Carlisle BINKS - Pneumatic Pump Electronic Stroke Counter User manual

Carlisle
Brand
Carlisle
Model
BINKS - Pneumatic Pump Electronic Stroke Counter
Type
User manual
EN
IMPORTANT! DO NOT DESTROY
It is the Customer's responsibility to have all operators and service personnel read and understand this
manual.
Contact your local Carlisle Fluid Technologies representative for additional copies of this manual.
READ ALL INSTRUCTIONS BEFORE OPERATING THIS PRODUCT
Service Manual
Pneumatic Pump
Electronic Stroke Counter
• Model
104263
• Model
104261
• Model
104262
77-3336 R1.0 www.carlisleft.com
EN
Attestation of Conformity
The object of the Attestation described above is in conformity with the relevant Union
harmonisation legislation:
This Attestation of conformity is issued under
the sole responsibility of the manufacturer:
Carlisle Fluid Technologies UK Ltd,
Ringwood Road,
Bournemouth, BH11 9LH. UK
Product Description / Object of Attestation:
This Product is designed for use with:
Solvent and Water based materials
Suitable for use in hazardous area:
Zone 1 / Zone 2
Protection Level:
h IIB T4 Gb X
Notified body details and role:
Element Materials Technology (2812)
Lodging of Technical file
Director of Sales (EMEA)
5/2/20
Bournemouth,BH11 9LH,UK
Signed for and on behalf of Carlisle Fluid
Technologies UK Ltd:
D Smith
Machinery Directive 2006/42/EC
ATEX Directive 2014/34/EU
by complying with the following statutory documents and harmonized standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN ISO 80079-36:2016 Explosive Atmospheres- Part 36: Non Electrical equipment for explosive atmospheres-
Basic methods and requirements.
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.
77-3336 R1.0 2/24 www.carlisleft.com
EN
AUTOMATIC EQUIPMENT. Automatic
equipment may start suddenly without
warning.
PROJECTILE HAZARD. You may be
injured by venting liquids or gases that
are released under pressure, or flying
debris.
Important installation, operation or maintenance
information.
WARNING
Read the following warnings before using this equipment.
KEEP EQUIPMENT GUARDS IN PLACE.
Do not operate the equipment if the
safety devices have been removed.
NEVER MODIFY THE EQUIPMENT. Do
not modify the equipment unless the
manufacturer provides written
approval.
PINCH POINT HAZARD. Moving parts
can crush and cut. Pinch points are
any areas where ther are moving
parts.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE
OPERATOR OF THE EQUIPMENT.
PRESSURE RELIEF PROCEDURE.
Always follow the pressure relief
procedure in the equipment instruction
manual.
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as
follows:
WARNING
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
KNOW WHERE AND HOW TO SHUT
OFF THE EQUIPMENT IN CASE OF AN
EMERGENCY.
CAUTION
OPERATOR TRAINING. All personnel
must be trained before operating
finishing equipment.
PACEMAKER WARNING. You are in the
presence of magnetic fields which may
interfere with the operation of certain
pacemakers.
77-3336 R1.0 3/24 www.carlisleft.com
•
•
•
•
•
•
•
•
•
•
•
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•
Any earthing straps disconnected to carry out work on the pump unit must be replaced before
pump is restarted.
Maple pumps: Fitting or removing the stroke counter requires handling magnets
with intense field strengths - not to be carried out by those wearing a pacemaker or
similar device. Unrestrained magnets may move suddenly resulting in impact
damage or attract debris.
Use appropriate PPE when handling fluids such as grease.
The stroke counter unit must not be exposed to long term sunlight or other sources of ultra-
violet radiation to reduce risk of damage to plastic parts.
Turn off switching isolation barrier power before connecting or disconnecting cable plug from
sensor.
PRODUCT SPECIFIC WARNINGS
Maximum operating pressure (Bar):
The sensor must only be connected via the supplied cable to a suitable switching
isolation barrier unit located outside the hazardous zone designed to operate
NAMUR type sensors.
The sensor must not be subjected to any applied mechanical forces (examples: impacts, cable
pulling).
