembly
14 Table A, Item B Table B, Item J Spacer Block, 1.5
15 Table C, Item N 78079-00 Ftg. 7/16-20 X 3/8 NPS******** / ***********
17 Table B, Item F A12772-01 Screw, #10-24 X 1/2, Stainless, SHCS
19 Table A, Item B Table B, Item K Spacer Plate (Dual)
20 Table A, Item A A12766-02 Screw, SHCS, 5/16-18, SS
21 Table A, Item A A12766-01 Screw, SHCS, 5/16-18, SS
22 Table B, Item G A12744-XX Threaded Rod
24 8 77588-07 Lock Washer
25 8 A12765-00 Hex Nut, 5/16-18, SS
26 8 A12857-00 Washer, Flat 5/16 Special
27 Table C, Item M A12858-00 Purge Block Assembly, Left (Dual) *********
28 Table C, Item M A12827-00 Purge Block Assembly *********
29 1 A10766-00 Tool, Valve Seat Removal (Not Shown)
30 1 A10756-00 Tool, Valve Removal (Not Shown)
31 1 CS-11-02 Service Literature
*** When building option with one color, threaded rod length to be 5.03 long (2) pieces.
**** Each assembly requires 4 pieces each of threaded rod cut lengths, deburr ends of rod
and chase threads.
***** Torque to 15-20 lbs•in after valve is down.
****** Torque to 8-12 lbs•in.
******* Apply A11545-00 Petrolatum jell onto all o-rings before installation.
******** Torque to 30 lbs•ft.
********* When ordering this option, add 2.6 to length of G in Table B.
13
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
COLOR CHANGER ASSEMBLY MODEL IDENTIFICATION (Continued)
TABLE A - NUMBER OF COLOR BLOCKS
DASH NO. DESCRIPTION A QTY Q QTY B QTY H QTY
01 Number of Color Blocks 2 1 0 4
02 Number of Color Blocks 4 2 2 6
03 Number of Color Blocks 6 3 4 8
04 Number of Color Blocks 8 4 6 10
05 Number of Color Blocks 10 5 8 12
06 Number of Color Blocks 12 6 10 14
07 Number of Color Blocks 14 7 12 16
08 Number of Color Blocks 16 8 14 18
09 Number of Color Blocks 18 9 16 20
10 Number of Color Blocks 20 10 18 22
11 Number of Color Blocks 22 11 20 24
12 Number of Color Blocks 24 12 22 26
13 Number of Color Blocks 26 13 24 28
14 Number of Color Blocks 28 14 26 30
15 Number of Color Blocks 30 15 28 32
16 Number of Color Blocks 32 16 30 34
17 Number of Color Blocks 34 17 32 36
18 Number of Color Blocks 36 18 34 38
19 Number of Color Blocks 38 19 36 40
20 Number of Color Blocks 40 20 38 42
TABLE C
DASH NO. DESCRIPTION M N O P
00 None 1 2 2 2
01 Purge Block Assembly ********** 0 1 1 1
TABLE B - FLUID SUPPLY SIZE
DASH NO. DESCRIPTION E F QTY J K G LENGTH OF THREADED ROD
01 1/2 Standard A12845-01 0 -- -- 1.91 + (2.12 X Number of Colors) Pipe
Assemblies will be on 2/16 Centers ****
02 3/4 Standard A12845-02 0 -- -- 1.91 + (2.12 X Number of Colors) Pipe
Assemblies will be on 2 1/16 Centers
03 1 Standard A12845-03 4 A12742-00 A12856-00 1.91 + (3.06 X Number of Colors) Pipe
Assemblies will be on 3 Centers ***
04 1 1/2 Standard A12845-04 4 A1242-00 A12856-00 1.91 + (3.06 X Number of Colors) Pipe
Assemblies will be on 3 Centers ***
05 1/2 Standard A12845-01 4 A12861-00 A12883-00 1.91 + (2.48 X Number of Colors) Pipe
Assemblies will be on 2 1/2 Centers
06 3/4 Standard A12845-02 4 A12861-00 A12833-00 1.91 + (3.06 X Number of Colors) Pipe
Assemblies will be on 2 1/2 Centers
INSTALL 78077-00 CHECK
VALVES ON INCOMING AIR
AND SOLVENT LINES TO
PURGE BLOCK ASSEMBLY.
