Carlisle Binkes 201-510

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The Binks Model 201-510 Roving Cutter is a specialized device designed for cutting glass roving into short, manageable lengths and dispensing them into a resin fan. This process is crucial for composite applications, where a consistent glass/resin mixture is desired with minimal subsequent rolling.

Function Description

The primary function of the 201-510 Roving Cutter is to precisely cut glass roving into specified lengths, ranging from 1/4" to 1". Once cut, the glass fibers are dispensed directly into a resin fan. When properly adjusted, this integration ensures an optimal mixture, reducing the need for extensive manual rolling. The cutter assembly features a cutting head with blades that rotate at high speed, emphasizing the need for extreme caution during operation.

Important Technical Specifications

Max. Air Consumption: 27 cfm (47 m³/h)
Max. Air Inlet Pressure: 80 psi (5.52 bar)
Air Supply Hose: Requires a minimum 5/16" ID. Using lower air pressures or a smaller diameter hose can lead to poor operation.
Cutting Lengths: Factory set to 1" lengths using four evenly spaced blades. Adjustable to 1/2" or 3/8" by inserting or removing blades.
Cutting Head Assembly (207-11185): Available in different configurations for various cut lengths:
- 1 Inch: Uses 4 blades (207-11191-1 cutting head). Standard.
- 1/2 Inch: Uses 8 blades (207-11191-1 cutting head). Sold separately.
- 3/8 Inch: Uses 12 blades (207-11191-3 cutting head). Sold separately.
Air Motor Assembly (207-12393): The core power unit for the cutting action.
Manifold Assembly (207-11198-1): Manages air flow and controls for the motor and blower.
Mounting Bracket Kit (207-11415): Allows for adjustment of the cutter angle.
Repair Kits:
- 106-1265: Air Motor Repair Kit for Item 5 (Air Motor Assembly).
- 207-10903: Spare Parts Kit, which includes various O-rings, retaining rings, cutter blade spacer, and cutter blades.

Usage Features

Roving Introduction: To begin, double over one end of the roving and insert it through one of the three holes in the feed bar (18) on top of the cutter assembly.
Air Motor Control: The air motor control knob, located on the front of the manifold (6), should be opened three or four turns to initiate operation.
Blower Control: The blower control knob, on the rear of the manifold, should be opened a 1/4 turn.
Dispensing: Pulling the trigger dispenses glass into the resin stream.
Glass Pattern Adjustment: The width of the glass pattern can be varied by opening or closing the blower control knob.
Glass Content Adjustment: Opening the motor control knob increases glass content, while closing it decreases it.
Optimal Adjustment: Both motor and blower controls should be adjusted to achieve the desired output and pattern. The resin fan should ideally be about 3" wider than the glass pattern to pre-wet and post-wet the part effectively.
Cutter Alignment: The cutter's position can be adjusted forward or backward to ensure the roving enters the resin fan with minimal fallout. The cutter angle can be adjusted side-to-side by turning the knob (22g) on the mounting bracket (22).
Cutting Head Tension: The cutting head (11) must have sufficient tension against the anvil sleeve (17) for proper cutting. Excessive tension overloads the air motor and causes starting problems, while insufficient tension prevents complete cutting. The eccentric nuts (4) are used to adjust this tension.
Idler Bearing Adjustment: The idler bearing (16) should have slight contact with the anvil sleeve (17). Eccentric nut (4) on the end of the idler bearing adjusts its tension.