Cable plug and sensor connector attach in one angular location only - do not force: align
locating lug in sensor with notch in cable plug before pushing together and tightening threaded
collar to secure.
Some stroke counter components are plastic - do not use aggressive chemicals to clean. Use a
cloth damped with water for wiping unit clean if required.
Ensure pump is stopped and isolated from air and fluid systems before dismantling any part of
the pump.
During operation some surfaces of the pump may become very cold - be aware of a risk of skin
burn if dismantling pump parts immediately after shutting down.
Route sensor cable away from power cables and in a manner to avoid it becoming a trip
hazard.
Do not coil or heap excess cable inside the hazardous zone.
The stroke counter does not contain serviceable parts - if output from sensor fails, the complete
unit containing the sensor must be replaced.
Switching state indicator:
Ambient temperature (°C) - minimum to maximum:
Nominal operating voltage (Volts):
Operating speed (cycles/min): minimum to maximum:
EN
104262 for use with pump:
104263 for use with pump:
Sensor output:
Current consumption (mA) low to high state:
Specification
104261 for use with pump:
77-3336 R1.0 4/24 www.carlisleft.com
EN
1: Supply
2: Return
3:
#:
• Model
104261 #
Sensor connections
• Model
104263
• Model
104262 #
Connection locating
lug
Dimensions and Mounting Details
These stroke counter units can be fitted at the
opposite end of the valve block if preferred.
77-3336 R1.0 5/24 www.carlisleft.com
EN
n1:
Note:
Stroke Counter Kit Contents
-
ITEM
PART NO.
DESCRIPTION
QTY
REMARKS
1
3
162767
O-RING
1
n1
Spares kit 1 also includes o-ring
for item 1.
195726
STROKE COUNTER UNIT WITHOUT
CABLE - MAPLE 60
1
2
195714
SENSOR CABLE - 10 METRES
1
77-3336 R1.0 6/24 www.carlisleft.com
EN
A:
B:
C:
D:
E:
F:
G:
H:
I:
J:
K:
-
Installation
Discard o-ring (8) removed from unit on end cap (2). Retain this end cap.
System check (if desired): Connect cable (9) to the sensor on unit (7) with power off and
observing correct orientation. Turn on power then gently press in black plastic pin opposite
end to sensor in unit (7) until it comes to a halt. The yellow sensor LED should turn off and
then re-illuminate when the pin is released. Power off and remove cable from sensor.
Fit new o-ring (8) to cleaned end cap (2).
With reference to images and table over page
With the pump stopped and isolated from the air supply system, use 1/2" drive square to
unscrew then remove both end caps with their o-rings (2/8 & 10) from main air valve assembly
(1). Magnets may come out with the end caps.
Remove complete spool assembly (3), both spacers (6) and bumpers (4) along with magnets
(5) if not already removed.
The simplest fitting procedure is to remove end cap and o-ring (10) and replace with stroke counter
unit (7), ensuring magnet remains in its correct location. The following procedure outlines the
removal of the spool valve assembly and associated parts for cleaning to avoid contamination of the
stroke counter.
Clean all remaining removed components. Spool and sleeve assembly (3) have a precision fit
together - if separated must be completely clean to avoid jamming and / or damage.
Replace spool and sleeve assembly (3), spacers (6) and bumpers (4) in their correct order of fit
(as shown) into main air valve assembly (1), lightly greasing where indicated.
Grease stroke counter unit (7) thread its o-ring and with magnet (5) aligned inside, insert then
tighten into main air valve assembly (1). Tighten to specified torque.
Screw the cable plug (9) onto the sensor connector on unit (7) - observe correct orientation.
Discard one valve block end cap and o-ring (10) but first remove magnet if trapped inside and
fit it into the stroke counter unit (7) inside the housing around the black plastic operating pin.
Keep magnet clean - if metallic swarf attaches, it can often be removed by applying then
removing sticky tape to the magnet surface.
Grease o-ring (8) and end cap (2) and with its magnet (5) fitted inside, fit and tighten into main
air valve assembly (1). Tighten to specified torque.
