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E480 CS Gun Manual 9836 4175 01
- E480 CS Gun Manual 9836 4175 01 [ English ]
EN
SERVICE MANUAL
www.Binks.com
Binks E480 CS
Swiveling applicator for Robotic
Sealing Applications
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1. Safety information ................................................................... 3
1.1 Warnings ............................................................................. 4
2. Description ............................................................................... 5
2.1 Central body ......................................................................... 6
2.2 Swivel housing ....................................................................... 8
2.3 Connection housing ............................................................. 10
2.4 Nozzle head ........................................................................ 11
2.5 Intermediate piece .............................................................. 12
2.6 Cylinder ............................................................................. 13
2.6.1 Cylinder, optional equipment ........................................... 14
2.7 Laser sensor bracket ........................................................... 15
2.8 Swivel locking bracket ......................................................... 16
2.9 Mounting flange .................................................................. 17
3. Installation instructions ........................................................ 18
4. Dismounting instructions ...................................................... 26
5. Disassembly instructions ....................................................... 28
6. Assembly instructions ............................................................ 37
6.1 Testing before installation .................................................... 50
7. Technical specifications ......................................................... 51
8. Dimensions ............................................................................. 52
9. Maintenance ........................................................................... 53
This manual contains important information about warnings and cautions. Read the manual thoroughly be-
fore starting to operate this equipment, and carefully follow the instructions. Always keep the manual handy
until such time the equipment is no longer being used. If your manual is lost or damaged,
immediately contact your supplier for a new copy.
Content:
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1. Safety Information
Thank you very much for choosing the Binks E480 CS sealing applicator.
In order to keep the equipment in the best condition for an extended period, please carefully
read this manual before use. Above all, the specifications, warnings and prohibitory or cau-
tionary instructions shown shall be fully understood and observed while using the equipment.
The equipment covered by this manual is designed for automotive sealing application. It shall
only be used by those who have been correctly trained regarding the handling and scope of
application and have a full understanding of the operating procedure.
If you need further information about this product, please contact your supplier and refer to
the model and serial No. of your equipment.
The Binks E480 CS 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 work on this equipment.
All personnel working with this equipment must study this manual so that they are familiar
with the equipment, how it operates and it’s safety features.
Keep the equipment clean at all times to ensure safe operation.
Make sure to release pressure from the material supply system before attempting any
maintenance work on the Binks E480 CS applicator.
To prevent any personal injury or equipment damage, make sure that the maximum operating
pressures are not exceeded.
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In this manual, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows:
Read the following warnings before using this equipment
! WARNING
NOTE
or
in
or
in minor
AUTOMATIC EQUIPMENT
Automatic equipment may start suddenly without warning.
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.
NEVER MODIFY THE EQUIPMENT
Do not modify the equipment unless the manufacturer provides written
approval.
NOISE HAZARD
You may be injured by loud noise. Hearing protection may be required when
using this equipment.
READ THE MANUAL
read and all safety,
and maintenance in the
TRAINING
All must be before equipment.
EQUIPMENT HAZARD
can cause the to or start
and result in injury.
LOCK OUT / TAG-OUT
Failure to de-energize, disconnect, lock out and tag-out all power sources
before performing equipment maintenance could cause serious injury or
death.
PRESSURE RELIEF PROCEDURE
Always follow the pressure relief procedure in the equipment instruction
manual.
KEEP EQUIPMENT GUARDS IN PLACE
Do not operate the equipment if the safety devices have been removed.
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT IN CASE
OF AN EMERGENCY
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.
STATIC CHARGE
Fluid may develop a static charge that must be dissipated through proper
grounding of the equipment, objects to be sprayed 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 injury or death if inhaled. Wear a respirator
as recommended by the fluid and solvent manufacturer’s Safety Data Sheet.
TOXIC FLUID & FUMES
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in
the eyes or on the skin, inhaled, injected or swallowed. LEARN and KNOW the
specific hazards or the fluids you are using.
FIRE AND EXPLOSION HAZARD
Improper equipment grounding, poor ventilation, open flame or sparks can
cause a hazardous condition and result in fire or explosion and serious injury.
MEDICAL ALERT
Any injury caused by high pressure liquid can be serious. If you are injured or
even suspect an injury:
Go to an emergency room immediately.