14
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
COLOR CHANGER ASSEMBLY MODEL IDENTIFICATION (Continued)
A12827-00 PURGE BLOCK ASSEMBLY (RIGHT SIDE)
4
5
7
9
8
10
10
1
3
2
6
TORQUE TO 15-20 LBS/IN AFTER VALVE IS DOWN
TORQUE TO 15-20 LBS/IN
1
2
DESCRIPTIONPART NUMBERQTYITEM
PURGE BLOCKA12754-0011
VALVE SEAT ASSEMBLY77367-0022
VALVE ASSEMBLY78949-0023
SHUTOFF VALVE ASSEMBLYA12727-0024
O-RING, SOLVENT PROOF79001-3025
COLLET, 4 MM77516-0426
O-RING, SOLVENT PROOF79001-0627
PURGE BLOCK END PLATE ASEMBLYA12829-0018
FTG, 7/16-20 X 3/8 NPS78079-0029
CHECK VALVE, 3/8 NPS (F) x 3/8 NPS (M)78077-00210
A12827-00 PURGE BLOCK ASSEMBLY
1
2
3
TORQUE TO 30 LBS/FT
APPLY A11545-00 PETROLATUM JELL TO
ALL
O-RINGS PRIOR TO INSTALLATION
3
4.
15
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
COLOR CHANGER ASSEMBLY MODEL IDENTIFICATION (Continued)
A12858-00 PURGE BLOCK ASSEMBLY (LEFT SIDE)
7 5
6
8
10
9
11
3 4
12
1
2
3
A12858-00 PURGE BLOCK ASSEMBLY, LEFT (DUAL)
DESCRIPTIONPART NUMBERQTYITEM
VALVE ASSEMBLY (NON-REPAIRABLE)78949-0023
VALVE SEAT ASSEMBLY77367-0024
INLET BLOCK ASSEMBLY, LEFT (DUAL),
PURGE BLOCK
A12849-0015
O-RING, SOLVENT PROOF79001-0626
FTG 7/16-20 X 3/8 NPS78079-0027
SHUTOFF VALVE ASSEMBLYA12727-0028
O-RING, SOLVENT PROOF79001-3029
COLLET, 4 MM77516-04210
PURGE BLOCK, LEFT (DUAL)A12855-00111
CHECK VALVE, 3/8 NPS (F) x 3/8 NPS (M)78077-00212
TORQUE TO 15-20 LBS/IN AFTER VALVE IS DOWN
TORQUE TO 15-20 LBS/IN
1
2
TORQUE TO 30 LBS/FT
APPLY A11545-00 PETROLATUM JELL TO
ALL
O-RINGS PRIOR TO INSTALLATION
3
4.
16
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
This information is intended ONLY to indicate the general installation parameters of this product and, where applicable,
its working relationship to other Binks system components in typical use.
Each installation is unique and should be directed by an authorized Binks representative or conducted using the Binks
installation drawings provided for your particular installation.
COLOR CHANGER INSTALLATION PROCEDURES
Determine Location for Color Changer
The color changer should be located as close as possible to the spray device in order to save paint and solvent. If possible, use an
enclosure to protect the color changer from airborne paints and solvents.
Calculate Footprint of Color Changer (See Mounting Single Valve Color Changer Figure)
To calculate the footprint of the color changer add:
1. The dimension of the purge assembly (if used).
2. The dimension(s) of the color block(s) used to create the desired number of color valves.
3. The dimension of the inlet/outlet block.
Dimension of Purge Assembly: 2.60 (66.04mm)
Dimension of Color Block Assembly: 2.064 (52.43mm)
Dimension of Spacer Block: .936 (23.77mm)
Dimension of Inlet or Outlet Block: .655(16.64mm)
Example of 1/2 and 3/4 Pipe Assembly with 2 Color Blocks:
Inlet Block .655 .655+ .655+ 2.064+ 2.064 = 5.438(138.13mm)
Outlet Block .655
#1 Color Block 2.064
#2 Color Block 2.064
Section 3: INSTALLATION
TYP.
.655 [16.64]
2.064 [52.42]
3.13 [79.48]
2.064 [52.43]
EXAMPLE OF A 2 COLOR UNIT WITH PURGE BLOCK ATTACHED FOR A
COMBINATION INCLUDING 1/2 AND 3/4 PIPE SIZE (NO SPACER REQUIRED)
17
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
Example of 1and 1 1/2 Pipe Assembly with 2 Color Blocks:
Inlet Block .655 (16.64mm) .655+ .655+ 2.064+ 2.064 + .936= 6.374(161.90mm)
Outlet Block .655 (16.64mm)
#1 Color Block 2.064
#2 Color Block 2.064
Spacer Block .936
(NOTE: If adding Purge Block Assembly, only Outlet Block required.)
