Matsui JL4-6V-3~6 Operating instructions

Brand: Matsui

Model: JL4-6V-3~6

Type: Operating instructions

This manual is also suitable for

Issued March 2005

JET LOADER

JL4-V･VC-3~6 MODELS

(U version)

OPERATION MANUAL

WARNING

Thank you for choosing our product.

Before operating this equipment, please read this manual thoroughly.

Keep this manual in a location near the equipment so that it may be readily

referred to whenever a question arises during equipment operation.

Introduction

[WO-4841;JL4-V・VC-3～6]

Thank you for purchasing of our JL4 JET LOADER. Please read this manual carefully for proper and

safe operation. This instruction manual contains warranty information. Please carefully store this

manual after you have read it.

1. Warranty Period

If any defect is found in our equipment under normal operating conditions, and we determine it to be a

defective, we will repair it or replace the parts free of charge within the following period and terms:

1） This warranty shall remain valid for twelve (12) months from the date when the new products you

purchased leave our facility.

2. Scope

This warranty shall be limited to repair of our equipment or replacement of its parts, and shall not

cover any products manufactured by means of our equipment or defects in manufacturing such

products.

3. Exceptions

This warranty shall not apply to the following defects:

1） Defects caused by modifications or repairs made by any party other than our company;

2） Defects resulting from natural disasters such as earthquakes, hurricanes, typhoons and floods,

accidents and fires;

3） Defects resulting from use exceeding limitations in the specifications set forth in the instruction

manuals or catalogs;

4） Defects resulting from non-performance of maintenance and inspection by not observing manual

instructions.

5） Defects in the equipment caused by outside factors such as peeling of coating caused by generated

gas and malfunction due to electrical noise;

6） Defects resulting from non use of genuine parts (oil, medium, filters, etc.)

7） Consumables (hoses, filters, gaskets, O-rings, etc.).

4. After the warranty period expires

We will make repairs for a charge, if the performance of our equipment can be maintained by such

repairs.

5. Period during which parts can be supplied

As an approximate standard, service parts for our equipment can be supplied for eight (8) years after

the equipment is discontinued. However, some parts may be supplied even after the period elapses. So,

please make an inquiry at our service department about the availability of service parts.

Contents

- Ⅰ -

[WO-4841;JL4-V・VC-3～6-Ⅰ]

The following marked chapters are very

important. Please read them in advance and pay

attention to them.

Introduction

Contents ································································································································· I - II

Chapter 1 Configuration of Equipment

1. Product model ·················································································· 1

Flow diagrams ·················································································· 2

Packing list ······················································································· 4

Chapter 2 For Safe Operation

1. Label and meaning of each indication ············································· 7

2. Items to be observed for safety ······················································· 8

3. Labels ····························································································· 9

Chapter 3 Installation

1. Mounting the collection hopper························································· 10

2. Installation ························································································ 14

3. Connecting the power······································································· 17

Chapter 4 Preparations for Operation

1. Checking the status of each component··········································· 19

2. Control panel description ·································································· 21

Chapter 5

Operating Procedures

1. Starting procedure ··········································································· 22

2. Stopping procedure ·········································································· 23

3. Cleaning procedure ·········································································· 24

Contents

- Ⅱ -

[WO-4841;JL4-V・VC-3～6-Ⅱ]

Chapter 6 Operational Descriptions and Timing Charts

1. Jet Clone types- limit or level switch control collection hopper ······· 25

2. Vacuum hopper types, E2K control collection hopper ····················· 27

3. Jet Clone types- cylinder control or suction hopper type ASD control

collection hopper ············································································· 29

Chapter 7 Respective Parameter Setup

1. Setting guide ··················································································· 31

2. Setting procedures ··········································································· 36

Chapter 8 Inspection and Maintenance

1. Daily inspection ················································································ 38

2. Monthly inspection············································································ 41

3. Component adjustment procedure ··················································· 44

4. Operation check procedure of 3-6 way selector valve ······················47

5. Operation check procedure of automatic slide gate ························ 48

Chapter 9 Troubleshooting························································ 49

Chapter 10

List of Consumables······················································ 59

Chapter 11 Specifications········································································60

Chapter 12 Options························································································ 61

Chapter 1 Configuration of Equipment

- 1 -

[WO-4841;JL4-V・VC-3～6-1]

The following marked chapters are very

important. Please read them in advance and pay

attention to them.