Tell the doctor you suspect an injection injury.
Show the doctor this medical information or the medical alert card
provided with your airless spray equipment.
Tell the doctor what kind of fluid you were spraying or dispensing.
GET IMMEDIATE MEDICAL ATTENTION
To prevent contact with the fluid, please note the following:
• Never point the gun/valve at anyone or any part of the body.
• Never put hand or fingers over the spray tip.
• Never attempt to stop or deflect fluid leaks with your hand, body, glove
or rag.
• Always have the tip guard on the spray gun before spraying.
• Always ensure that the gun trigger safety operates before spraying.
It is the of the to this to the of the
For see the
PINCH POINT HAZARD
Moving parts can crush and cut. Pinch points are basically any areas where
there are moving parts.
CAUTION ! WARNING !
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2. Description:
The Binks E480 CS is a lightweight, high-pressure applicator designed for robotic application of
cosmetic sealing, an application requiring high precision and quality demands. The applicator is equipped
with a swivel for optimum robot flexibility and is designed to be used with a single nozzle or with a tool
changer. It is designed to handle most types of single component adhesives and sealants with medium to
high viscosity.
The swivel makes it possible for the robot to rotate the nozzle head independently of the cables and hoses
supplying the applicator. The nozzle head can be specified for various nozzle angles and directions.
The solenoid valves controlling the pistons for material valves are placed externally for ease of
maintenance.
The gun includes three material valves, two of them are controlling opening/closing of nozzle 1 and nozzle
2, the third is controlling the opening/closing of the circulation flow. Material circulation with the integrated
circulation valve is provided through the entire length of the applicator for material thixotropy breakdown
and temperature control.
If required, the following optional features can be added to the configuration of the applicator:
• Induction sensors for indication of needle opened/closed and actuation times.
Main parts:
Connection housing
Mounting flange
Cylinder assembly
Central body
Nozzle head
Lock ring
Swivel chamber
Needle sensors
(optional)
Laser sensor bracket
Intermediate piece
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2.1 Central body:
The Binks E480 CS applicators central body consists of these main parts:
A needle guide is located at the front end of the central body to
align the needle valves with the valve seats in the intermediate piece.
Important! Note that the needle guide is asymmetrical.
The gasket seals between the central body and the intermediate piece and keeps the material supply and
the material return channel separated. Two locating pins ensure that the intermediate piece is always
mounted in the correct position.
Valve needles packing sets. The packing sets seal off the valve needles from material and air pressure.
Correct mounting of
needle guide
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2.1 Central body:
The central body connects material and air to the nozzle head and the cylinder block, respectively.
Two channels supply material up to the nozzle head. A third channel is provided for the material return
flow back to the swivel housing.
Channel arrangements in the central body:
Material supply channels
Material return channel
Air signals
Material supply channel
Material return channel
Air channel
Air signals
Nozzle 1
Needle channel
Nozzle 2
Needle channel
Return
Needle channel
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2.2 Swivel housing:
The swivel housing supplies the material from the connection housing to the central body and the
cylinder unit. External solenoid valves supply compressed air to the cylinder unit.
The material supply normally includes two channels (1), one for the material supply, the other for the
material return. The return channel is in the front end of the swivel housing.
The supply and return channels are separated by a seal ring.
At both sides of the swivel chamber a bearing (2) ensures that the swivel chamber is always in a centered
position on the central body.
The distance ring (3) in front of the leakage hole is located between the channels for material and air.
All sealings and distance rings are locked in place by the bearing housing (4) at the rear end of the swivel
chamber.
2
3
1
2
4
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2.2 Swivel housing:
The external solenoid valves (1) controlling the product valves are easily accessible under the cover (2).
The solenoid for the circulation valve (R) is placed on the left of the manifold. The solenoid for application
in the nozzle head is placed in the middle (3) while the solenoid for application through the intermediate
piece is placed on the right (4), as shown below.
1
2
R 3 4
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1
Connection housing with sensors
S
R
4
2 3
2.3 Connection housing:
The connection housing is designed as the common platform for all external connections to the
Binks E480 CS applicator.
The connections for material supply (S) and return (R) are placed in the upper connection piece.
