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IMS
SERIES LOADERS
Hopper Mount and
Just-In-Time Material Loaders
Models 200, 400, 800, 200JT & 300JT
INSTRUCTION MANUAL
March 2017
IMS Company
10373 Stafford Road
Chagrin Falls, OH 44023-5296
© Copyright 2017 IMS Company. All rights reserved.
1
Telephone: (440) 543-1615
Fax: (440) 543-1069
Email: [email protected]
Website: www.imscompany.com
An ISO 9001:2008 Registered Quality Company
LOADER OPERATING MANUAL
TABLE OF CONTENTS
Hopper Mount and Just-In-Time Material Loaders -------------------------------------------------------------------4
1 INTRODUCTION -----------------------------------------------------------------------------------------------------------------4
1.1 Warning and Symbols Information -------------------------------------------------------------------------------------4
1.2 Safety Information and Precautions -----------------------------------------------------------------------------------4
1.2.1 For your Safety1.2.2 For the Safety of the Loader -------------------------------------------------------------4-5
1.2.2 For the Safety of the Loader --------------------------------------------------------------------------------------------5
1.3 Unpacking and Inspection -----------------------------------------------------------------------------------------------5
2 INSTALLATION AND START UP -------------------------------------------------------------------------------------------6
2.1 Mounting Instructions --------------------------------------------------------------------------------------------------6-7
2.2 Connection Instructions -------------------------------------------------------------------------------------------------7
3 DESCRIPTION AND SPECIFICATIONS ----------------------------------------------------------------------------------8
3.1 Setting Loading Parameters ------------------------------------------------------------------------------------------8-9
3.1.0 Standby mode (C3) --------------------------------------------------------------------------------------------------------9
3.1.1 Delay Time -------------------------------------------------------------------------------------------------------------------9
3.1.2 Filter Cleaning Time --------------------------------------------------------------------------------------------------------9
3.1.3 Quantity of Filter Cleaning -------------------------------------------------------------------------------------------------9
3.1.4 Loading Time -----------------------------------------------------------------------------------------------------------------9
3.1.5 Line Clearing Time ----------------------------------------------------------------------------------------------------------9
3.1.6 Empty Time ------------------------------------------------------------------------------------------------------------------9
3.1.7 Fault Mode -------------------------------------------------------------------------------------------------------------------9
3.1.8 Alarm Setting ---------------------------------------------------------------------------------------------------------------10
3.1.9 Alarm Function -------------------------------------------------------------------------------------------------------------10
3.2.0 Motor reversal protection time ------------------------------------------------------------------------------------------10
3.2.1 Preparation time -----------------------------------------------------------------------------------------------------------10
3.2.2 motor stopped delay time ------------------------------------------------------------------------------------------------10
3.2.3 Blanking detection time ---------------------------------------------------------------------------------------------------10
3.2.4 cleaning action time -------------------------------------------------------------------------------------------------------10
3.2.5 Material valve action time --------------------------------------------------------------------------------------------10-11
4 OPERATION INSTRUCTIONS ---------------------------------------------------------------------------------------------11
4.1 Operating the Loader -----------------------------------------------------------------------------------------------11-12
4.2 Grounding the Loader --------------------------------------------------------------------------------------------------12
5.TECHNICAL SPECIFICATIONS -------------------------------------------------------------------------------------------13
5.1 Reed Switch Adjustment -----------------------------------------------------------------------------------------------13
5.2 Changing Reed Switch -------------------------------------------------------------------------------------------------14
5.3 Reed Switch Mounting Detail -----------------------------------------------------------------------------------------14
5.4 Ground ---------------------------------------------------------------------------------------------------------------------14
6 TROUBLESHOOTING --------------------------------------------------------------------------------------------------------15
6.1 Troubleshooting Problems --------------------------------------------------------------------------------------------15
6.2 Troubleshooting Conditions and Solutions -------------------------------------------------------------------15-16
7 MAINTENANCE ----------------------------------------------------------------------------------------------------------------16
7.1 Scheduled Maintenance ------------------------------------------------------------------------------------------------16
7.2 Brush Replacement -------------------------------------------------------------------------------------------------16-17
8.SPARE PARTS -----------------------------------------------------------------------------------------------------------------18
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LOADER OPERATING MANUAL
8.1 Spare Parts List & Drawing for Model 200 -----------------------------------------------------------------------18
8.2 Spare Parts Drawing for Model 400 --------------------------------------------------------------------------------19
8.3 Spare Parts Drawing for Model 800 --------------------------------------------------------------------------------20
8.4
Spare Parts Drawing for Model 200JT ------------------------------------------------------------------------------21
8.5
Spare Parts Drawing for Model 300JT -------------------------------------------------------------------------------22
8.6 Circuit diagram -------------------------------------------------------------------------------------------------------23
8.7 Control box explosion figure ----------------------------------------------------------------------------------24-25
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LOADER OPERATING MANUAL
Hopper Mount and Just-In-Time Material Loaders
Model 200 400
Hopper capacity ( LBS )
6.6
13.2
Motor power ( Volts )
Throughput ( LBS /hr ) * 154 308
Probe diameter ( inch )
Mounting diameter ( mm ) 214
Depth ( mm ) 334
Overall height ( mm ) 500
Weight approx ( Kg ) 12
265
347
620
13
* Material Dependant
800
26.4
110/115/60/1
440
1.5
265
347
755
15
200JT
6.6
154
60x60
312
615
13
300JT
13.2
308
60x60
347
735
14
1 INTRODUCTION
IMS Company reserves the right, at any given time, to alter the information in this operation manual.