1. Product model

1) Collection Hopper and Control Procedure

Collection Hopper Control Procedure

Limit control

Level switch control

Jet Clone

Cylinder control

E2K control

Vacuum hopper

ASD control

2) Loader Unit

Model

JL4-4V-3～6

JL4-5V-3～6

JL4-6V-3～6

JL4-4VC-3～6

JL4-5VC-3～6

JL4-6VC-3～6

3) Flow Diagrams

Flow Diagrams No.

Flow diagram type1

Flow diagram type2

Flow diagram type3

Flow diagram type4

Flow diagram type5

Flow diagram type6

Flow diagram type7

Flow diagram type8

Flow diagram type9

Flow diagram type10

Chapter 1 Configuration of Equipment

- 2 -

[WO-4841;JL4-V・VC-3～6-2]

2. Flow diagrams (V type)

Flow diagram type 1

Flow diagram type 2

Flow diagram type 3

Flow diagram type 4

Flow diagram type 5

Jet Clone type

limit control

Conveying hose

PVC hose

Suction nozzle

Signal cord

Suction unit

Jet Clone type

Connector

E2K control

Suction hoppertype

SD control

Suction hopper type

Jet Clone type

limit control

cylinder control

Suction hose

GL-1V Hose

Connector

2-way valves are shown in the following diagrams, however, in actuality,

3-6-directional valves can additionally be installed.

Chapter 1 Configuration of Equipment

- 3 -

[WO-4841;JL4-V・VC-3～6-3]

Flow diagrams (VC type)

2-way valves are shown in the following diagrams, however, in actuality,

the valve is additionally installed in 3 to 6 directions, similarly.

Flow diagram type 6

Flow diagram type 10

Flow diagram type 7

Flow diagram type 8

Flow diagram type 9

Jet Clone type

cylinder control

Connector

GL-1V Hose

Connector

Signal cord

limit control

Jet Clone type

PVC hose

Suction nozzle

Conveying hose

Power cord

Suction hopper type

Connector

SD control

Connector

limit control

Connector

Suction unit

E2K control

Suction unit

Jet Clone type

Suction unit

Chapter 1 Configuration of Equipment

- 4 -

[WO-4841;JL4-V・VC-3～6-4]

3. Packing list

Please confirm that all purchased devices are included.

Component Name Style of Packing

●Vacuum unit

JL4-（4,5,6）V-3～6 type

●Vacuum unit

JL4-（4,5,6）VC-3～6 type

●Nylon hose

Aperture φ６， Length ５ｍ

（Standard）

With one touch joint （１ pc.）

※1/4B equivalent product should be

used for coupler connection.

＊ The hose is contained in shrink wrap.

3～6 way selector valve

Chapter 1 Configuration of Equipment

- 5 -

[WO-4841;JL4-V・VC-3～6-5]

Component

Name

Style of Packing

● Jet Clone type limit control

● Jet Clone type level switch control

●

Suction hopper type E2K control

＊

This unit is supplied with an injection

molding machine match base or chute.

● Jet Clone type cylinder control

＊

This unit is contained in a corrugated

cardboard case.

● Suction hopper type ASD control

Collection hopper

<NOTES> The elbow is contained for the Jet Clone type cylinder control and Vacuum

hopper type ASD control. The conditions are as follows.

1. For collection hoppers with an SUS lid, the elbow is attached to the lid.

2. For collection hoppers with an aluminum lid, the elbow is contained in

the corrugated cardboard case or the hopper in the collection hopper.

Chapter 1 Configuration of Equipment

- 6 -

[WO-4841;JL4-V・VC-3～6-6]

Style of Packing

JL4-4V（VC）

JL4-5V（VC）

● Conveying hose (φ38 PVC hose)

JL4-4V(VC): Length 15 ft.

JL4-5V(VC): Length 15 ft.

● Vacuum hose (φ38 GTG hose)

Length 15 ft.