The nipples (R, S) and the gaskets (1) are internal 3/8 BSP.
One 18-pin connector for electrical signals (2) is mounted in the bracket attached to the base module.
The base module also includes a PT 100 temperature sensor (3) and a pressure transducer (4) in the
material inlet channel.
Unless the pressure or temperature sensors are malfunctioning they
should NOT be removed from the lower connection housing. Removing or
cleaning either of the sensors may damage them and cause them to
malfunction.
CAUTION !
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2.4 Nozzle head:
The front side of the nozzle head is designed to accommodate an external tool changer with one tungsten
carbide seat (1).
The nozzle head is attached to the intermediate piece (described on page 12) by two short screws (2) and
one long screw (3), that goes through the intermediate piece and screws into the central body.
Two locating pins (4) are used to guide the tool changing bracket. Important! The pins are placed
asymmetrically to mirror the tool changing bracket.
1
3
2
4
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2.5 Intermediate piece:
The intermediate piece is connected to the central body with two screws (1), and a third screw which is
describe on page 11. Locatin pins (2) guides the nozzle head to its correct possition. Two O-rings are used
to seal between the nozzle head and the intermediate pice, one O-ring (3) seals the return channel and a
second O-ring (4) is fitted into a curvatured slot. A needle seal (5) is placed in the front to separat the
return channel in the central body.
The rear side has one needle seat (6) for the second nozzle. The nozzle in the intermediate piece is
mounted by two screws (7) onto the planar surface or by the use of a nozzle holder (8). An o-ring (9) is
used to seal between the nozzle and intermediate piece. Two guiding sleeves (10) with different diameter
ensures that the position of the second nozzle is correct. Note the placement and direction (11) of the two
needle seals (5).
1
4
5
1
3
5
6
7
8
10
9
11
>
>
<
<
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2.6 Cylinder:
The main part of this assembly is the cylinder block (1) which has three pneumatic cylinders that operate
the material valves. In each of the cylinders, a piston (2) is fixed to a 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.
Inductive sensors (5) is an optional part of this assembly, see next page.
1
4
3
2
5
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2.6.1 Cylinder, optional equipment:
Additional inductive sensors (1) for needle actuation times can be fitted in the cylinder cover (2).
Electrical signals for these components are handled by slipring disks in the swivel housing (3) and central
body (4).
2
3
4
1
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2.7 Laser sensor bracket assembly:
The bracket (1) is clamped onto the central body with a U-clamp (2) and fastened with two screws (3). Two
guide pins (4) ensures the correct position on the central body. Two guide pins (5) for the sensor are fixed
in the bracket (1).
3
1
4
5
2
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2.8 Swivel locking bracket:
Connected to the swivel housing is the swivel locking bracket, that locks the swivel housing and the
connection housing to a fixed 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.
Depending on robot type the swivel lock might have too be aligned to the rotational centre of the 5th axis
of the robot using a calibration tool.
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1
5
3
2
4
2.9 Mounting flange:
The mounting flange (1) is the interface between the Binks E480 CS applicator and the sixth axis of the
robot. Consequently, the design of the mounting flange is robot dependant.
The flange is fixed to the robot using screws with an extra-low head (2). The guide pin (3) locks the flange
in position on the robots sixth axis. With the flange fixed to the robot, the applicator is mounted on the
flange and fixed in position by two guide pins (4) and three M6 screws (5).
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3. Installation instructions:
To ensure a trouble free operation of the Binks E480 CS applicator it is very important that the unit is
properly installed on the robot. It is also very important that the function of the applicator is carefully
checked before start up.
It is recommend using the tools supplied in the specific tool kit (sold separately) for
convenience and correct fit, Part nr. 6004 0154 05
Installation of the Binks E480 CS applicator
Following parts are normally required:
1 pc. Binks E480 CS applicator with nozzle head and nozzle cap.
1 pc. Robot mounting flange.
1 pc. Swivel locking bracket.
1 pc. Cable with 18-pin connector (other configurations possible).
3 pc. Nozzles
(See accessories list (9836 4139 02) for available options)
Before the applicator is installed for the first time a calibration tool (part nr. 6004 0154 03)
must be used to align the swivel lock to the 5th axis of the robot.