IMS Company is not responsible for any mishandling or damages occurring when using this operation manual.
Translation and copying for purposes other than the purchasers’ personal use must have the approval of
IMS Company.
All rights reserved.
1.1 Warning and Symbols Information
The following warnings and symbols are used in this operation manual:
This symbol indicates key operating instructions.
This symbol indicates that serious damage to the machine or personal injury may occur if indicated precautions are not followed accordingly.
1.2 Safety Information and Precautions
The safety information and precautions noted in this operation manual are directed to all personnel.
This operation manual should be used by all personnel operating the Loader.
In every instance, be sure all operating personnel are familiar with this manual and the Loader.
1.2.1 For Your Safety
Keep this operation manual available and near the Loader at all times.
IMS Company assumes no responsibility for changes or modifications to the Loader without prior consent . These changes could damage the equipment and result in physical harm or violate your warranty. Please contact IMS Company prior to making structural modifications to the Loader.
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LOADER OPERATING MANUAL
Maintenance of and repairs to the Loader should be carried out by qualified personnel only, and with the spare parts provided only by IMS Company.
Operating and maintaining the Loader must be done by qualified personnel only.
Disconnect power supply before beginning any maintenance of, or repairs to, the Loader.
1.2.2 For the Safety of the Loader
Use only original Loader spare parts.
Observe the maintenance schedule.
Be aware that electronic components can be damaged by static.
1.3 Unpacking and Inspection
Loaders are shipped complete with all controls for automatic operation. The only utilities required are:
110 /115/120 volt power supply
Compressed air at approximately 80 PSI (minimum 70 PSI; not exceeding 100 PSI)
After receipt of the IMS Series Loader, completely inspect it for damage.
NOTE: Although Loaders are packaged securely, vibration and mishandling during transit can cause damage.
The Loader is shipped with a complete hardware package, consisting of:
Flexible tubing for 15 ft. rise
Material suction wand
Hose clamps
5
LOADER OPERATING MANUAL
2 INSTALLATION AND START-UP
IMS Series Loaders are completely automatic, self-cleaning vacuum loaders designed to convey virgin pellets, additives, and regrind materials from storage containers to drying hoppers, or directly to process machines.
IMS Series Loaders utilize a powerful vacuum motor to create a vacuum to draw material into the hopper body. A cycle is initiated when control receives a request signal from the flap switch located on the side of the Loader. The Loader cleans the filter with pulses of compressed air before each loading cycle. After the cleaning cycle is finished, the vacuum motor starts operation and draws material into the hopper body for a pre-adjusted amount of time. When the vacuum motor stops, material discharges through the flap door. During discharge, any signal from the flap door is ignored.
The cleaning, loading, and emptying continues until the hopper or surge bin is full. At that time, the material holds the flap door open, placing the system in a standby mode. As material is withdrawn from the hopper, the material level drops, the flap door swings free, and the Loader activates again.
Once the filter cleaning pulses start, the entire cycle continues even if the flap door is held in the open position. The length of cleaning, loading, and emptying cycles is adjustable.
To efficiently operate the hopper loader, adjust the material probe and loading times.
Loading times should be adjusted so the hopper loader is half full at the end of the convey cycle.
Warning: DO NOT allow the Loader to overfill. Overfilling may result in damage to vacuum motor and filter.
Clean virgin pellets require a minimum pulse sequence, while very dusty regrind material may require a maximum pulse sequence.
