Carlisle BINKS E420, Operating Manual

Page 1: ...77 3345 R1 1 06 2022 EN OPERATING MANUAL www carlisleft com Binks E420 Swiveling applicator for Robotic Sealing Applications ...

Page 2: ... instructions 22 5 Disassembly instructions 24 6 Assembly instructions 40 6 1 Testing before installation 56 7 Technical specifications 57 8 Dimensions 58 9 Maintenance 60 This manual contains important information about warnings and cautions Read the manual thoroughly before starting to operate this equipment and carefully follow the instructions Always keep the manual handy until such time the e...

Page 3: ...urther information about this product please contact your supplier and refer to the model and serial No of your equipment The Binks E420 is designed for safe operation It s important that the conditions for safe operation are respected so that accidents and personal injury are prevented These safe conditions are described in this manual Only qualified maintenance personnel may perform maintenance ...

Page 4: ...and all other electrically conductive objects in the dispensing area Improper grounding or sparks can cause a hazardous condition and result in fire explosion or electric shock and other serious injury PROP 65 WARNING WARNING This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WEAR RESPIRATOR Toxic fumes can cause serious in...

Page 5: ...y seam sealing UBS and Interior seam sealing ISS The Binks E420 is designed to handle most types of single component adhesives and sealants with medium to high viscosity The solenoid valves operating the pistons for the material valves are mounted externally for easy maintenance Material circulation is provided through the entire length of the applicator for material thixotropic breakdown and temp...

Page 6: ...hese main parts The central body has two main parts which are the extension 1 and the axis 2 The two parts are mounted together with the help of two rings 3 which also act as a lock ring for the swivel housing Inside the central body axis are packing sets 4 that seal off the needles from material pressure 1 2 3 4 4 ...

Page 7: ...turn flow back to the swivel housing When a version of the applicator without circulation is used material is supplied through all three channels in the central body Channel arrangements in the central body Product in Product Return Product in Air signals Material return channel Material inlet channel Material inlet channels Material return channel Air channel Air signals Material return channel N...

Page 8: ...l solenoid valves supply compressed air to the cylinder unit There is one inlet channel 5 and one return channel 6 in the material housing In case no circulation is used both are used as inlet channels Note also the drainage holes 7 that connects to the front and back drainage chambers The internals of the material chamber differs depending on if circulation 8 is used or if no circulation 9 is req...

Page 9: ...and a back 3 drainage chamber in the swivel chamber that are both sealed by additional seals 4 to prevent material leakage into the air chamber and onto the car chassis Note the material inlet 5 material return 6 and drainage channels 7 in the swivel housing The internal chamber rings are all locked in place by interconnecting pins 8 which are locked to the inside of the material chamber 9 with on...

Page 10: ...hed to the air housing They are easily removed and replaced during production without dismounting the applicator from the robot should they fail An 8 mm coupling 2 that is connected to the air chamber supplies the solenoids with compressed air From the solenoids compressed air is supplied to the central axis through the air distributor ring 3 1 3 2 ...

Page 11: ...terial inlet and a pressure transducer 5 in the material return channel When spraying there is no return flow the pressure in the return line is equal to the pressure just before the nozzle head The connection housing uses either an 18 pin connector 6 or a 5 pin connector 7 All internal cabling is handled by plug and pull connectors 8 for easy maintenance 5 1 2 4 Connection housing with PT100 temp...

Page 12: ...zzle head comes in a variety of different designs depending on the material and method of application used The nozzle heads are designed to accommodate guided nozzles with standard measurements Standard nozzle head Square adapter Square adapter and rectangular nozzle head ...

Page 13: ... which has three pneumatic cylinders that operate the material valves In each of the cylinders a piston 2 is fixed to the valve needle On top of the cylinder block is a cylinder cover 3 fitted that includes springs 4 that close the material valves The cylinders are actuated by 24 V monostable 3 2 port solenoid valves 1 4 3 2 ...

Page 14: ...ixed point between axis 5 and 6 on the robot This design makes sure that the connections follow the motion of axis 5 Only the central body follows the motion of axis 6 The swivel lock depends on the make and model of the robot manufacturer Depending on robot type the swivel lock might have to be aligned to the 5th axis of the robot using a calibration tool The image shows an example of a swivel lo...