The calibration toolbox contains the following:
1 pc. Calibration tool robot
1 pc. Calibration tool axis
3 pcs. Pin 6x12 mm
6 pcs. M6x12 mm hex socket screws
Follow the instructions on the next pages for the swivel locks that
requires a calibration. Make sure to position the 6th axis of the
robot in accordance to the type of swivel lock that is used.
If the robot bracket or frame is removed a recalibration is required.
Before starting installation of the Binks E415
applicator, always read chapter 2: Descrip-
tion, in order to be familiar with the various
parts of the applicator.
NOTE
Be especially careful when connecting the
high pressure material supply system and
always keep clear of the nozzles when test
spraying.
WARNING !
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3. Installation instructions:
Swivel locking bracket (6004 0154 54 and 6004 0154 95) (instructions are shown with a ABB robot)
Fasten the calibration tool on the 6th axis of the
robot.
Attach the robot bracket to the robot, do not
tighten the screws.
Do not tighten
Put the calibration tool for the axis in place without
forcing it and tighten the screw.
Tighten the screws on the frame.
Tighten the
screws
Remove the calibration tools. The swivel lock is
calibrated and the applicator can be installed.
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Fasten the calibration tool on the 6th axis of the
robot.
Attach the frame to the robot, do not tighten the
screws.
Attach and fasten the robot bracket to the frame. Put the calibration tool for the axis in place without
forcing it and tighten the screw.
Tighten the screws on the frame. Remove the calibration tools. The swivel lock is
calibrated and the applicator can be installed.
Do not tighten
Tighten the
screws
3. Installation instructions:
Swivel locking bracket with frame (6004 0154 87 and 6004 0154 99) (instructions are shown with
a ABB robot)
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3. Installation instructions:
For the applicator with a tool changer nozzle head, a bracket (1) needs to be instaled before it can be used.
Mount it with four screws (2). Note that the pins (3) are asymmetrically placed on the nozzle head
to fit the bracket, see page 48. Attach the nozzle on the intermediate piece with the two screws (4) by
either using a bracket (5) or the base of the nozzle itself.
Fasten the mounting flange to the 6th axis of the robot using the six screws with low heads (6), make sure
the pin (7) is in the correct position. Align the applicator with the two pins (8) in the mounting flange and
then fasten the applicator using the three screws and spacers (9).
6
7
8
8
8
9
8
1
3
3
2
4
5
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Fasten the robot bracket to the robot. Hold the distance piece in place and put the swivel
locking bracket in place. Do not tighten the
screws for the plastic bearings.
Tighten the screws by the distance piece. Keep the
plastic bearing screws loose.
Apply hand pressure on the sides of the plastic
bearings to push them against the axis.
Tighten the
screws
Tighten the screws while still applying hand
pressure on the plastic bearings.
Do not tighten
The swivel lock is installed.
3. Installation instructions:
Next step in installing the applicator is the swivel locking bracket. The installation instructions on this page
and the two following shows how to install the standard swivel locking brackets. (instructions are shown
with a ABB robot)
Swivel locking bracket (6004 0154 95)
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Fasten the frame to the robot.
Fasten the robot bracket to the frame. Hold the distance piece in place and put the swivel
locking bracket in place. Do not tighten the
screws for the plastic bearings.
Tighten the
screws
Tighten the screws by the distance piece. Keep the
plastic bearings screws loose.
Apply hand pressure on the sides of the plastic
bearings to push them against the axis.
Attach the last piece of the frame.
Do not
tighten
3. Installation instructions:
Swivel locking bracket with frame (6004 0154 99) (instructions are shown with a ABB robot)
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3. Installation instructions:
When the applicator is fixed in the correct position the electrical cables can be connected. First, connect the
cable (1) to the applicator and the cables to the laser scanner (2), then install the cable to the robot and
make the appropriate connections in the control cabinet.
Swivel locking bracket with frame (6004 0154 99)
Tighten the screws while still applying hand
pressure on the plastic bearings.
The swivel lock is installed.
1
2
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3. Installation instructions:
The air supply is connected to the 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).
After completion of the installation of hoses and cables, their free movement must be checked by moving
the fifth axis of the robot. The hoses and cables must be able to move freely without stretching or
scratching the robot arm.