The material probe should be positioned firmly down in the drum or gaylord box until steady material flow is achieved.
2.1
Mounting Instructions
Mount the IMS Series Loader onto the hopper lid or loader mounting bracket.
Position the Loader so the material inlet is directed toward the material pickup point.
Make sure the flap door has enough room to operate freely.
The conveying line should be horizontal and/or vertical and should be as straight as possible without any slope.
If the Loader is mounted on a moving machine, the flap door on the Loader must be perpendicular to the machine’s motion.
All line connections should be no longer than necessary. Excess hose will reduce the IMS Series Loader’s conveying efficiency.
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LOADER OPERATING MANUAL
2.2 Connection Instructions
Connect the filtered and regulated 3/8˝ compressed air line to the air valve inlet on the loader lid. The minimum requirement for effective filter cleaning is 70 PSI.
Warning: DO NOT exceed 100 PSI.
It is recommended that a dedicated 20-amp 115V supply be used to power the Loader.
Warning: DO NOT use an extension cord over 20 feet in length. This may result in overheating and will cause damage to the vacuum motor and controls.
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LOADER OPERATING MANUAL
3. DESCRIPTION AND SPECIFICATIONS
The IMS Series Loader control requires 115V single-phase power supply
OVERVIEW OF CONTROL PANEL
3.1 Setting Loading Parameters
To adjust parameters, you must be in the function menu.
To enter the functions menu press
To select and set a specific function (F0-F6),
To adjust the function’s value, press
Press to save the value press
To exit the functions menu without saving the value and default to the formerly saved value, press
For Example: To adjust the loading time F3
1) Check that the power is ON.
8
2)Press
3)Press
LOADER OPERATING MANUAL until F3 is shown on the display. and choose F3 to display the current loading time set point.
4)Press
5) Press repeatedly to change the loading time. or wait 10 seconds to save the new value, or press to abandon changes and begin normal operation.
3.1.0 Setting Loading Parameters, continued
3.1.1 Delay Time (F0)
Delay Time is the time from when the loader signals that it needs material to the time that the clean cycle initializes to begin the loading of your Loader. This can be set from 0-99 seconds and is shown on the display as function F0.
3.1.2 Filter Cleaning Time (F1)
Filter Cleaning Time is the time (in seconds) that the Loader pulses to clean its cloth filter. This can be set from 3-99 seconds and is shown on the display as function F1. If set to 0, it will disable filter cleaning.
3.1.3 Quantity of Filter Cleaning (F2)
Quantity of Filter Cleaning is the number of loads that the Loader performs for every single filter cleaning.
This can be set from a range of 0-99 times and is shown on the display as function F2. If you set this to 0, it will clean the filter after every loading cycle.
3.1.4 Loading Time (F3)
Loading Time is the time the vacuum motor will be initialized to pull material for a load cycle. This is the time the loader is actually pulling from a storage location to the loader and can be adjusted from 0-99 seconds. It is shown on the display as function F3. The higher the value stored for F3, the more material brought per loading cycle
3.1.5 Line Clearing Time (F4)
Line Clearing Time is the time the vacuum motor runs to evacuate all excess material from the material line. This can be set from a range of 0-99 seconds and is shown on the display as function F4. If the
Loader does not have line clearing, or if you prefer to disable line clearing, set F4 to 0.
3.1.6 Empty Time (F5)
Empty Time is the amount of time from when the Loader’s loading cycle ends to the time the control checks for completion of falling material. This can be set from a range of 0-99 seconds and is shown on the display as function F5. The more material the Loader pulls for a single loading cycle, the higher in value the empty time must be set. This is to avoid alarming from a faulty loading cycle. Storing a value of 0 can disable this function.
3.1.7 Drop Detection Mode Selection (F6)
Check Loading Fault Mode can be set to a value of 0 or 1 and is shown on the display as function F6. If a value of 0 is set, the Loader checks for a proper signal AFTER empty time. If a value of 1 is set, the Loader checks for a proper signal DURING empty time.
3.1.8 Alarm Setting (F7)
Alarm Setting sets the number of consecutive convey faults before the alarm is activated: (0 =1, 1 = 2, etc.
to 99 = 100) .The factory setting is 0
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LOADER OPERATING MANUAL
3.1.9 Alarm Stop Function (F8)
Alarm Function sets the loader so it will either continue to convey after the alarm (0) or won’t convey until the fault is cleared (1). The factory setting is 0.
3.2.0 Motor reversal protection time (F9)
To delay the motor start time by temporarily shutting down its operation to prevent motor damage. This can be set from a range of 1-99 seconds and is shown on the display as function F9 .
