Matsui JL4-5V-3~6, JL4-4V-3~6, JL4-6VC-3~6, JL4-6V-3~6, JL4-4VC-3~6 Operation Manual
...
JET LOADER
JL4-V･VC-3~6 MODELS
(U version)
OPERATION MANUAL
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.
WARNING
Issued March 2005
Introduction
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 fro m the date when the new product s you
purchased leave our fa cility.
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.
[WO-4841;JL4-V・VC-3～6]
Contents
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
2.
Flow diagrams ·················································································· 2
3.
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
[WO-4841;JL4-V・VC-3～6-Ⅰ]
- Ⅰ -
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
Contents
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
[WO-4841;JL4-V・VC-3～6-Ⅱ]
- Ⅱ -
Chapter 1 Configuration of Equipment
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
Jet Clone
Vacuum hopper
2) Loader Unit
3) Flow Diagrams
Limit control
Level switch control
Cylinder control
E2K control
ASD control
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
[WO-4841;JL4-V・VC-3～6-1]
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
- 1 -
2. Flow diagrams (V type)
Flow diagram type 1
Suction hose
GL-1V Hose
Jet Clone type
limit control
Connector
PVC hose
Conveying hose
Signal cord
d
r
o
c
Suction nozzle
r
e
w
o
P
Suction unit
Flow diagram type 2
Jet Clone type
limit control
Chapter 1 Configuration of Equipment
2-way valves are shown in the following diagrams, however, in actuality,
3-6-directional valves can additionally be installed.
Flow diagram type 4
Jet Clone type
cylinder control
Connector
Suction unit
Flow diagram type 5
Suction hopper type
SD control
Connector
Suction unit
Flow diagram type 3
Suction hoppertype
E2K control
Connector
Connector
Suction unit
Suction unit
[WO-4841;JL4-V・VC-3～6-2]
- 2 -
Flow diagrams (VC type)
Flow diagram type 6
GL-1V Hose
Jet Clone type
limit control
Connector
PVC hose
Conveying hose
Signal cord
d
Suction nozzle
Flow diagram type 7
r
o
c
r
e
w
o
P
Chapter 1 Configuration of Equipment
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 9
Jet Clone type
cylinder control
Connector
Suction unit
Flow diagram type 10
Jet Clone type
limit control
Connector
Power cord
Flow diagram type 8
Suction unit
E2K control
Connector
Suction hopper type
SD control
Connector
Suction unit
Suction unit
[WO-4841;JL4-V・VC-3～6-3]
- 3 -
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
Chapter 1 Configuration of Equipment
3～6 way selector valve
●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.
3～6 way selector valve
＊ The hose is contained in shrink wrap.
[WO-4841;JL4-V・VC-3～6-4]
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Component
Name
Collection hopper
● Jet Clone type limit control
● Jet Clone type level switch control
Style of Packing
●
Chapter 1 Configuration of Equipment
Suction hopper type E2K control
＊
● Jet Clone type cylinder control
This unit is supplied with an injection
molding machine match base or chute.
● Suction hopper type ASD control
This unit is contained in a corrugated
＊
cardboard case.
<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.
[WO-4841;JL4-V・VC-3～6-5]
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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)
JL4-6V（VC）
Chapter 1 Configuration of Equipment
Style of Packing
Material & Vacuum hoses are wound with shrink wrap.
● 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.
[WO-4841;JL4-V・VC-3～6-6]
- 6 -
Chapter 2 For Safe Operation
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.
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.
WARNING
1. Label and meaning of each indication
This instruction manual uses different indications depending on the extent of
danger as follows:
Label Meaning
WARNING
DANGER
This indication is used when failure to observe this may cause
user death. Instructions with this indication explain how to
prevent it.
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
NOTE
＊
[WO-4841;JL4-V・VC-3～6-7]
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.
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.
- 7 -
2. Items to be observed for safety
To operate this product safely, general instructions which should be
observed are described below.
Chapter 2 For Safe Operation
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
6) Maintenance
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.
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.
[WO-4841;JL4-V・VC-3～6-8]
- 8 -
Chapter 2 For Safe Operation
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.
CAUTION
3. Labels
1) Handling of label
1) Wiping
Labels are pasted where special care must be taken to prevent danger.
Warnings or cautions must be thoroughly understood before starting an
operation.
● 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
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.
[WO-4841;JL4-V・VC-3～6-9]
- 9 -
Chapter 3 Installation
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
Material port hose
Vacuum port hose
Material port
hose
Jet Clone
Hopper
Jet Clone- limit switch control Jet Clone- pneumatic cylinder control (not common)
Jet Clone
Step Task Description
Drilling mounting holes Drill holes in the hopper to be mounted so that they match the
1
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
2
Mounting level switch
3
＊ Only when the
collection hopper is
controlled by the
level switch
(not common)
Mount the Jet Clone on the hopper on which mounting holes are
drilled.