Page 15: ...er dependent The flange is fixed to the robot using screws 2 where the guide pin 3 locks the flange in position on the robot s sixth axis With the flange fixed to the robot the applicator is mounted on the flange and fixed in position by two guide pins one that centers the applicator 4 and one locating pin 5 The applicator is then mounted onto the mounting flange using the three M6 6 6 1 3 5 2 4 T...

Page 16: ...ex key 2 5 mm Hex key 3 mm Hex key 4 mm Hex key 5 mm Hex key 7 mm Wrench Philips screwdriver PH1 It is recommended to use the special tools kit for the E420 sold separately Part no 6004 0803 00 The special tools kit contains 6004 0802 00 6004 0802 03 6004 0154 11 6004 0154 10 Not using correct tooling might void warranty CAUTION ...

Page 17: ...equired 1 piece Binks E420 applicator with nozzle head and nozzle cap 1 piece Robot mounting flange 1 piece Swivel locking bracket 1 piece Cable with 5 pin or 18 pin connector other configurations possible 3 piece Nozzles See accessories list 9836 4139 02 for available options Before starting installation of the Binks E420 applicator always read chapter 2 Descrip tion in order to be familiar with ...

Page 18: ...is of the robot using the 6 screws with low heads 2 make sure the pin 3 is in the correct position Align the applicator with the two pins 4 in the mounting flange and then fasten the applicator using the three screws 5 Use the markings to align the applicator and the flange 6 1 1 4 4 3 2 5 Nm 4 5 6 5 Nm 6 The mounting flange and the swivel lock are only for illustration Both are depending on the r...

Page 19: ...6 into place in the sliding block 7 then fasten it with the two screws 8 3 Installation instructions The next step in installing the applicator is the swivel locking bracket The installation instructions on this page show how to install the standard swivel locking bracket instructions are shown with an ABB robot and the mounting flange and swivel lock are for illustration purposes 1 3 2 6 5 Nm 4 5...

Page 20: ...he applicator with an 8 mm PU hose to the push in coupling on the side of the swivel housing 1 The material supply hose is connected to the connection point Inlet I The material return hose is connected to the connection point Return R If circulation was not selected the applicator only has the inlet nipple After completion of the installation of hoses and cables their free movement must be checke...

Page 21: ...king properly by open and closing each valve from the robot pendant and listen to the sound of the piston in operation Apply material supply pressure and check for leakage Move the applicator to the purge position and purge all nozzles one by one until the unit is filled up with material and all entrapped air is removed from the supply system Open the circulation valve and purge the material throu...

Page 22: ... the gable Unscrew the two screws 5 that fix the swivel locking bracket to the applicator and prevent the swivel housing from rotating A swivel lock for an ABB robot is shown below 1 2 3 4 Clean the unit and all parts surrounding it before removing the applicator NOTE Before any service or cleaning action is undertaken on the applicator make sure that air and material pressures are relieved WARNIN...

Page 23: ...screw the three screws 1 holding the applicator to the mounting flange The screws can be left in the cylinder housing due to their design 2 With the applicator removed from the robot disassembly and service can be performed Be sure to store all removed parts in a safe place 1 1 2 ...

Page 24: ...ng the adapter to the central body then remove the adapter The nozzles can be removed from the nozzle head by unscrewing the two screws 7 holding the nozzle plate 8 to the nozzle head Nozzle seals 9 and adapter seals 10 can be removed 1 2 Be sure to store all removed parts in a safe place Immediately clean all parts after removal that will be fitted again and inspect the cleaned parts for damage a...

Page 25: ... remove the cylinder cover 3 and the springs 4 Remove the seal 5 then push the needles or pull the pistons to a position where you can access the screws 6 that holds the pistons to the needles Loosen the two screws 7 that hold each piston to its needle and remove the piston 8 from the needle Remove the seal 9 and the guide rings 10 from the piston 8 2 Always use a vice with soft jaws NOTE 3 4 1 1 ...