With the applicator properly installed on the robot, the functions of the unit can be tested. First, open the
air supply. There must be no sound from leaking air.
Check that the solenoid valves are working 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 the nozzles 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 through the dump valve until all entrapped air in the
material return is removed.
1
I
R
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4. Dismounting instructions:
Disconnect the material inlet hose and the material return hose (1), and disconnect the air hose (2).
Always use two wrenches when loosening the high pressure hose connection.
Disconnect the cables to the laser sensor (3) and unplug the electrical connector (4) by pulling the cable
connectors backwards from the gable.
Before any service or cleaning action is
undertaken on the applicator make sure that
air and material pressures are relieved!
WARNING !
Clean the unit and all parts surrounding it
before removing the applicator.
NOTE
4
3
1
2
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Be sure to store all removed parts in a safe place.
4. Dismounting instructions:
Unscrew the two screws (1) which fixes the swivel housing to the swivel lock bracket. Two different types
of swivel locks are shown below:
Unscrew the three screws (2) that mounts the applicator to the robot mounting flange.
Now the main parts of the applicator can be removed from the robot.
1 1
2
2
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5. Disassembly instructions:
The disassembly starts with removing the laser sensor
arrangement. To do this, unscrew the two clamp fixing
screws (1) and remove the two parts.
Observe the orientation pins (2) which might come loose
when disassembled.
Unscrew the four socket head screws (3) that fix the
nozzle holder fixation frame and remove it.
Note the two locating pins for the fixation frame (4).
Unscrew the three screws (5) that fasten the nozzle head
connection to the central body. You can now
remove the nozzle head connection (6) that is fixed with
two locating pins.
Immediately clean all parts after removal
that will be fitted again and inspect the
cleaned parts for damage and excessive
wear and replace if so necessary.
NOTE
Ensure a proper work bench with a vice with
soft jaws and that access to compressed
air is available to facilitate the work. Do not
fasten the central body on the sleeve.
CAUTION !
Be sure to store all removed parts in a safe place.
1
2
3
3
4
5
6
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
To remove the intermediate piece the two needles (1) that
are visible needs to be removed.
Unscrew the three screws (2) holding the cylinder cover (3)
and remove it and the springs (4).
Pull on the piston or carefully push on the needles (1) to
move the piston to a position where the set screws are
accessible.
Loosen the screws (5) for the two pistons.
The pistons can then be pulled out of the cylinders.
With the two pistons removed the needles (6) can be pulled
out of the central body from the front.
To remove the intermediate piece unscrew the two screws
(7), holding it to the central body, and pull it (8) of the
locating pins (9).
1
2
4
3
5
6
7
8
9
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
The nozzle can be removed by unscrewing the two screws
(1). Remove o-rings (2), and needle seals (3) from the
intermediate piece, the needle seals are placed inside the
intermediate piece as shown below.
The last piston can now be removed if so was not done
earlier. Pull on the piston on gently push the needle to
move the piston to a position where the set screws are
accessible. Loosen the set screws (4) and pull the piston
out of the cylinder.
After the piston has been removed pull the remaining
needle (5) out from the central body. Also remove the
needle guide (6) and the packing (7).
2
3
3
1
3
3
4
6
7
8
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
With the intermediate piece removed from the central body, loosen the two screws (1) and slide the lock
ring off the central body. (2)
Remove the seal ring (3). Next step is to separate the central body with the swivel housing. This is easiest
done by first fastening the connection housing or swivel housing in a vice with soft jaws (4). Then by use of
moderate force first rotate (5) and then push (6) the central body out of the swivel housing.
2
1
1
6
5
4
4
3
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
If an intermediate service is done the swivel housing and connection housing does not need to be taken
apart from each other. For a major service swivel and connection housing, needs to be taken apart.
Unscrew the four screws (1) holding the solenoid valve cover and then remove it (2).
When the cover over the solenoid vales has been removed the cables (3) can be unscrewed. To separate
swivel and connection house first unscrew and remove the connection housing covers (4). Then unscrew
the four screws (5) holding the two parts together.
1
2
1
3
4
4
4
5
5
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
All internal parts can now be removed from the swivel chamber. If need be the solenoid valves can also be
detached. All internal gaskets and seals should be replaced if the swivel chamber is dismantled.