Purge Block Assembly 3.13 (79.502mm) 3.13 + 2.064 + 2.064 + .53 = 7.788 (197.82mm)
#1 Color Block 2.064
#2 Color Block 2.064
Outlet Block .53
3 [75]
RETRO FIT APPLICATION FROM EXISTING BINK PCC
MODEL 78428-XX FOR 1 AND LARGER PIPE ASSEMBLIES
RETRO-FIT FROM EXISTING BINKS PCC TO NEW BINKS COLOR CHANGER (1 AND 1 1/2 PIPE SIZE ONLY)
EXAMPLE OF A 2 COLOR UNIT FOR A COMBINATION
INCLUDING A 1 1/2 PIPE SIZE
SPACER REQUIRED
3 [75]
X
6.34 +/- 1/16
[161.04 +/- 1.57]
3/4 PIPE = 2.663 [67.64]
1 PIPE = 2.788 [70.82]
1 1/2 PIPE = 3.038 [77.07]
1/2 PIPE = 2.538 [64.47]
X
4.71 [119.63]
COLOR CHANGER INSTALLATION PROCEDURES (Continued)
TYP.
.655 [16.64]
2.064 [52.42]
3.13 [79.48]
2.064 [52.43]
EXAMPLE OF A 2 COLOR UNIT WITH PURGE BLOCK ATTACHED FOR A
COMBINATION INCLUDING 1/2 AND 3/4 PIPE SIZE (NO SPACER REQUIRED)
18
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
Section 3: OPERATION
This information is intended ONLY to indicate the general installation parameters of this product and, where applicable,
its working relationship to other Binks system components in typical use.
Each installation is unique and should be directed by an authorized Binks representative or conducted using the Binks
installation drawings provided for your particular installation.
The assembly consists of modules attached to each other. Modules may be added or removed from the assembly as desired. If, for
instance, the number of required materials increases, the assembly can be expanded by adding additional modules. Each module can
also be individually serviced. The Dual Modular Color Changer is recommended for use with waterborne or solventborne paints.
19
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
GROUNDING OF THE COLOR CHANGERS
For safety, the color changer MUST be grounded. Using a 12-gauge wire, ground the output plate of the color changer to a true earth
ground. Using an ohm meter, check for ground, testing the earth ground to the purge assembly top plate. The resistance should be 10
ohms or less.
OPERATION (Continued)
FLUID INLET AND OUTLET FITTINGS
The in and out of the pipe assemblies have standard sanitary fittings.
• The color changer MUST be properly grounded. Proper grounding (as described below) will prevent static
charge build-up and possible discharge from the color changer.
WARNING
NOTE - IN and OUT hoses CAN be reversed on the color changer.
AIR PILOT HOSE
Each color changer valve requires a 5/32(4mm) pilot hose to activate the color valve.
FLUID OUTPUT HOSE
The fluid output hose of the color changer has a 3/8NPS (M) fitting. For safety and solvent savings, it is recommended that a PFA
type fluoroethylene hose be used between the color changer and the spray device.
OHMS
10 0
GROUND WIRE
20
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
OPERATION (Continued)
MICROVALVE WEEP HOLE
SPACER BLOCK
COLOR 1
COLOR 2
FLO
W
O
F PAIN
T
OUTLET OF COLOR BLOCK
3/8 NPSM THREADS
OUTLET BLOCK
COLOR BLOCK (REF.)
1 1/2 PIPE ASSEMBLY WITH COLOR BLOCK (REF.)
SANITARY FITTINGS ENDS
TYPICAL BOTH ENDS
SOLVENT/AIR INLET FROM REMOTE PURGE BLOCK
3/8 NPSM THREADS (CHECK VALVE FITTING RECOMMENDED)
SOLVENT/AIR INLET FROM REMOTE PURGE BLOCK
3/8 NPSM THREADS (CHECK VALVE FITTING RECOMMENDED)
INLET BLOCK
ASSEMBLY WITH NO PURGE BLOCK ATTACHED
OUTLET OF COLOR BLOCK
3/8 NPSM THREADS
FLO
W
O
F PAIN
T 1 1/2 PIPE ASSEMBLY WITH COLOR BLOCK (REF.)
SPACER BLOCK
COLOR 2
FLO
W
O
F PAIN
T
COLOR VALVE PILOT
5/32 [4MM] TUBING
PAINT SHUTOFF VALVE
COLOR BLOCK (REF.)
1 1/2 PIPE ASSEMBLY WITH COLOR BLOCK (REF.)
NOTE - Microvalve Weep Holes
These holes will give an indication of fluid valve failure. In the event of the fluid seal failure, paint or solvent will be seen coming out of
this hole. In the event that the air seal for the piston falls, air will be heard or felt coming from this hole.