● Hose band (One set is 4 pcs.)

● Suction nozzle (φ38)

Material & Vacuum hoses are wound with shrink wrap.

JL4-6V（VC）

● Material hose (φ50 PVC hose)

Length 15 ft.

● Vacuum hose (φ65 GTG hose)

Length 15 ft.

(One set including 2 pcs.)

● Hose band (One set including 4

pcs.)

● Suction nozzle (φ50)

Material & Vacuum hoses are wound with shrink wrap.

＊

The suction nozzle is wrapped in shrink wrap.

Chapter 2 For Safe Operation

- 7 -

[WO-4841;JL4-V・VC-3～6-7]

This chapter contains instructions for operation, maintenance, and repair to operate

this equipment properly and safely. Also, this chapter explains the labels and

meaning of each indication on the product.

WARNING

Indications for safety described in this manual should be observed when

operating or inspecting this product.

We shall not be responsible for any injury or accidents caused by failure to

observe these indications and we make no warranty against such injury or

accidents.

1. Label and meaning of each indication

This instruction manual uses different indications depending on the extent of

danger as follows:

Label Meaning

DANGER

This indication is used when failure to observe this may cause

user death. Instructions with this indication explain how to

prevent it.

WARNING

This indication is used when failure to observe this may cause

users to be seriously injured. Instructions with this indication

explain how to prevent the injury.

CAUTION

This indication is used when failure to observe this may cause

users to be injured slightly or products to be damaged.

Instructions with this indication explain how to prevent them.

NOTE

This indication is used when special care must be taken in

operation procedure or descriptions, and when the information

should be emphasized.

This mark is used when special care must be taken in handling.

＊

This mark is used when exceptional conditions or cautions are

described in Tables and Figures.

Chapter 2 For Safe Operation

- 8 -

[WO-4841;JL4-V・VC-3～6-8]

2. Items to be observed for safety

To operate this product safely, general instructions which should be

observed are described below.

WARNING

1) Using environment

・ This equipment should be used indoors only.

・ This equipment should be used at ambient temperatures from 32°F / 0°C

to 104°F / 40°C and an ambient humidity of 25-85%.

2) Knowledge of electricity

Inspection or replacement by persons without sufficient knowledge of

electricity may cause defects or danger. Therefore, inspection and

replacement should be performed by a person at your company who has

sufficient knowledge about electricity.

3) Prohibition against operation in gases

Do not operate this equipment in flammable or explosive gases or vapors.

Operating this equipment in such an environment is very dangerous.

4) Prohibition against Modifications

This equipment must not be modified or altered by users without

obtaining our approval. We shall not be responsible for any accidents

caused by modifications or alterations.

5) Inspection

Before maintenance and inspection, be sure to stop operation and turn

“OFF” the power of the primary power supply of your equipment and

power switch of the control panel.

Also stop the compressed air fed to the air kit, press the drain valve of the

filter regulator to release residual pressure in air pipe.

6) Maintenance

Inspection and replacement of parts must be performed by persons who

have sufficient knowledge about this product. Inspection and replacement

by persons without sufficient knowledge about the product may cause

defects or danger.

When maintenance or repair advice is necessary, contact the Matsui

service department, or your local sales representative.

Chapter 2 For Safe Operation

- 9 -

[WO-4841;JL4-V・VC-3～6-9]

CAUTION

1) Disposal of the product and parts

This product and parts are handled as industrial waste and are regulated

by the “Waste Disposal and Public Cleaning Law.” Request subcontractors

who have received an “industrial waste collecting and transporting

permit” or “industrial waste disposal permit” to dispose of products and

parts. For details, contact your local or state environmental development

office.

2) Power supply

This equipment should be operated with a line voltage and frequency

conforming to local or state specifications.

* Be sure to connect the ground wire (to earth).

3) Use of the equipment

This product is a conveying unit for resin pellets. This is not suitable for

other materials, and conveying materials other than resin pellets may

cause defects.

We make no warranty against any problems caused by using materials

other than resin pellets.

3. Labels

Labels are pasted where special care must be taken to prevent danger.

