Binks E4-60 User manual

EN

• 107073 (USA Model)

• 107072 (Japan Model)

• 107070 (EU Model)

Service Manual

E4-60

Electric Drive Pump

77-3229 R4.1 www.carlisleft.com

EN

Suitable for use in hazardous area:

Zone 1

Protection Level:

II 2 G X IIB T4 (Pump)

II 2 G Exd/Exde IIB T4 IP55 (Motor) CE0722

II 2 GD ck T4 (Gearbox)

The object of the declaration described above is in conformity with the relevant Union

harmonisation legislation:

Machinery Directive 2006/42/EC

ATEX Directive 2014/34/EU

EMC Directive 2014/30/EU

by complying with the following statutory documents and harmonized standards:

EN ISO 12100:2010 Safety of Machinery - General Principles for Design

EN 12621:+A1:2010 Machinery for the supply and circulation of coating materials under pressure - Safety

requirements

EN 1127-1:2011 Explosive atmospheres - Explosion prevention - Basic concepts

EN 13463-1:2009 Non electrical equipment for use in potentially explosive atmospheres - Basic methods and

requirements

EN 13463-5:2011 Non electrical equipment for use in potentially explosive atmospheres - Protection by

constructional safety "c"

EN 13463-8:2003 Non-electrical equipment for potentially explosive atmospheres. Protection by liquid immersion

'k'

EN 60079-0:+A11:2013 Explosive atmospheres - Equipment. General requirements

EN 60079-1:2014 Explosive atmospheres - Equipment protection by flameproof enclosures "d"

EN 60079-7:2015 Explosive atmospheres. Equipment protection by increased safety "e"

EN 60034-1: 2010 Rotating electrical machines

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.

This Declaration of conformity / incorporation

is issued under the sole responsibility of the

manufacturer:

Carlisle Fluid Technologies UK Ltd,

Ringwood Road,

Bournemouth, BH11 9LH. UK

EU Declaration of Conformity

Notified body details and role:

Element Materials Technology (0891)

Lodging of Technical file

Product Description / Object of Declaration:

Electric Pump E2, E4

This Product is designed for use with:

Solvent and Water based materials

Signed for and on behalf of Carlisle Fluid

Technologies UK Ltd:

D Smith

Director of Sales (EMEA)

20/10/17

Bournemouth,BH11 9LH,UK

77-3229 R4.1 2/36 www.carlisleft.com

EN

In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as

follows:

WARNING

CAUTION

NOTE

Hazards or unsafe practices which could result in

severe personal injury, death or substantial property

damage.

Hazards or unsafe practices which could result in

minor personal injury, product or property

damage

Important installation, operation or maintenance

information.

INSPECT THE EQUIPMENT DAILY. Inspect the equipment for worn or

broken parts on a daily basis. Do not operate the equipment if you

are uncertain about its condition.

OPERATOR TRAINING. All personnel

must be trained before operating

finishing equipment.

NOISE LEVELS. The A-weighted sound level of pumping and spray

equipment may exceed 85 dB(A) depending on equipment settings.

Actual noise levels are available on request. It is recommended that

ear protection is worn at all times while equipment is in use.

PRESSURE RELIEF PROCEDURE.

Always follow the pressure relief

procedure in the equipment instruction

manual.

WARNING

Read the following warnings before using this equipment.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE

OPERATOR OF THE EQUIPMENT.

HIGH PRESSURE CONSIDERATION. High pressure can cause serious

injury. Relieve all pressure before servicing. Spray from the gun,

hose leaks or ruptured components can inject fluid into your body

and cause extremely serious injury.

KEEP EQUIPMENT GUARDS IN PLACE.

Do not operate the equipment if the

safety devices have been removed.

STATIC CHARGE. Fluid may develop a static charge that must be

dissipated through proper grounding of the equipment, objects to be

sprayed and alll other electrically conductive objects in the dispensing

area. Improper grounding or sparks can cause a hazardous condition

and result in fire, explosion or elecrtic shock and other serious injury.

NEVER MODIFY THE EQUIPMENT. Do

not modify the equipment unless the

manufacturer provides written

approval.