Drill holes at the specified positions in the hopper on which the
suction hopper is mounted, and install the level switch.
Pneumatic
Split pin
Flat washer
Packing
Vacuum port hose
Hopper
Level switch main body
[WO-4841;JL4-V・VC-3～6-10]
Nut
Connector
Blade
- 10 -
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.
NOTE
Chapter 3 Installation
[WO-4841;JL4-V・VC-3～6-11]
- 11 -
2) Vacuum hopper type- E2K control
Step Task Description
Mounting the base Attach the base to the molding machine.
１
２
Vacuum hopper
mounting
Chapter 3 Installation
Inlet Vac. hose
Material port hose
Molding
machine
Vacuum hopper
Proximity switch (E2K)
(Fix with hexagon socket head cap screws.)
＊ Be sure to install a gasket between the hopper base and the
molding machine mounting plate.
Mount the vacuum hopper flange (sight glass section) on the base.
Use hexagon socket head
socket screws.
Packing
Matching
base
Countersunk hole (for
molding machine
mounting)
Tap hole (for suction hopper
mounting)
Packing
[WO-4841;JL4-V・VC-3～6-12]
- 12 -
3) Vacuum hopper type ASD control (not common)
Material port hose
Vacuum hopper
Step
Drilling the mounting
1
Task Description
holes
Mounting suction hopper Mount the suction hopper to the hopper on which the mounting holes
2
Hopper
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.
are drilled.
Vacuum port hose
Level switch
Chapter 3 Installation
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)
Blade
Nut
Connector
[WO-4841;JL4-V・VC-3～6-13]
- 13 -
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
２
Mounting the vacuum
hoses (Grey GTG Hose)
Chapter 3 Installation
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.
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.
Connecting the material
３
hose (White PVC Hose)
Connecting the signal
４
cords
＊ 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.
For 3 way
For 4 – 6 way
（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.
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.
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!
[WO-4841;JL4-V・VC-3～6-14]
- 14 -
Step Task Description
５
Supplying compressed
air to the (3 ~ 6 way)
selector valve
Chapter 3 Installation
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.
Adjustment
knob
Supply valve
（1/4”）
(Your valve may
Pressure
gauge
differ).
Bowl
Drain valve
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.
[WO-4841;JL4-V・VC-3～6-15]
- 15 -
Step
Supplying compressed
６
Task
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)
Chapter 3 Installation
Description
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.
AutoSlide gate
↓
↓
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.
Adjustment knob
Pressure gauge
Bowl
Drain valve
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.
[WO-4841;JL4-V・VC-3～6-16]
- 16 -
3. Power cord Information
WARNING! Only qualified personnel should attempt any electrical connections!
Step Task Description
１
Connecting / Checking
the power cord
２
Checking forward and
reverse phase
After checking that the power breaker in the control panel is OFF, check
the 15ft. long power cord to the primary power of your existing source.
R phase …Red
Power cord … S phase …White …For the primary
T phase …Black
E phase …Green …………For grounding
○ Before any power cord connection, be sure to set the power circuit
○ The power cord should be securely connected to the power source. A
○ Be sure to connect the ground.
Turn OFF the primary power of your existing source.
↓
CAUTION
breaker in the control panel to OFF.
loose power cord connection may cause abnormal equipment
operation, single-phase operation and heat generation, or danger.
Turn ON the primary power of your existing source.
↓
Turn on the power breaker in the control panel.
↓
Chapter 3 Installation
1
Press the operation panel No. 1 start/stop switch
blower for the suction unit starts after the predetermined time.
↓
Apply your hand to the blower exhaust port to check that air is
blowing out from the exhaust port. If so, the blower rotates in the
forward direction (forward phase). Connection of the power cord is
completed.
↓
Continued on the next page.
No.
and the
- 17 -
[WO-4841;JL4-V・VC-3～6-17]
Step Task Description
３
Checking forward and
reverse phase
Chapter 3 Installation
↓
If no air is blowing out from the exhaust port, it means that the blower
rotates in the reverse direction (reverse phase). In this case, turn OFF
the primary power and reverse the R phase and T phase of the three
wires of the power cord.
↓
Again, turn ON the primary power and check that air is blowing out
from the exhaust port.
Exhaust port
[WO-4841;JL4-V・VC-3～6-18]
- 18 -
Chapter 4 Preparations for Operation
This chapter describes checks before starting operation.
1. Check status of each component
Unit to be checked Check
Filter case for suction unit Check that the cartridge and cap are set to the filter case.
Filter case
Filter case
Separator
Dust box for suction unit
＊ Only for VC type
Cap
V type VC type
Check that the dust box is installed on the lower part of the separator.
(Refer to the above diagram.)
Dust box
[WO-4841;JL4-V・VC-3～6-19]
- 19 –
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