3.2.1 Preparation time (FA)
Loading signal on after running time, repeat loading action. This can be set from a range of 0-99 seconds and is shown on the display as function FA .
3.2.2 Motor Delay Stopped Time (FB)
If no loading signal, the motor can be delayed before attempting to load again. This can be set from a range of 0-99 seconds and is shown as function FB.
3.2.3 Drop Detection Time (FC)
Drop detection signal OFF time This can be set from a range of 1-99 seconds and is shown on the display as function FC .
3.2.4 Cleaning Action Time (FD)
On = FD, Off = 0.8 SEC
3.2.5
Recycling material valve action time (FE)
When “unlocked”, this feature allows the user to program how long the unit will run before switching valves of an attached proportional valve. (Sold separately). This can be set from a range of 0-99 seconds and is show on the display as FE.
Setting Parameters
NO. Name Parameters unit
F0
F1
F2
F3
F4
F5
Delay Time
Filter Cleaning Time
Quantity of Filter Cleaning
Loading Time
Line Clearing Time
Empty Time
30
5
30
Factory value setting Range
3
20
20
99
0-99
0-99
1-99
0-99
0-99 sec time sec sec sec sec
F6
F7
F8
F9
FA
FB
FC
Drop Detection Mode Selection
Alarm Setting
Alarm Stop Function
Motor reversal protection time
Preparation time
Motor Delay Stopped Tme
Drop DetectionTime
0
3
0
30
0
0
1
0-1
0-99
0-1
1-99
0-99
0-99
1-99 sec sec sec
0.025
sec
FD Cleaning Action Time 5 0-1 sec
FE Recycling material valve action time 0 0-99 sec
Note :Features F9 through FE are unavailable or “locked” by default. To “unlock” the features, set F3 (Loading Time) to 98 and F4 (Line Clear Time) to 97. Some features are not used unless the loader is equipped with a proportional valve or connected to other equipment.
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1.
If you don’t press the button in order to stop the loader.
LOADER OPERATING MANUAL
2. Press to display F0 , press
F2>F3---->F8>F0 orderly. again to display F1 , will display
3. Choose the parameter you would like to revise, you can press
4. if need to revise other parameters , press to set. enter into next parameter screen. If need not to revise other parameters, press to finish.
4. OPERATING INSTRUCTIONS
4.1 Operation of the Loader
Flip the toggle switch located on the right side of the control to the “ON” position. POWER
ON LED indicator should light.
Set up parameters F0 through F6 if necessary, as described in the previous section.
"On/Off"
Press to start operation of the Loader . If the material Loader's hopper is empty, REQUEST LED indicator will light and the Loader will start operating. If the Loader's hopper is full, FILL LED indicator will light and Loader will go into a standby mode .
Operation of the Loader starts with Delay Time (F0). When Delay Time expires, the loader activates Filter Cleaning Time (F1)
During Filter Cleaning Time (F1), compressed air is blown in pulses across the cloth filter to remove accumulated particles. During this function, FILTER CLEAN LED indicator will light. Filter Cleaning Time may not occur every cycle depending on the setting of Quantity of Filter cleaning function (F2).
Once the Filter Cleaning Time expires, the loader activates Loading Time (F3). During this function, the vacuum motor is turned on and material is drawn from the material source into the loader’s hopper body. The creation of the vacuum inside the loader’s hopper body will close the flap door. During this function, LOADING LED indicator will light.
If Line Clearing Time (F4) is set in the loading parameters, the vacuum motor will run for the length of
Loading Time (F3) plus the length of Line Clearing Time (F4). When Loading Time expires, the vacuum motor turns off, the weight of material inside the loader’s hopper body opens the flap door, and material is discharged.
Discharging of material is also called Empty Time (F5). During this time, the signal from the flap switch to the controller is ignored. If the material hopper is full after discharging, material will hold the flap door open placing the system in a standby mode. As material is withdrawn from the hopper, the material level will drop, the flap door will swing free, and the Loader will activate again. If the material hopper is not full, a new cycle will be initiated. In addition, an audible alarm will sound and the FAULT LED indicator will light.
11
LOADER OPERATING MANUAL
This is to alert the operator of possible loading problems such as a clogged material line or an empty material source, etc.
4.2 Ground the Loader for Static Control
Static electricity can build up at the material line, the suction wand /probe , or on the Loader itself due to the movement of the material. It is recommended the loader be grounded.
Static can cause damage to the electronic circuitry and sensors.