Page 26: ...ow be pushed to the bottom of the cylinder 1 and pulled out from the central body 2 To separate the central body extension from the central body axis start with unscrewing the three 3 screws holding the two pieces of the lock ring together This will allow you to remove one piece of the lock ring 4 but also the central body extension 5 1 2 3 4 5 ...

Page 27: ...e second piece of the lock ring 3 Separate the central body axis and cylinder block from the swivel housing by first rotating 4 then pull it out 5 Important Do not use a tool to hammer on the central body axis side with cutouts for O rings 6 1 2 4 5 6 The surface with cutouts for o rings on the central body axis is fragile Do not use a tool to hammer on this fragile area CAUTION ...

Page 28: ...rom the swivel housing unscrew the three screws 2 holding the cylinder block 3 to the axis 1 Remove three seals 4 and three O rings 5 from the back of the cylinder block Pull out the upper needle guides 6 the top hole of the needle guides is threaded and an M4 screw can be used as a tool Remove the seal 6 and the O ring 7 from the three needle guides 1 2 3 4 5 5 8 7 ...

Page 29: ...see page 16 Remove the seals 3 and O rings 4 from the distances The central body parts have all been disassembled and can be cleaned appropriately The bracket for the swivel lock can be removed by unscrewing the four screws 5 holding the bracket 6 to the air housing Then remove the bracket 6 the two pins 7 can also be removed Be sure to store all removed parts in a safe place 1 2 4 3 5 6 6 7 ...

Page 30: ... a safe place 5 Disassembly instructions Unscrew the four screws 1 holding the cover 2 to the swivel housing and slide it off Unplug the cable 2 to the solenoid valves Unscrew the four screws 3 holding the connection housing 4 and swivel housing 5 together then separate them 1 2 3 3 5 4 ...

Page 31: ... 4 If need be the plug 5 and push in elbow coupling 6 can be removed for easier access to the drainage channel Version with circulation and sensors Unscrew the four screws 7 holding the connector plate 8 to the connection housing Unplug all the push and pull connectors 9 from the connector Be careful when removing the connector plate to avoid damaging the cables and connectors for the sensors 1 7 ...

Page 32: ... the material channels between the two parts and the two pins 5 help guide the part when they are assembled If need be the plug 6 and push in elbow coupling 7 can be removed for easier access to the drainage channel The nipples 8 can be removed and exchanged should it be needed 2 3 5 4 Unless the pressure or temperature sensors are malfunctioning they should NOT be removed from the lower connectio...

Page 33: ... the O rings for the material 1 and the drainage 2 channels Unscrew the four screws 3 for the solenoid valve block 4 and remove them The O ring 5 can be removed if it needs to be changed or service is required Unscrew the four screws 6 holding the material housing 7 and the air housing 8 together and separate the two 2 1 4 3 5 6 7 8 ...

Page 34: ...y disassembly Align the pins and the corresponding holes 3 in both the air housing 4 and the tool 5 When the air housing 4 has been placed in the tool 5 press the air distributor ring 6 out of the air housing using the pressing tool 7 A vice with soft jaws can be used to help with pressing out the air distributor ring Take out the four seals 8 from the inside of the air distributor ring after it h...

Page 35: ...manifold The air coupling 4 can also be removed and exchanged if so is necessary For removal of the sealing package tool 6004 0802 03 needs to be used see page 16 Begin with placing the tension tool 5 into the cutout 6 in the cup tool 7 Place the material housing 8 on top of the two tools align the pins 9 with the holes for the screws Note the orientation of the material housing 8 and the cup tool...

Page 36: ...ew 2 to expand the tension tool 3 so that it gets fastened to the material distribution ring Screw the tension tool clamp 1 down by using hand force or a flat screwdriver note the approximate height over the material housing 4 The cup tool 5 is then moved to the other side of the material housing 6 note the orientation Align the pins 7 with the holes for the screws 3 1 2 4 7 7 5 5 ...

Page 37: ...l seal package Important Do not use a hammer or any other tool to force the sealing package out of the material chamber A controlled linear force is needed to avoid possible damages to the material seal package and material chamber When the material seal package 3 has been fully pressed out the parts and tools can be separated by pulling of the swivel housing 4 and unscrewing the tension tool clam...