To get access to the components in the swivel housing start with unscrewing the four screws (1) that hold
the bearing housing (2) to the swivel chamber and then remove it. After the bearing housing is removed
the air distributor assembly, the seals and distance rings can be removed from the swivel chamber by
using the swivel house tool (3) and pulling them out. The solenoid valves (4), manifold (5), manifold
packing (6), and air connector (7) can also be removed if service is needed.
1
2
3
4
5
7
6
Cut view of swivel chamber
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
The connection housing can also be further dismantled, by unscrewing the four screws (1), if o-rings (2)
needs to be replaced. In case the sensors, pressure (3) and temperature (4), are malfunctioning they can
also be removed.
If the pressure sensor is removed it needs to be handled with utmost care since even the smallest force to
the pressure plate might cause the sensor to malfunction.
2
2
3
1
4
Unless the pressure or temperature sensors are malfunctioning they
should NOT be removed from the lower connection housing. Removing or
cleaning either of the sensors may damage them and cause them to
malfunction.
CAUTION !
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Unscrew the three screws (1) and remove the cylinder
housing from the central body.
Remove the three needle packings (2) from the cylinder
housing.
Remove the cylinder packing (3) and pull out the needle
packing spacers (4). See accessories manual for additional
information and special tools. Remove the needle packings
(5) from the needle packing spacers.
1
2
3
4
5
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Pick up the needle packings and needle guides with the special tool (6004 0154 11).
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6. Assembly instructions:
Assembly of the E480 CS starts with assembling of the swivel chamber. The swivel chamber is described on
page 8. When assembling the swivel chamber it is important that the various parts are assembled in the
correct order.
Follow instructions below on how to mount seals in the swivel housing in a safe way and avoid o-ring
damage. Always use spare parts from your dealer. Item article numbers can be found in the spare parts list
for your model. For easy installation lightly lubricate o-rings and seals!
Angle the seal ring to avoid the sharp edge. Push the seal ring into place using the swivel
house tool.
Sharp edge
Before assembly, make sure all spare parts
are available (new in unopened package if so
delivered), other parts thoroughly cleaned.
NOTE
Ensure a proper work bench with a vice with
soft jaws. Do not fasten the central body
on the sleeve. Suitable lubricant and thread
locking compound should also be available.
CAUTION !
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6. Assembly instructions:
Angle the seal ring to avoid the sharp edge.
Sharp edge
Push the seal ring into place using the swivel
house tool.
Angle the seal ring to avoid the sharp edge.
Sharp edge
Push the seal ring into place using the swivel
house tool.
Lightly lubricate the inside of the swivel chamber.
Use the O-ring mounting protector to cover the
sharp edges. Lightly lubricate the side facing the
air ring.
Sharp edges
Push down the air ring with your thumbs. Lightly
lubricate the O-rings for easier mounting.
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6. Assembly instructions:
Pull out the plastic strip.
When all the parts are mounted in the swivel chamber the bearing housing (1) can be fastened with four
screws (2). Do not forget to mount the two bearings (3) on both sides of the swivel.
When mounting the bearing housing note the four pins (4)
and the corresponding holes in the air distributor ring (5).
They need to be aligned when the bearing housing is
fastened and stops the air distributor ring from rotating.
2
3
3
5
4
1
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6. Assembly instructions:
Mount the air connection (1) and the cover (2) in case
they have been removed or changed.
Place the manifold packing (3) on the swivel housing
and fasten the manifold (4) with the two screws (5).
Make sure that the swivel housing and the manifold are
clean.
Mount the solenoid valves (6) on the manifold.
Note the position of the valves in correspondence to the
central body channels.
1
2
3
5
4
6
R 1 2
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6. Assembly instructions:
If the connection housing has been disassembled it needs to be put back together and mounted to the
swivel housing. Start with attaching the upper connection piece (1) to the lower (2), do not forget the
o-rings (3). Mount the connection housing to an already serviced swivel housing with four screws (4). When
mounting the connection housing on the swivel housing it is important to check that the o-rings for the ma-
terial channels are in their correct positions (5).