77-3336 R1.0 7/24 www.carlisleft.com
EN
n1:
n2:
Installation
-
Note:
External surfaces only around o-rings.
Align lug in sensor with notch in plug before fitting.
Stroke counter unit
Magnet
Partial section showing fitting of magnet in stroke counter unit.
(AGMD-010)
TORQUE
KEY
GREASE
MAGNET HAZARD
77-3336 R1.0 8/24 www.carlisleft.com
EN
Components Identification
-
6
ITEM
PART NO.
DESCRIPTION
5
0115-010428
MAGNET
MAIN AIR VALVE ASSEMBLY
2
4
0115-010427
BUMPER
0115-010431
SPACER
7
195726
0115-010425
VALVE BLOCK END CAP
STROKE COUNTER UNIT WITHOUT
CABLE - MAPLE 60
3
0115-010424
SPOOL AND SLEEVE ASSEMBLY
REMARKS
REPLACE O-RING AND
REUSE
8
162767
O-RING
USED ON ITEM 2
9
195714
SENSOR CABLE - 10 METRES
10
0115-010425 &
162767
END CAP AND O-RING
DISCARD ASSEMBLY
193605
1
77-3336 R1.0 9/24 www.carlisleft.com
EN
n1:
Stroke Counter Kit Contents
-
Note:
ITEM
PART NO.
DESCRIPTION
QTY
REMARKS
1
0115-010049
O-RING
1
2
195727
STROKE COUNTER UNIT WITHOUT
CABLE - MAPLE 30
1
n1
5
195709
MAGNET - COUNTER
2
6
195710
SPACER - COUNTER
2
7
195714
SENSOR CABLE - 10 METRES
1
3
195707
VALVE BLOCK END CAP
1
4
195708
BUMP STOP
2
Spares kit 2 also includes o-ring
for item 2.
MAGNET HAZARD
77-3336 R1.0 10/24 www.carlisleft.com
EN
A:
B:
C:
D:
E:
F:
G:
H:
Installation
-
System check (if desired): Connect cable (9) to the sensor on unit (3) with power off and
observing correct orientation. Turn on power then gently press in black plastic pin opposite
end to sensor in unit (3) until it comes to a halt. The yellow sensor LED should turn off and
then re-illuminate when the pin is released. Power off and remove cable from sensor.
With the pump stopped and isolated from the air supply system, use 1/2" drive square to
unscrew and then remove and discard at both ends: existing end caps (12) with their o-rings
(8), magnets (11) and bumpers (10).
Remove spool and sleeve assembly (2) from air valve assembly (1), clean, lightly grease o-ring
faces only and re-insert with solid end of spool facing end to receive stroke counter unit (see
note 3 in illustration). Spool and sleeve assembly (2) have a precision fit together - if
separated must be completely clean to avoid jamming and / or damage.
At both ends insert new bump stops (5) and magnets (6). Ensure bumpers are inserted the
correct way round with smaller diameter inside sleeve and magnets are sitting inside valve bore
(see note 4 in illustration).
Fit one spacer (7) into mating bore of stroke counter unit (3) and the other into the bore of the
new end cap (4).
With reference to images and table over page
Fit new o-ring (8) onto new end cap (4), grease thread and the o-ring then using a 1/2" drive
screw in and tighten to specified torque.
Screw the cable plug (9) onto the sensor connector on unit (3) - observe correct orientation.
Grease stroke counter unit (3) thread and its o-ring then fit and tighten into end of valve bore
of air valve assembly (1). Tighten to specified torque.
77-3336 R1.0 11/24 www.carlisleft.com
EN
n1:
n2:
n3:
n4:
Installation
-
Align lug in sensor with notch in plug before fitting.
External surfaces only around o-rings.
Note:
Valve spool end with solid face must be same end as
stroke counter.
Bump stop sits with smaller diameter inside end of
sleeve, slotted face outwards - both ends. Magnet
must sit inside valve block sleeve bore - both ends
(arrowed).