PROP 65 WARNING. WARNING: This product contains chemicals

known to the state of California to cause cancer and birth defects or

other reproductive harm.

EQUIPMENT MISUSE HAZARD. Equipment misuse can cause the

equipment to rupture, malfunction or start unexpectedly and result in

serious injury.

PACEMAKER WARNING. You are in the

presence of magnetic fields which may

interfere with the operation of certain

pacemakers.

PINCH POINT HAZARD. Moving parts

can crush and cut. Pinch points are

any areas where ther are moving

parts.

READ THE MANUAL. Before operating finishing equipment, read and

understand all safety, operation and maintenance information

provided in the operation manual.

AUTOMATIC EQUIPMENT. Automatic

equipment may start suddenly without

warning.

WEAR SAFETY GLASSES. Failure to wear safety glasses with side

shields could result in serious eye injury or blindness.

PROJECTILE HAZARD. You may be

injured by venting liquids or gases that

are released under pressure, or flying

debris.

DE-ENERGIZE, DE-PRESSURISE, DISCONNECT AND LOCK OUT ALL

POWER SOURCES DURING MAINTENANCE. Failure to de-energize,

disconnect and lock out all power supplies before performing

equipment maintenance could cause serious injury or death.

KNOW WHERE AND HOW TO SHUT

OFF THE EQUIPMENT IN CASE OF AN

EMERGENCY.

77-3229 R4.1 3/36 www.carlisleft.com

2'' Sanitary

SHC 630 Synthetic Oil

* Pressure when used in 'Smart Mode' (Closed Loop Pressure Mode)

Class 1, Group D.

Total Weight of Pump (inc electric motor)

Max. Inlet Pressure

e.g. E4-60 Maximum Set Pressure of 18 bar to operate Pump on a 24/7 basis

NOTE

E4-60

Nominal flow volume / cycle:

1.50 l/m [0.40 US gal/m]

EN

SPECIFICATION

20 bar [290psi]

Gearbox Oil (EU Model)

Synthetic 220 (typically Agip Blasia S)

Gearbox Oil (USA Model)

Rated 20 to 80 Hz (c/w thermisters)

Gearbox Ratio:

56:1

355kg [737lbs]

3.0 kW 4Pole 1400 RPM

EEx d 11B T3

15 l/m [4.0 US gal/m]

Fluid Output @ 80 HZ [40 cycles/min]

Fluid Output @ 20 HZ [10 cycles/min]

60 l/m [16.0 US gal/m]

2 bar [29 psi]

Reduce Maximum working pressure by 2 bar [29 psi] when using in Open Loop Flow Mode

460V 3PH 1 Hp @ 60HZ

Maximum fluid pressure:

E4-60*

Nominal pump stroke:

50mm [1.97 ins]

AC Induction Electric Motor- EU Model

400V 3PH 3.0 kW @ 50HZ

3.0 kW 4Pole 1400 RPM - Japan Model

Rated 20 to 80 Hz (c/w thermisters)

AC Induction Electric Motor - USA Model

Fluid inlet connection:

Fluid outlet connection:

'A'

'B'

77-3229 R4.1 4/36 www.carlisleft.com

EN

Head screw for pump earth grounding;

the Pump Frame must be wired to a suitable earth

ground to ensure that there is no possibility of static

build up.

DIMENSIONS AND MOUNTING DETAILS

M6 HEX.

B

A

77-3229 R4.1 5/36 www.carlisleft.com

EN

An adapter to mount a pressure switch and pressure sensor is available, see accessories.

It is recommended that the switch setting is set to 1 bar [14.5 psi] above the maximum required pressure.

The maximum pressure setting the Pressure Switch should be set to is 20 bar [305 psi] and 17 bar [246 psi]

respectively.

The main Pump Control Panel must be positioned within an Electrically Safe Area.

A Pressure switch (and/or Pressure relief valve) must be connected to the outlet manifold port and set to stop the

pump (or relieve the fluid pressure) in the event of the system overpressure

The Pressure Switch is classified as simple apparatus and as such should be electrically connected as part of an

intrinsically safe electrical circuit.