When the connection housing is mounted to the swivel, if the cables for the valves and sensors (if they are
available) were disconnected reconnect them to the connector. Attach and screw the cables (6) for the
solenoid valves to the solenoid vales. Then fasten the three covers (7) for the connection house and the
cover for the solenoid valves (8).
3
5 2
1
4
4
8
7
7
6
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6. Assembly instructions:
To assemble the central body, the first step is to insert the
needle packings (1). The seals are inserted using the special
packing mounting tool 6004 0154 10 (2). When inserting
the packings it’s important that the needle packing faces the
right direction (3).
Insert the tool, with the needle packing mounted, into the
central body and use the special tool 6004 0154 11 to press
the needle packing into place (4). After the needle packings
are mounted insert and push down the needle guides (5).
Now the packings spacers (6) can be inserted. Please
observe that the end with the smaller dimension (7) must
face the nozzle head.
3
<
<
1 2
4
5
6
7
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6. Assembly instructions:
Before mounting the cylinder block, the cylinder packing (1)
must be placed in the correct position. It is important to check
that the holes in the cylinder packing correspond to the
channels in the central body.
The smaller size holes (2) are for the air channels and the
bigger (3) are for the cylinder block screws. When mounting the
needle packings (4) on the top of the needle spacers the special
mounting tool must be used in the same manner as when
mounting the needle packings in the central body.
Mount the needle packings (5) on the cylinder block (6)
before it is fastened to the central body with three screws (7).
When mounting the needle packings the special mounting tool
must be used in the same manner as when mounting the needle
packings in the central body.
When mounting the cylinder block, guide it to its correct
position over the needle packing spacers, then push the
cylinder block down against the packing.
Apply light lubrication to the inside walls of the cylinders (8).
Make sure to dry off any lubricant that gets to the bottom (9) of
the cylinders.
3 2
1 4
5
6
7
8
9
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6. Assembly instructions:
Mount the gasket (1) and the needle guide (2). Important! Note that the needle guide is asymmetrical
(3).
Lightly lubricate (4) the top of the short needle and insert it (5) into the central body, it is inserted into
channel 2 (6). Inserting the needles is easiest done with the central body in a horizontal position.
With the cylinder block and needles in position the pistons, lightly lubricated (7) on its sides, can be
inserted in the cylinders and pushed firmly to the bottom position. The needle is then pushed (8) against
the piston, with some pressure against the piston (9), to make sure that the needle bottoms out in the
piston.
1
2
3
Correct mouting
of needle guide.
4
5
6
7
9
8
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6. Assembly instructions:
The needle and piston are then fixed to each other with two set
screws (1) on each piston. Alternately tighten the screws.
When tightening the screws, a small drop of soft thread
sealant (Loctite) should be used on the threads of the screws
so that the screws stay put and to avoid air leakage through
the threads. Wipe off any excess sealant after the screw has
been fastened.
Due to the design of the applicator the next step is to mount the central body in the swivel housing.
Fasten (2) the connection housing in a vice with soft jaws and lightly lubricate the seals inside the swivel
chamber and the sleeve on the central body (3). Slide the central body into the swivel chamber and apply
moderate force to push (4) it down all the way, rotating (5) the central body while pushing help.
1
5
3
4
2
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6. Assembly instructions:
Slide the swivel lock onto the central body and while applying moderate force (1) on the two halves of the
lock ring fasten the screws (2). Important! The screws in the swivel lock should be firmly fastened but not
to tight, note the play between the two halves (3). Mount the seal ring (4).
Before the intermediate piece is attached to the central body
the two needle seals (5) needs to mounted into it. Note the
seals direction (6).
The intermediate piece is then mounted to the central body
with two screws (7). Locating pins (8) and corresponding holes
(9) guides the intermediate piece to the correct position.
5
5
6 6
1
3
2
7
8
8
9
4
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6. Assembly instructions:
Mount the two longer needles and the pistons into the central
body in the same way done with the short needle, which is
described on page 42-43. Mount the two different size O-rings
(2) in their positions.
When the pistons are fixed, the springs (2) are inserted into the pistons and the cylinder cover (3) is
fastened with three screws (4). Alternate between the screws when fastening the cover.