SPACER BLOCK
SPACER BLOCK
COLOR 1
COLOR 2
COLOR 3
OUTLET OF COLOR BLOCK
3/8 NPSM THREADS
PAINT SHUTOFF VALVE
COLOR VALVE PILOT
5/32 (4MM) TUBING
CHECK VALVES
3/8 NPSM THREADS
AIR INLET FOR PURGE BLOCK
SOLVENT INLET FOR PURGE BLOCK
AIR INLET FOR PURGE BLOCK SOLVENT INLET FOR PURGE BLOCK
PURGE BLOCK ASSEMBLY
MICROVALVE WEEP HOLE
ASSEMBLY WITH PURGE BLOCK ATTACHED
21
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
Section 4: MAINTENANCE
CAUTION
• Before attempting to remove BOTH the Microvalve Assembly (78949-00) and the Valve Seat Assembly
(77367-00), first turn the Shut-Off Valve (A12727-00) counter-clockwise to its open position. Then relieve
and flush the main inlet circulating paint line.
NOTE—If ONLY the Microvalve Assembly (78949-00) is to be removed or replaced, turn the Shut-Off Valve (A12727-00) clock-
wise to it’s closed position. Then relieve and flush the microvalve or downstream side of the color changer.
1. Microvalve Assembly (78949-00) - Using the valve
removal tool (A10756-00 or A11922-00), engage the
four (4) pins of the tool into the four (4) pin holes of
the valve assembly. Turn the assembly counter-
clockwise until removed).
2. Valve Seat Assembly (77367-00) - If required to
remove the valve seat assembly, use the valve seat
removal tool (A10766-00) turning the valve seat
counter-clockwise until removed. Clean and inspect
the valve body and o-rings for defects, replace if nec-
essary.
3. Seat and Microvalve Installation—If valve seat was re-
moved, lightly lubricate the o-ring on the seat assembly with
petroleum jelly. Install valve seat and tighten to 15-20 lbs•in
(1.7-2.3 Nm) of torque. Lightly lubricate the o-rings on the
microvalve assembly. Install the valve and tighten to 15-20
lbs•in (1.7-2.3 Nm) of torque after valve is down.
22
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
TEST AND CHECK OUT PROCEDURE FOR COLOR
CHANGER
Step 1: Test Setup
A. Connect a main air line to the regulator #4.
B. Attach the output of #4 to a push button, manually operat-
ed pneumatic On/Off valve #5 and #3, two-way manual
ball valve. Attach a 5/32 hose from the output of #5 to
pilot connection for the color valve.
C. Attach the output of #3 the sanitary fitting input of the
valve. Plug the opposite sanitary fitting of valve.
D. Attach pipe tee, gage, #2 and two-way ball valve assem-
bly #1 to the output of the color changer. Plug off other
side.
Step 2: Testing Color Valve Assembly
A. Set output pressure of regulator #4 to 90-100 psi.
NOTE—Turn the shutoff valve #6 counter-clockwise to the
OPEN position.
B. With ball valves #1 and #3 in the Off position, push and
release the button on the pneumatic valve #5, triggering
the microvalve assembly (78949-00) On and Off.
C. Visually inspect the movement of the valve and check for
air leaks from the weep hole on the color valve body. If
air is leaking, repair or replace valve assembly (78949-
00). Check for leaks between the pipe/plate assembly
and color valve block. Tighten screws or replace o-ring if
necessary.
D. With ball valves #1 and #3 in the On (open) position, push
and release the button on the pneumatic valve #5 trigger-
ing the microvalve assembly (78949-00) On and Off.
Check for a crisp and sharp actuation of air flow through
the output of the #1 ball valve. If valve is sluggish, repair
or replace valve assembly (78949-00).
TEST AND CHECK OUT PROCEDURE FOR COLOR CHANGER (Continued)
• NEVER wrap the equipment in plastic to keep it clean. A surface charge may build-up on the plastic
surface and discharge to the nearest grounded object. Efficiency of the equipment will also be re-
duced and damage or failure of the equipment’s components may occur. WRAPPING THE EQUP-
MENT in plastic will void warranty.
WARNING
Step 3: Testing Valve Body Leak Test
A. With ball valve #3 in the On (open) position and valve #1
In the Off position, push and release the button on the
pneumatic valve #5 triggering the microvalve assembly
(78949-00) On and Off several times.
B. Check the pressure gage reading on the #2 assembly.
This should be within 5 psi of the pressure of the set pres-
sure on regulator #4. The pressure should remain until
the valve #1 is returned to the open position. If the pres-
sure does not remain, check all fittings, hardware, and o-
rings on the valve body and plate assembly.