INSTALLATION

The Pump Units are designed for location in Zone 1 Hazardous areas, ATEX Category 2.

Electrical connections must be in accordance with Local Regulations for installation in Hazardous Areas.

The Pressure Switch should be wired as a Normally Closed contact (fail safe) and be hard wired to stop the motor

on operation, to minimise response time.

It is recommended that a Local Control Box is positioned in close proximity to the pump, as a convenient local

Start / Stop facility and Junction box.

e.g. blocked paint filter, otherwise Pump warranty may be invalidated.

This is necessary to protect the Pump mechanics from overload.

77-3229 R4.1 6/36 www.carlisleft.com

EN

5 Seconds

0.1 Seconds

Inverter

Required Inverter Settings

6.7 A

Rated Motor Power Factor

0.81

Rated Motor Efficiency

80%

Electric Motor

Rated Motor Frequency

50 Hz

Value

Maximum Hz Output

Once operating temperature is reached, this device quickly changes the resistance;

The motor must be wired to provide a clockwise direction of the cam.

Electric Motors for hazardous areas are specially designed to comply with official regulations concerning the risk

of explosion.

Rated Motor Current

If improperly used, badly connected, or altered no matter how minor, their reliability could be in doubt.

it must be connected to a suitable releasing device mounted within the control panel and wired to stop the motor

if an over temperature occurs.

Rated Motor Voltage

INSTALLATION

400 V

Rated Motor Speed

1440 RPM

80 Hz

Mininmum Hz Output

20 Hz

Acceleration Ramp

Deceleration Ramp

Rated Motor Power

3.0 kW

Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into

consideration.

Only trained personnel familiar with these standards should handle this type of apparatus.

The motor is fitted with PTC temperature sensors (Thermistors).

77-3229 R4.1 7/36 www.carlisleft.com

EN



Suction - Ø50 I.D. [-1 to 10 bar working pressure]

Outlet - Ø38 - 50 I.D. [20 bar working pressure]

Attach suitable flexible hoses to the inlet and outlet connections.

Ensure the gearbox is filled with oil.

INSTALLATION

e.g.,

Ensure adequate air space around the Pump for maintenance and electric motor cooling requirements.

Check that the oil plug on top of Gearbox has been replaced with the correct venting plug.

The vent plug is supplied in a bag attached to the gearbox.

(The gearbox is filled with the correct amount of oil at the factory)

77-3229 R4.1 8/36 www.carlisleft.com

EN



The return line ‘back pressure’ regulator responds to the changes in system fluid flow demand, (due to variable

paint usage) by dynamically adjusting the paint flow rate returning to the system paint tank, thus maintaining the

set pressure.

Before starting:-

All required interlocks are tested and operational.

Suitable material for pumping is available at the suction hose.

Check the gearbox oil level, please note the the gearbox is supplied with life lubricant and does not need

any maintenance.

SYSTEM OPERATION

Inspect for any system leaks.

Set the pump cycle rate to achieve the required paint volume and then adjust the system back pressure regulator

to achieve the desired system fluid pressure.

Smart Mode:

The outlet connection is not blocked or isolated by any valves.

Ensure all electrical and mechanical connections are correctly made.

Set the pump speed to the minimum frequency 20 Hz and start the pump to remove any air from the circuit.

77-3229 R4.1 9/36 www.carlisleft.com

EN

E4-60 MECHANICAL ASSY

H083 ATEX GEARBOX

H083 GEARBOX

M12 x 40 HEX HEAD CAP SCREW

M12 WASHER

M12 SPRING WASHER (ST ST)

192918

3

4

164469

4

192684

8

FLUID SECTION

7

2

194251

4

3.0KW ELECTRIC MOTOR

(Not Shown)

2

194545

JAPAN MODEL

1

192819

2

3.0KW ELECTRIC MOTOR

USA MODEL

1

192685

3

DESCRIPTION

PARTS LIST

-

1

(Not Shown)

1

193711

PART NUMBER

Pump Assembly

ITEM

1

6

EU MODEL

(Not Shown)

3.0KW ATEX MOTOR

1

JAPAN MODEL

1

192686

2

192687

USA MODEL

EU MODEL

REMARKS

2

1

QTY

4

164470

(Not Shown)