Guide the nozzle head to its correct position with the help of the two locating pins (5) and the
corresponding holes (6) in the nozzle head. The nozzle head in then fastened to the intermediate piece with
three screws (7), the long screw (8) goes through the intermediate piece to attach to the central body. To
make the installation of the tool changing bracket easier place the four screws (9) beforefor attaching the
nozzle head to the applicator.
1
2
2
4
3
5 6
8
7
9
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6. Assembly instructions:
Mount the two small locating pins (1) on the nozzle head. Important! The tool changer bracket (2) is
asymmetrical and must be mounted correctly onto the nozzle head. Compare the correct way (3) and the
incorrect way (4).
Mount the laser sensor by placing the two pins (5) in the slots in the central body. Guide the laser scanner
mounting bracket (6) to its correct position then place the mounting bracket (7) on the opposite side and
fasten both parts with the two screws (8).
2
1
3
4
5
6
7
8
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6. Assembly instructions:
Place the two locating pins (1) in their position on the bracket to guide the laser sensor (2) to its correct
position then fasten it with the three screws(3).
Mount the o-ring (4) on the side of the intermediate piece and fasten the nozzle with the two screws (5),
either by use of the nozzle itself or with the help of a plate (6).
4
6
5
3 1
2
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6.1 Testing before installation:
If the applicator has been assembled after a major repair or maintenance operation, it is recommended to
do a function test before the applicator is returned to production.
The extent of the test is dependent on the degree of maintenance performed on the applicator and the avail-
able test facilities.
A minimum level of function test is to connect a compressed air supply then 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) to mount the
applicator on the robot.
If the applicator has slipring discs, control that the distance between slip ring disc and the electric slip ring
brushes are approximately 2,1 - 2,3 mm. If the distance is not within this interval, contact the
manufacturers.
If the applicator is tested off-line with mate-
rial pressure applied it’s very important to
take appropriate safety measures to prevent
personal injury!
WARNING !
2,1 mm—2,3 mm
Slip ring disc
Electric slip ring brushes
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7. Technical specification:
Torque requirement Nm
M3 1.35
M4 3.3
M5 6.5
M6 11.1
M8 26.6
480 CS (operational)
Weight Approx. 4 kg
Length 401 mm
Swivel height 211 mm
Mounting arrangement Robot mounting flange
Max working pressure 250 bar
Max working temperature 65° C
Material inlet Male 3/8 BSP connector
Material return Male 3/8 BSP connector
Air ports 8 mm
Minimum air pressure requirement 4 bar
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8. Dimensions:
Standard connection housing with tool changer nozzle head
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9. Maintenance:
To ensure top performance, it is very important to maintain the unit properly. This chapter describes the
minimum level of daily, monthly and preventive maintenance.
Daily maintenance
Check the applicator for material leakages by ocular inspection.
Check the leakage detection hole on the swivel chamber and all connections.
Listen carefully for air leakages.
Clean the applicator thoroughly.
Monthly maintenance
All of what is mentioned in daily maintenance
Inspect hoses and cables for excessive wear.
If possible, run a spray test on a spray test table.
Preventive maintenance
Typical wear parts in the applicator are the sealing rings inside the swivel chamber, the central body, the
needles, needle packings and the needle seats. Refer to spare parts manual for additional information and
spare parts numbers.
The wear of these parts is very dependent on the sealer material being used and also depending on the
operation conditions of the applicator.
Due to this, the frequency for preventive maintenance has to be evaluated for each case of application. Re-
fer 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 the preventive
maintenance.
The figures below can thus only be used as a guidance for the maintenance frequency and are best
estimates based on standard material.
If a normal PVC material and supply pressure are used, it is recommended that the needle packings should
be replaced after 1 000 000 cycles (1 cycle = open and close).
The Sealing rings in the swivel chamber is expected to be changed after 2 000 000 rotation cycles
(1 cycle = start to stop).
Preventive maintenance service
Dismount and disassemble the Binks E480 CS applicator according to chapter 4-5.
Clean all parts thoroughly and make sure no parts are damaged or worn out. Replace all parts included in
the service kits. Please refer to the spare parts list for available service kits. After reassembly of the
applicator, test all functions of the applicator to make sure that all parts are installed correctly.
Before any service action is undertaken on
the applicator, make sure that air and
material pressure is relieved.
WARNING !
Always use original spare parts!
NOTE
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