✓
n3
GREASE
KEY
TORQUE
MAGNET HAZARD
(AGMD-010)
n4
77-3336 R1.0 12/24 www.carlisleft.com
EN
7
195710
Components Identification
-
9
195714
VALVE BLOCK END CAP
5
6
ITEM
195708
BUMP STOP
0115-010015
SPOOL AND SLEEVE ASSEMBLY
DESCRIPTION
1
0115-010102
AIR VALVE ASSEMBLY
195709
MAGNET - COUNTER
PART NO.
10
0115-010016
BUMPER
11
0115-010017
MAGNET
3
195727
STROKE COUNTER UNIT WITHOUT
CABLE - MAPLE 30
4
195707
SENSOR CABLE - 10 METRES
2
SPACER - COUNTER
8
0115-010049
O-RING
12
0115-010018
VALVE BLOCK END CAP
REMARKS
DISCARD PART
DISCARD PART
DISCARD CAP AND ITS
FITTED O-RING
77-3336 R1.0 13/24 www.carlisleft.com
EN
n1:
n2:
3
SPA-122X
O-RING
1
4
DVX-346
GASKET
1
5
Alternative variant which may be
supplied as item 1.
Note:
195728
SENSOR AND HOUSING ASSEMBLY -
DX200-3
1
195714
SENSOR CABLE - 10 METRES
1
Stroke Counter Kit Contents
-
ITEM
PART NO.
DESCRIPTION
QTY
REMARKS
1
195725
SPOOL AND TARGET ASSEMBLY -
DX200-3
1
2
Spares kit 3 has 4 o-rings for
both ends and spool.
n2
77-3336 R1.0 14/24 www.carlisleft.com
EN
A:
B:
C:
D:
E:
F:
G:
H:
I:
J:
K:
L:
M:
N:
O:
P:
Use circlip pliers or similar to remove circlips (7) at both ends of the valve spool bore. Caution -
circlips may spring out!
Screw the cable plug (10) onto the sensor connector (9) - observe correct orientation.
-
Refit air line connection (11) to the valve block (1). It may be necessary to use low strength
thread sealant or PTFE tape to provide an airtight seal into the valve block.
Retain one end cap (4), remove and discard its existing o-ring, clean cap then fit new o-ring in
kit (5).
Insert new spool (3) into valve block (1) bore with metal target end (note 4) facing to the right
(looking onto air line connection face of block). Avoid damaging o-rings.
Press the end cap (4) into the left end of the bore and the sensor housing with sensor (9) into
the right end (looking onto air line connection face of block). Avoid damaging o-rings.
Refit circlips (7) into their grooves in the valve block (1) at both ends. Check spool (3) slides
up and down the bore.
Regrease then refit the slider block (2) (large flat face inwards) followed on by ceramic slider
block (6) (larger slot profile outwards).
Place new gasket (8) supplied in the kit onto valve block (1) face then refit valve block (1) to
the pump unit with sensor end at the top using the four caphead screws (12). Tighten evenly
to achieve specified torque.
With reference to images and table over page
Use an M5 threaded screw to pull out existing end caps (4) & (14) then push out the original
spool (13).
Discard one end cap (14) and the existing spool (13) with their o-ring seals.
System check (if desired): Connect cable (10) to the sensor (9) with power off and observing
correct orientation. Turn on power then bring the steel target on the end of the spool (3) up
against the end face of the black plastic housing containing the sensor (9) to trigger it. The
yellow sensor LED should turn off and then re-illuminate when the steel target is moved away
from the sensor. Power off and remove cable from sensor.
With the pump stopped and isolated from the air supply system, remove the air line connection
(11) from the valve block (1).
Release the four caphead screws (12) in the valve block (1) and lift the complete valve block
assembly off the pump. Remove and discard the existing valve block gasket (8).
Remove ceramic valve plate (6) and slider block (2) inside. Clean and retain both for reuse.
Grease o-rings on spool (3), cap (4) and housing (9). Grease valve bore (note 6).
Installation
77-3336 R1.0 15/24 www.carlisleft.com
EN
n1:
n2:
n3:
n4:
n5:
n6:
n7:
Chamfered face inside.