Warnings or cautions must be thoroughly understood before starting an

operation.

1) Handling of label

● Keep the labels legible until scrapping the equipment.

● When a label becomes dirty, wipe it with a soft cloth soaked in warm

water and well wrung out.

NOTE

1) Wiping

Do not wipe the equipment using petroleum solvents. Cleaning with

benzene, thinner, and polishing powder will scratch the surface.

When equipment is blemished badly, wipe it with a soft cloth soaked in

warm water.

Chapter 3 Installation

- 10 -

[WO-4841;JL4-V・VC-3～6-10]

This Chapter describes installation work of the product for each piece of

equipment according to the procedure.

1. Mounting collection hopper

1) Jet Clone type limit, level, cylinder control

Pneumatic

Jet Clone- limit switch control Jet Clone- pneumatic cylinder control (not common)

Step Task Description

Drilling mounting holes Drill holes in the hopper to be mounted so that they match the

mounting holes in the Jet Clone.

＊ It is recommended to tap the hopper holes so that the collection

hopper can be secured with bolts alone. When the holes are not

tapped, the collection hopper should be secured with bolts and

nuts. In this case, an adequate measure should be taken to

prevent the bolts and nuts from falling into the hopper if they

loosen and fall off.

Mounting Jet Clone

Mount the Jet Clone on the hopper on which mounting holes are

drilled.

Mounting level switch

＊ Only when the

collection hopper is

controlled by the

level switch

(not common)

Drill holes at the specified positions in the hopper on which the

suction hopper is mounted, and install the level switch.

Split pin

Flat washer

Packing

Nut

Blade

Connector

Level switch main body

Vacuum port hose

Hopper

Material port

hose

Jet Clone

Hopper

Jet Clone

Material port hose

Vacuum port hose

Chapter 3 Installation

- 11 -

[WO-4841;JL4-V・VC-3～6-11]

NOTE

○

The hopper on which the Jet Clone is mounted should be sized so that the damper of the Jet Clone

does not contact the inner wall of the hopper.

○ Install the Jet Clone horizontally. Otherwise, it may not accurately detect the hopper is full of

material.

○ The damper of the Jet Clone has been adjusted at the factory, therefore do not adjust, or knock it.

Otherwise, it may not accurately detect the hopper is full of material.

Chapter 3 Installation

- 12 -

[WO-4841;JL4-V・VC-3～6-12]

2) Vacuum hopper type- E2K control

Step Task Description

１

Mounting the base Attach the base to the molding machine.

(Fix with hexagon socket head cap screws.)

＊ Be sure to install a gasket between the hopper base and the

molding machine mounting plate.

２

Vacuum hopper

mounting

Mount the vacuum hopper flange (sight glass section) on the base.

Use hexagon socket head

socket screws.

Packing

Matching

base

Packing

Vacuum hopper

Proximity switch (E2K)

Molding

machine

Inlet Vac. hose

Material port hose

Tap hole (for suction hopper

mounting)

Countersunk hole (for

molding machine

mounting)

Chapter 3 Installation

- 13 -

[WO-4841;JL4-V・VC-3～6-13]

3) Vacuum hopper type ASD control (not common)

Step

Task Description

Drilling the mounting

holes

Drill holes in the hopper to be mounted so that they match the

mounting holes in the Jet Clone.

＊ It is recommended to tap the hopper holes so that the collection

hopper can be secured with bolts alone. When the holes are not

tapped, the collection hopper should be secured with bolts and

nuts. In this case, an adequate measure should be taken to

prevent the bolts and nuts from falling into the hopper if they

loosen and fall off.

Mounting suction hopper Mount the suction hopper to the hopper on which the mounting holes

are drilled.

3 Mounting level switch Drill holes at the specified positions in the hopper on which the

suction hopper is mounted, and install the level switch.

Split pin

Flat washer

Packing

Level switch (main body)

Nut

Blade

Connector

Level switch

Vacuum hopper

Hopper

Vacuum port hose

Material port hose

Chapter 3 Installation

- 14 -

[WO-4841;JL4-V・VC-3～6-14]

2. Installation

Install the equipment as shown in 2. Flow diagrams in Chapter 1.