Maintenance Features

Daily Inspection: Inspect the equipment daily for worn or broken parts. Do not operate if uncertain about its condition.
Air Motor Oiling: Lubrication is critical. The air motor (5) should be oiled every 2-4 hours of continuous use. This is done by removing the motor control knob from the manifold assembly (6), inserting 2-3 drops of light-weight machine oil (Binks 207-11155-1), replacing the knob and cutter guard, and running for a few seconds. Excess oil should be wiped off. Alternatively, oil can be added to an in-line oiler on the air supply hose.
Blade Replacement: Blades (11f) are sharp and require caution. They are placed in every other slot for standard 1-inch cut length. For proper balance, blades should be inserted equally around the cutting head (11c).
Disassembly Procedure:
1. Remove cutter guard assembly (14) and chute (13).
2. Remove air motor assembly (5) and manifold assembly (6) by first removing the outer retaining ring (5b) and anvil sleeve (17) from the air motor assembly.
3. Loosen Allen head cap screw (2) to release the air motor and manifold assemblies from the back plate (1). If stuck, apply slight pressure with a screwdriver between the air motor and back plate. Do not use a hammer.
4. To remove the manifold assembly (6), remove the air hose (25), valve, and elbow (21, 23), and the modified head screw (7). This exposes the three O-rings (6f).
5. Inspect muffler (6a) and blower tube (6c) for wear and replace if necessary, ensuring blower holes point in the correct direction.
6. To remove control knobs from the manifold assembly, remove the thumbscrew (6k), then use a screwdriver to remove the packing nut (6i) and O-rings (6g, 6h). Replace O-rings as needed.
7. For air motor disassembly (5), remove pins (5d) holding the tire shaft (5c) to the rotor, then pull the tire off the shaft. Refer to Part Sheet 77-2883 for details.
8. Check bearings (5e) for wear and replace if necessary.
9. To remove the cutting head assembly (11), hold the eccentric nut (4) and unscrew the cutting head bolt (12). To remove cutting blades (11f), pry out the blade spacer (11e) and retaining spring (11d) with a small screwdriver.
10. To remove the cutter bearing (16), hold the eccentric nut (4) and unscrew the hex head screw (15).
Re-assembly Procedure:
1. Manifold Assembly: Lubricate O-rings (6g, 6h) with petroleum jelly and insert into manifold body (6e). Thread packing nut (6i) and lock nut (6j) onto thumbscrew (6k) and into manifold body. Repeat for the other side. Thread jam nut (6d) onto blower tube (6c) and into manifold body, noting blower tube hole position. Thread muffler (6a) into muffler adapter (6b) and into manifold body.
2. Cutting Head Assembly: Insert cutting blade (11f), then blade spacer (11e) into cutting head (11c), followed by retaining spring (11d) using needle nose pliers. Secure with two retaining rings (11a).
3. Final Assembly: Attach cutter bearing (16) and spacer (10) to back plate (1) with hex head screw (15) and eccentric nut (4). Attach cutting head assembly (11) and spacer (10) to back plate using cutting head axle (12) and eccentric nut (4).
4. Add manifold assembly (6) to back plate, ensuring O-rings (6f) are lubricated.
5. Connect tire shaft (5c) to air motor (5) using roll pins (5d). Attach air motor assembly (5) by sliding shaft through back plate, aligning air passages with manifold assembly and O-rings. Secure air motor assembly to manifold assembly with modified screw (7), then to back plate by tightening socket head screw (2).
6. Add anvil sleeve (17) to air motor shaft by applying pressure while rotating cutting head assembly (11) to prevent blade damage. Do not use any tool to force the anvil sleeve on the motor tire shaft, as damage to the motor can occur. Replace retaining rings (5b) and run motor for one minute for proper break-in.
7. Finally, add guard assembly (14) and chute (13).
Air Motor Repair Kit (106-1265) Instructions:
1. Remove end cap, dead end plate bolts, and dead end plate.
2. Remove rotor using an arbor press and remove vanes.
3. Remove shaft seal and bearings from drive end plate and bearing from dead end plate.
4. Clean parts. Replace air motor if scoring exists.
5. Place new cam ring between rotor and drive end plate.
6. Place drive shaft of rotor assembly through drive end plate. Press drive bearing onto drive shaft.
7. Lightly tap inner race of drive bearing to snug up rotor to drive end plate.
8. Install new vanes, ensuring angle cuts on vane face point to center of rotor.
9. Place proper end plate gasket on body of dead end. Replace with new one from repair kit if damaged.
10. Place dead end plate on body.
11. Install dead end bearing and press into place with arbor press.
12. Fully tighten remaining bolts to 75-100 in-lbs.
13. Set end clearance: Total end clearance: .002 in. (.05 mm); Top clearance: .0015 in. (.038 mm). Lightly tap inner race of dead end bearing to free up and center rotor. Rotor must not rub on either end plate.
14. Apply grease to bearing seal and install drive end bearing seal by pressing flush.
15. Reattach end cap.
16. If air motor is lubricated, apply a few drops of 207-11155-1 lubricant into ports and rotate shaft by hand.