Page 38: ...seal package has been removed from the swivel housing all the material seals 1 and v seal 2 can be removed With the material seal package taken out from the material chamber remove the four O rings 3 and the v seal 4 from the material housing 5 1 1 2 1 1 1 2 Material seal package with circulation Material seal package witout circulation 3 4 5 5 ...

Page 39: ... to be reused in the assembly need to be cleaned This cleaning process differs depending on the material of the part and application material All parts included in the applicator should also be inspected for damages that can affect the lifetime of the part itself or other parts that it is in contact with Should the part be damaged it needs to be replaced ...

Page 40: ...nternal cables for the pressure and temperature sensor 9 should the applicator have it and the cable bridge for the solenoids 10 to the connector 11 When all the cables have been properly connected fasten the connector and plate 12 onto the connection housing using the four screws 13 Before assembly make sure all spare parts are available new in unopened package if so delivered other parts thoroug...

Page 41: ... tools with article number 6004 0802 00 are used see page 16 Place the seal mounting tool 6 on top of the material distribution ring 5 then place a seal into the seal mounting tool 6 and mount it into the material distance ring by pressing it into position using the pressing tool 7 Lightly lubricate the inside 8 of the seal mounting tool for easier mounting of the material seal rings There are two...

Page 42: ...age Lightly lubricate the inside of O rings 1 when they are mounted in the material chamber and the outside of the material seal package 5 Place the material seal package at the top of the material chamber align the pin 6 with the cutout 7 in the swivel housing Put the parts between the jaws of the vice then tighten the vice to press the material seal package into place The material seal package c...

Page 43: ...e the air distributor ring 5 Lightly lubricate the inside of the O rings 1 and the outside of the air distributor ring 5 Place the air distributor ring 6 on top of the material seal package use the pins 7 and corresponding holes 8 for correct alignment Align the air housing pins 9 with the holes 10 in the material housing 1 3 4 5 Ensure a proper work bench with a vice with soft jaws CAUTION 7 6 8 ...

Page 44: ...r pressing the internal parts in position fasten the air housing and the material housing together with four screws 2 Place the three O rings 3 in position in the cutouts in the air housing 1 Fasten the solenoid valve block 4 to the air housing using four screws 5 Note the O ring 6 and make sure it does not fall out when the solenoid valve block is mounted 1 Ensure a proper work bench with a vice ...

Page 45: ...nnection housing to the swivel housing with the two screws in the front 3 and the two screws in the back 4 Plugin the cable bridge connector 4 into the header 5 for the solenoid valves The connection housing and the swivel housing have been assembled and mounted together They can be put to the side and assembly of the central body and its parts need to be done next 1 3 11 1 Nm 2 4 6 5 Nm 4 4 5 ...

Page 46: ...istance piece There are a total of 6 of each seal and O ring that are mounted to the different distances Note the difference between the needle guides for the inlet 3 and return 4 channels Lightly lubricate the O ring 5 before mounting the needle guides in the central body axis 6 Mount the distance rings 7 in place Lightly lubricate the O rings 8 then mount the upper needle guides 9 into the centr...

Page 47: ... 10 4 and 6004 0154 11 5 needs to be used Place the seal 2 on a flat surface then push the seal 2 in place in the tool note the cutout 6 on one side of the tool and the correct direction 7 of the seal Place the tool 4 over the position of the seal then push the seal 2 into position with the tool 5 Make sure that the two pins 8 9 are in their correct position or place them in position if they have ...

Page 48: ...s 4 5 in the cylinder block and the corresponding holes in the central body axis 6 7 to guide the two parts to the correct mounting position With the cylinder block 1 mounted to the central body axis 2 it can be installed into the swivel chamber Lightly lubricate the seals 8 inside the swivel housing and the outside of the central body axis 9 3 6 5 Nm 6 7 8 2 9 4 5 ...

Page 49: ...tion housing and swivel housing in a vice with soft jaws 1 Place the two pins 2 in place in the air housing should they have been removed Place the bracket 3 in place guided by the two pins 2 Mount the bracket 3 to the air housing using the four screws 4 1 1 Always use a vice with soft jaws NOTE 2 4 3 ...