5

165137

COVER C/W CAP FIXINGS

1

MANIFOLD & PRV ASSEMBLY

194942

9

77-3229 R4.1 10/36 www.carlisleft.com

EN

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

77-3229 R4.1 11/36 www.carlisleft.com

EN

PARTS LIST - PRV and Manifold Assembly

2'' SANITARY CLAMP

2'' SANITARY GASKET

2'' 90° STANDARD ELBOW

2'' 90° STANDARD ELBOW 289mm

2'' 90° STANDARD ELBOW 78mm

3

4

1

192791

6

10

12

192029

4

1

192635

5

192636

OUTLET MANIFOLD

ITEM

PART NUMBER

1

DESCRIPTION

QTY

REMARKS

7

1

194930

1

194931

8

1

104111-E4

1

2

FOOT MOUNTED PRV

INLET MANIFOLD

12

10

192544

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

77-3229 R4.1 12/36 www.carlisleft.com

EN

PARTS LIST - Mechanical Assembly

4

M12 WASHER (ST ST)

164470

4

2

M6 WASHER (BRASS)

M8 x 30 GRUB SCREW

M8 x 16 GRUB SCREW

M16 x 50 CAP HEAD SCREW (ST ST)

M16 x 30 CAP HEAD SCREW (ST ST)

M8 x 20 CAP HEAD SCREW (ST ST)

M10 x 20 GRUB SCREW

M8 NYLOC NUT

165959

15

M6 x 20 HEX HEAD CAP SCREW

(BRASS)

M6 x 20 CAP HEAD SCREW (ST ST)

M12 x 40 HEX HEAD CAP SCREW

M12 SPRING WASHER

1

163161

8

PART NUMBER

DESCRIPTION

QTY

REMARKS

ITEM

4

164469

3

12

163952

2

8

165660

11

5

165087

12

6

165100

6

7

165137

4

M16 SPRING WASHER

M6 SPRING WASHER

EYE BOLT

18

192601

1

2

192441

17

TOP PLATE MACHINED

8

192400

16

SPRING WASHER

❻

20

192603

2

21

192616

BEARING CAP

1

23

192634

2

12

165663

8

13

165671

2

165958

14

8

165552

16

9

165588

4

10

165592

24

19

192602

BASE PLATE MACHINED

1

SIDE PLATE

1

BEARING CLAMP

192617

22

MOUNTING FRAME

❻

1

ROLLER BEARING

192640

25

24

192639

BALL BEARING

1

77-3229 R4.1 13/36 www.carlisleft.com

EN

1

SHAFT COUPLING SPACER

193697

44

1/8'' - 6mm ELBOW

M50 BEARING LOCKNUT

M45 BEARING LOCKNUT

14 x 9 x 50 KEY

Ø12 x 30 DOWEL PIN

Ø100 x 2.5 O-RING

1/4'' - 10mm ELBOW

E4-60 SHAFT ASSEMBLY

E4-60 LEAK DETECTION HOSE ASSY

Ø58 X Ø80 X 8 SEAL

192661

8

❺

4

LINEAR BEARING ROD

192643

26

27

192644

2

❻

Parts list continued.

28

192645

1

32

192655

1

ITEM

PART NUMBER

DESCRIPTION

QTY

REMARKS

192650

29

192653

30

192654

31

34

5

GREASE NIPPLE

1

4

SHAFT CLAMP ASSY

192668

36

CARRIAGE ASSEMBLY

4

192682

37

DRIVE SHAFT COUPLING

1

192721

38

33

192656

1

4

❹

4

GREASE HOSE

192662

35

1

40

192817

41

193102

CARRIAGE SPRING ROD

39

192752

2

4

45

43

42

193104

CARRIAGE SPRING

❹

8

193105

8

SPRING KEEP ASSEMBLY

194510

1

46

194540

8

SPACER

77-3229 R4.1 14/36 www.carlisleft.com

EN

** Tighten bolts holding carriage ends once pump is fully assembled.

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

77-3229 R4.1 15/36 www.carlisleft.com

EN

M10 x 70 CAP HEAD SCREW

192600

PARTS LIST

-

Shaft Assembly

ITEM

PART NUMBER

DESCRIPTION

QTY

REMARKS

1

192604

1

MIDDLE SHAFT

TOP SHAFT

BASE SHAFT

CONSTANT VELOCITY CAM

2

1

20

2

3

4

5

165571

192606

192605

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

77-3229 R4.1 16/36 www.carlisleft.com

EN

1 2 3

1

2

3

4

5

6

Shaft Assembly

Assembly Tool

CAM Radial pitch offset

Hold assembly tool (502512) in a vice (flats provided) and install middle shaft.