Step Task Description

１

Installing the Loader Install the loader near each collection hopper (within the reach of the

5m-long air suction hose) in the vicinity of respective collectors.

＊ When the installing location is

determined, be sure to apply the caster

brakes (4 locations) to secure. As shown

in the diagram, the brake is applied by

stepping down on the ON side.

２

Mounting the vacuum

hoses (Grey GTG Hose)

Connect the vacuum hoses to the suction ports of each collection

hopper and the 3 ~ 6 way selector valve of the loader.

＊ Be sure to secure with a hose clamp.

＊ A direction label (No1.~ No.6) is attached to respective hose

openings on the selector valves. Please make sure to connect to

each proper valve.

（3 ~ 6 way selector valve viewed from above）

NOTE

Securely tighten the hose clamps to avoid leaks at the intake ports of

the material & vacuum hoses.

３

Connecting the material

hose (White PVC Hose)

Connect the material hose to the material port of each collection

hopper.

Install the suction nozzle to the end (conveying source side) of the

conveying hose.

＊ Firmly secure with a hose clamp.

４

Connecting the signal

cords

Connect the signal cords (with connector) of the loader to the signal

cord, or socket, of the collection hopper. Make sure each cable

matches the corresponding hose direction!

For 3 way

For 4 – 6 way

Chapter 3 Installation

- 15 -

[WO-4841;JL4-V・VC-3～6-15]

Step Task Description

５

Supplying compressed

air to the (3 ~ 6 way)

selector valve

Connect an air hose of

compressed air source from your facility

to the air supply valve (1/4”) of the 3~6 way valve.

Fully open the valve of the air kit to supply dry compressed air

of 0.5 MPa or higher from the compressed air source.

↓

Set the filter regulator outlet pressure of the air kit within a range of 0.4 to 0.5 MPa.

① Pull up the filter regulator adjustment knob to unlock it.

② Adjust the indication of the pressure gauge to 0.4 to 0.5

MPa by turning the adjustment knob clockwise or

counterclockwise. Turning the knob clockwise causes the

indicated value to rise, and vice versa.

③ After setting the pressure, push down the adjustment

knob to lock it.

NOTE

○ Set the pressure to

0.5 MPa or higher for dry compressed air

from a compressed air source.

Use an air dryer or air filter to obtain clean, dry compressed

air. Periodically drain to prevent freezing of the drain water,

especially in cold climates.

Adjustment

knob

Pressure

gauge

Bowl

Drain valve

Supply

valve

（1/4”）

(Your valve may

differ).

Chapter 3 Installation

- 16 -

[WO-4841;JL4-V・VC-3～6-16]

Step

Task

Description

６

Supplying compressed

air to collection hopper

air kit

＊ Only when the

collection hopper is Jet

Clone pneumatic

cylinder control type or

suction hopper type has

ASD control.

(not common)

Connect an air hose for a compressed air source to the air supply

port valve of the automatic slide gate air kit from your existing source.

↓

Fully open the valve of the air kit to supply dry compressed air of 0.5

MPa or higher from the compressed air source.

↓

Set the filter regulator outlet pressure of the air kit within a range of

0.4 to 0.5 MPa.

① Pull up the filter regulator adjustment knob to unlock it.

② Adjust the indication of the pressure gauge to 0.4 to 0.5 MPa

by turning the adjustment knob clockwise or counterclockwise.

Turning the knob clockwise causes the indicated value to rise,

and vice versa.

③ After setting the pressure, push down the adjustment knob to

lock it.

NOTE

○ Secure pressure of 0.5 MPa or higher for dry compressed air from

the compressed air source.

Properly process with an air dryer or air filter to use clean dry

compressed air. Sufficiently drain to prevent freezing of drain

water especially in cold climates.

Adjustment knob

Pressure gauge

Bowl

Drain valve

AutoSlide gate

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Matsui JL4-6V-3~6 Operating instructions

Brand: Matsui

Model: JL4-6V-3~6

Type: Operating instructions

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Matsui JL4-6V-3~6 Operating instructions

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Matsui JL4-6V-3~6 Operating instructions

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