Page 50: ...mber and pressed 1 into place Rotate the central body axis 2 whilst applying pressure for easier installation With the central body axis installed in the swivel chamber screw on the lock ring 3 to hold the central body axis in place and place the three O rings 4 into their grooves Mount the pin 5 should it have been removed 1 2 3 4 5 ...

Page 51: ...s 2 through from the front of the central body axis When the needle has been pushed through the piston can be attached Before the piston 3 is attached to the needle the O ring 4 and guide rings 5 needs to be mounted to it The piston 6 is mounted onto the needle and fastened with two stop screws 7 Make sure that the needle is bottomed out in the piston 8 so that the stop screws are fastened in the ...

Page 52: ...r block Repeat the steps on the previous and this page until this point for all the needles and pistons With all the needles and pistons in place the central body extension 5 is mounted to the central body axis The central body extension is fastened to the axis using the ring attachment 6 and three screws 7 Use the pin 8 and corresponding hole 9 to guide the extension to its correct position 1 3 2...

Page 53: ...g the pins 3 and corresponding holes 4 then fasten the nozzle head with three screws 5 For the square adapter 6 guide it using the pins 3 and corresponding holes in the adapter 7 The adapter is then fastened to the central body with three screws 8 After placing the seals 9 in place a nozzle head 10 can be attached to the square adapter 6 using four screws 11 1 4 4 5 3 3 Nm 2 3 3 3 6 8 3 3 Nm 9 10 ...

Page 54: ...tons The cylinder cover 2 is then placed on top of the springs and mounted to the cylinder block with three screws 3 which are tightened alternately Slide the protection cover 4 over the central body extension and in place on the swivel housing then use four screws 5 to fasten it 1 2 3 3 3 Nm 4 5 1 35 Nm 5 ...

Page 55: ... to the nozzle head using one screw 5 When mounting the nozzle cap to the nozzle head make sure that the nozzles do not fall out For the square nozzle head 5 put the seals 6 in place Then slot the nozzles 3 into the nozzle plates 7 and fasten the plates to the nozzle head using two screws 8 The applicator is now fully assembled and should be tested to ensure correct assembly 1 2 4 3 3 5 11 1 Nm 6 ...

Page 56: ...l of function test is to connect the compressed air supply checking for air leakage by opening each of the solenoid valves manually The electrical connections can be checked using an ohm meter to test the connections from the plug to the terminals and to make sure that there are no short circuits Make one last check on all fasteners and then follow the installation instructions Chapter 3 page 17 t...

Page 57: ...Approx 3 7 kg Length 469 9 mm Swivel height Basic Swivel height Circulation 172 8 mm 201 8 mm Mounting arrangement Robot mounting flange Max working pressure 250 bar Max working temperature 80 C Material inlet Male 3 8 BSP connector Material return Male 3 8 BSP connector Air ports 8 mm Minimum air pressure requirement Maximum air pressure 5 5 bar 7 bar Material leakage port 8 mm ...

Page 58: ...N www carlisleft com 77 3345 R1 1 06 2022 58 62 8 Dimensions Basic connection housing without circulation Round nozzle head Temperature and Pressure connection housing with circulation Round nozzle head ...

Page 59: ...EN www carlisleft com 77 3345 R1 1 06 2022 59 62 8 Dimensions Temperature and Pressure connection housing with circulation Square nozzle head ...

Page 60: ...ance has to be evaluated for each case of application Refer to the service interval instruction manual for additional information Maintenance frequency Due to the variations in working conditions it is not possible to give a general frequency for preventive maintenance The figures below can thus only be used as guidance for the maintenance frequency and are best estimates based on standard materia...

Page 61: ...EN www carlisleft com 77 3345 R1 1 06 2022 61 62 NOTES ...

Page 62: ...l assistance or to locate an authorized distributor contact one of our international sales and customer support locations For the latest information about our products visit www carlisleft com Region Industrial Automotive Automotive Refinishing Americas Europe Africa Middle East India China Japan Australia Carlisle Fluid Technologies is a global leader in innovative finishing technologies Carlisle...