Step 4: Testing Microvalve and Valve Seat Assemblies
A. With ball valve #1 in the On position, and valve #3 in the
On position, push and release the button on the pneumat-
ic valve #5 triggering the microvalve assembly (78949-
00) On and Off several times.
B. Close the 2-way ball valve on the #1 assembly. The
pressure should remain 0 psi.
If the pressure is greater than 0 psi, the valve seat assembly
(77367-00) should be replaced.
A11922-00
TOOL, VALVE REMOVAL
78949-00
VALVE ASSEMBLY
23
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
TEST AND CHECK OUT PROCEDURE FOR COLOR CHANGER (Continued)
NOTE - Microvalve Wee Holes
These holes will give an indication of fluid valve failure. In the event of the fluid seal failure, paint or solvent will be seen coming out of
this hole. In the event that the air seal for the piston fails, air will be heard or felt coming from this hole.
Valve Testing Assembly
24
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
TOOLS AND OPTIONAL EQUIPMENT (Continued)
TOOLS AND OPTIONAL EQUIPMENT
78949-00 VALVE ASSEMBLY / 77367-00 SEAT ASSEMBLY
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION
1 79001-01 O-Ring (Solventproof)
2 79001-02 O-Ring (Solventproof)
3 79001-04 O-Ring (Solventproof)
77620-00 VALVE PLUG KIT
ITEM
PART
NUMBER DESCRIPTION
1 79244-00 Plug
2 79001-19 O-Ring (Solventproof)
3 79001-14 O-Ring (Solventproof)
4 77618-00 Plug Seat
79001-16
0-RING
A12727-00
PAINT SHUTOFF ASSEMBLY
25
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
RECOMMENDED SPARE PARTS
RECOMMENDED SPARE PARTS
PART NUMBER DESCRIPTION QTY
A12727-00 Shut-off Valve Assembly 4
78949-00 Valve Assembly 2
77367-00 Valve Seat Assembly 2
77516-04 Collet, 4mm 2-4
78077-00 Check Valve 3/8 NPSF to 3/8 NPSM Swivel 1-2
Changes Made
Changes made to CS-11-02.2 Service Manual:
• Page 11 Revised bottom drawing to show check valves 78077-00.
• Page 13 Added Note.
• Page 14 Revised drawing to show check valves 78077-00 item 10
• Page 15 Revised drawing to show check valves 78077-00 item 10
• Page 16 Revised drawing to show check valves 78077-00.
• Page 17 Revised upper left drawing to show check valves 78077-00
• Page 18 Revised schematics to show check valves.
• Page 20 Revised upper drawing to show check valves 78077-00.
• Page 25 Added check valves to Recommended Spare Parts, also added Changes Made.
26
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
WARRANTY POLICIES
LIMITED WARRANTY
Binks will replace of repair without charge any part/or equipment that fails within the specified time (see below) because
of faulty workmanship or material, provided that the equipment has been used and maintained in accordance with Binks
written safety and operating instructions, and has been used under normal operating conditions. Normal wear items are
excluded.
THE USE OF OTHER THAN BINKS APPROVED PARTS VOIDS ALL WARRANTIES.
SPARE PARTS: One hundred and eighty (180) days from date of purchase, except for rebuilt parts (any part number
ending in R) for which the warranty period is ninety (90) days.
EQUIPMENT: When purchased as a complete unit, is one (1) year from date of purchase.
WRAPPING THE APPLICATOR IN PLASTIC WILL VOID THIS WARRANTY.
BINKS ' ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE
OF FAULTY WORKMANSHIP OR MATERIALS. THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF
EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. BINKS ASSUMES NO LIABILITY
FOR INJURY, DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR
PRODUCTION OR INCOME, WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR
OTHERS.
EXCLUSIONS:
If, in BINKS opinion the warranty item in question, or other items damaged by this part was improperly installed, operat-
ed or maintained, Binks will assume NO responsibility for repair or replacement of the item or items. The purchaser,
therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable.
27
CS-11-02.2: Inline / Piggable Dual Modular Color Changer
Product Manual Price: $50.00 (U.S.)
Manufacturing
1910 North Wayne Street
Angola, Indiana 46703-9100
Telephone: 260-665-8800
Fax: 260-665-8516
Technical Service - Assistance
320 Phillips Ave.
Toledo, Ohio 43612-1493
Telephone (toll free): 800-233-3366
Telephone: 419-470-2021
Fax: 419-470-2040
Technical Support Representatives can direct you to the appropriate telephone number for ordering spare parts.
© 2013 Binks. All rights reserved.
Models and specifications subject to change without notice.
Form No. CS-11-02.1
Litho in U.S.A.
02/13