Place CAM onto middle shaft ( with 'Top' engraving facing the shaft).

Place the base shaft on top of the CAM, align the holes and screw in the M10 x 70 cap head screws using

Loctite 243 and tighten to 65Nm.

Lift the assembly off of the assembly tool, rotate assembly and place back onto tool to complete

assembly.

Place the second CAM (with 'TOP' engraving facing up), ensure the CAM is 3 holes radially out of pitch

from the first CAM.

Fit top shaft, align holes and screw M10 x 20 cap head screws in using loctite 243 and tighten to 65Nm.

77-3229 R4.1 17/36 www.carlisleft.com

EN

❹

2

FOLLOWER GUARD WASHER

192611

5

1

FOLLOWER NUT WASHER

192612

7

Ø47 INTERNAL CIRCLIP

1/8'' x 6mm PUSH IN ELBOW

1/8'' GREASE NIPPLE / SLIP ON

M16 NYLOC NUT

Ø72 CAM FOLLOWER

M8 x 25 CAP HEAD SCREW

M8 SPRING WASHER

M8 x 20 CAP HEAD SCREW

ITEM

PART NUMBER

DESCRIPTION

QTY

REMARKS

192610

6

PARTS LIST

-

Carriage Assembly

1

LEFT HAND CARRIAGE END

13

165552

14

16

192649

192661

17

LINEAR BEARING

CARRIAGE ADAPTOR

RIGHT HAND CARRIAGE END

CARRIAGE MIDDLE

2

3

4

8

9

12

15

192607

192609

192618

192641

CAM FOLLOWER PIN

1

4

6

165553

192608

192642

165086

163152

❹

❺

1

6

2

1

LINEAR BEARING SPACER

❺

2

192615

10

❺

4

192652

11

77-3229 R4.1 18/36 www.carlisleft.com

EN

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

Bolts remain loose,

tightened when

mechanical assembly is

complete.

Tighten on final assembly to give correct

orientation for hose connection to grease

nipple.

When fitting new bearings: Ensure seals

have been removed from inside of

bearing to ensure a correct grease

supply path via centre spacer.

Orientate bearing so

black section along the

body is aligned to the

block's side.

77-3229 R4.1 19/36 www.carlisleft.com

EN

1/4'' BSP HEXAGON PLUG

Ø12.42 x 1.78 O-RING

Ø1 3/8'' BALL

M8 x 90 CAP HEAD SCREW

M8 SPRING WASHER

M6 SPRING WASHER

M12 SPRING WASHER

M6 x 25 CAP HEAD SCREW (ST ST)

14

165044

165087

165108

-

Piston Assembly

171788

192620

12

13

PARTS LIST

17

ITEM

PART NUMBER

DESCRIPTION

QTY

REMARKS

3

4

5

2

6

OUTLET CYLINDER

INLET CYLINDER

❶❷

192647

19

❶❷

192648

20

165960

7

❷

192505

9

❶❷

8

192632

SHAFT/BELLOWS ASSY

194237

194243

163921

165957

OUTLET CAP

OUTLET BLOCK

192621

192624

❷

Ø 41 x 1.78 O-RING - PTFE

Ø 50.5 x 2.62 O-RING - PTFE

OUTLET SPRING KEEP

192630

16

192625

192626

11

15

18

PISTON ASSEMBLY

192551

10

21

❶❷

PISTON SEAL

SEAT

OUTLET CAGE

192679

22

❶❷

BALL CHECK SPRING

160513

1

77-3229 R4.1 20/36 www.carlisleft.com

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