Grease o-ring mating faces.
Installation
-
Side with wider slots against gasket.
Grease all external faces.
Remove air line fitting before extracting spool.
Steel target end faces sensor.
Align lug in sensor with notch in plug before fitting.
Note:
TORQUE
KEY
GREASE
(AGMD-010)
77-3336 R1.0 16/24 www.carlisleft.com
EN
Components Identification
-
ITEM
PART NO.
DESCRIPTION
1
DVX-317
VALVE BLOCK
2
DVX-318
SLIDER BLOCK
DVX-346
GASKET
9
195728
SENSOR AND HOUSING ASSEMBLY -
DX200-3
10
195714
SENSOR CABLE - 10 METRES
3
195725
SPOOL AND TARGET ASSEMBLY -
DX200-3
4
DVX-324
END CAP
5
SPA-122X
O-RING
6
DVX-343
VALVE PLATE
OR SIMILAR
REMARKS
REPLACE O-RING AND
REUSE
USED ON ITEM 4
FIT NEW GASKET
DISCARD ASSEMBLY
DISCARD ASSEMBLY
11
EXISTING AIR LINE CONNECTION
12
DVX-344
M5 x 55 SOCKET HEAD CAP SCREW
13
DVX-323 &
2x SPA-122X
ORIGINAL SPOOL & O-RINGS
14
DVX-324 &
SPA-122X
END CAP AND O-RING
7
DVX-345
27mm INTERNAL CIRCLIP
8
180584
77-3336 R1.0 17/24 www.carlisleft.com
EN
Check: correct plug fit and orientation on sensor, connecting
cable is wired correctly to barrier unit, barrier unit is
operating correctly.
Incorrect electrical
connection
Drive pin fractured
104262: Broken part seen after removing stroke counter
unit - replace unit.
Spring fractured or
drive pin sticking
104261 & 104262: Drive pin pressed in and does not return -
replace unit.
Incorrect fitting
onto pump
Fault Finding
Symptom
Remedy
Possible Cause
104261: Check spool and sleeve are central in valve block
and spool not jammed. Check parts assembled and mounted
in correct order - check against outline dimensions.
104262: Check spool and sleeve are central in valve block
and spool not jammed. Check parts assembled and mounted
in correct order, bump stops are inserted the correct way
round, supplied end cap and magnet are fitted, drive pin has
not been snapped, orientation of valve spool correct (see
installation, note #2), check against outline dimensions.
104263: Check: spool is free to move, end cap and sensor
housing assy are sitting up against circlips, circlips are fitted
correctly in grooves, spool steel target face is same end of
bore as sensor.
104261 & 104262: Repeated pressing of drive pin after
removal from pump with sensor powered does not trigger
sensor LED - check: connecting cable for damage, barrier
unit is operating correctly. Alternatively sensor has failed -
replace stroke counter unit.
Electronics failure
During operation
stroke counter
stops working
104263: Remove sensor housing assembly and with sensor
powered, place sensing face up against a flat steel item -
sensor LED indicator should turn on/off - if not check:
connecting cable for damage, barrier unit is operating
correctly. Alternatively sensor has failed - replace sensor and
housing assembly.
Stroke counter
inoperative after
fitting
77-3336 R1.0 18/24 www.carlisleft.com
EN
Maintenance schedule
Inspection
Operation
77-3336 R1.0 19/24 www.carlisleft.com
EN
Accessories
PART NO.
195730
195714
195731
195732
QTY
1
1
1
1
DESCRIPTION
SENSOR CABLE - 5 METRES
SENSOR CABLE - 10 METRES
SENSOR CABLE - 20 METRES
SENSOR CABLE - 40 METRES
AGMD-010
KLUBER ISOFLEX TOPAS NB52 GREASE
1
77-3336 R1.0 20/24 www.carlisleft.com
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Carlisle BINKS - Pneumatic Pump Electronic Stroke Counter User manual

Carlisle
Brand
Carlisle
Model
BINKS - Pneumatic Pump Electronic Stroke Counter
Type
User manual
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