Grounding can save downtime and the cost of new circuit boards.
There is 1 holes at the top of the suction wand.
Start the loader with maximum airflow and adjust as necessary.
Figure 4.2(1)
Initially, d on’t cover the hole when install ing. If more suction is needed, then cover the hole.
Air Flow Hole
Figure 4.3
12
LOADER OPERATING MANUAL
5. TECHNICAL SPECIFICATIONS
5.1 Reed Switch Adjustment
1. Loosen the 3mm (M3) bolts (2)
2. Move the reed switch (15) to the desired position.
3. Remove the front cover of the control (circuit board is located in the back of the control enclosure).
4. Place ohm meter leads on the reed switch terminals “Require” and “-” located on the right hand side of the control board. The ohm meter should read infinite ohms (hopper loader full, or flap door open).
5. When allowing the flap door to hang freely, the ohm meter should read zero ohms (hopper loader needs material, or flap door is in free position).
6. Adjust the reed switch so the reading on the ohm meter is at infinite ohms when the flap door is approximately 3/4˝ back from the free hanging position.
7. When the reed switch is in the correct position, tighten the bolts.
Warning: DO NOT over-tighten the bolts. This could break the reed switch.
5.2 Changing the Reed Switch
1. Remove 3mm bolts (2).
2. Disconnect reed switch leads from the terminal board.
3. Remove the reed switch.
4. Install a new reed switch.
Warning: DO NOT over-tighten the bolts. This could break the reed switch.
Make sure the reed switch does not interfere with the movement of the flap door.
13
5.3 Reed Switch Mounting Detail
LOADER OPERATING MANUAL
5.4 Ground
14
LOADER OPERATING MANUAL
6. TROUBLESHOOTING
6.1 Troubleshooting Problems
Most loader problems are the result of dirty filters, air leaks, or improper adjustments. These items should be checked first before assuming equipment failure.
Problem
Motor will not run
Inadequate or no vacuum
Inadequate or no material flow
Motor runs but pulse solenoid not operating
Investigate
A, B, C, H, K
D, E, F, G, J
C, D, E, F, G, I
K, L
6.2
Troubleshooting Conditions and Solutions
A
B
C
D
E
F
G
H
I
J
K
L
Check
Power supply
Stop/Start Switch
Vacuum Motor
Cloth Filter
Vacuum and material
Leaks in system
Blowback air pressure incorrect
Reed Switch
Load time
Pulse rate
Power and/or pulse
Pulse Solenoid
Conditions
No voltage or incorrect supply-voltage at outlet
No voltage through switch
No voltage at motor
Voltage at motor, amperage incorrect
Filter dirty
Obstructed
Air leaking into system
Low pressure
No voltage through switch
Chamber not filling sufficiently
Chamber overfilling
Insufficient to clean filter
No voltage output to solenoids or motor SSR
No voltage through SSR
No voltage to solenoid
Voltage present at solenoid, but no pulse
Solution
Check incoming power
Replace switch
See A, B, and K
Replace motor
Clean or replace filter
(also see G and J)
Remove obstruction lines
Replace gaskets, repair leaks as necessary
Increase pressure
(not to exceed 100 PSI)
Replace or adjust switch
Increase load time
Decrease load time
Increase rate
Replace board
Replace SSR
See K
Replace solenoid
(also see G)
15
7. MAINTENANCE
7.1 Scheduled Maintenance
Daily: Bi-Monthly:
Check Filters: Check motor brushes
Semi-Annually: Check all mechanical connections
LOADER OPERATING MANUAL
7.2 Brush Replacement
1.
Disconnect power from unit
2.
Remove motor hood by removing the (4) 6mm screws .
3.
Disconnect and change the brushes in the following manner:
Note: Brushes should be changed before the brush stunt touches the commutator.
For 5.7˝ (145 mm) Diameter Vacuum Motors:
Insert a standard blade screwdriver between the top of the brush mechanism and the brush lead wire clip. Gently tap the screwdriver handle until the clip touches the commutator (some models have blade terminals on the brush holder). For these units, remove the connector from the blade terminal. For bypass motors, it is necessary to carefully remove the ventilation fan cover first
Remove the brush clamp screws with Phillips screwdriver.
Once the brush mechanism is free, remove the brush clip. To install a new brush mechanism, first insert the brush clip between the nylon insulator and the brass and push in straight by hand. Use needle nose pliers to gently seal the clip. For the units with a blade terminal in the brass sleeve of the brush mechanism, push the connector onto the terminal.
Insert the locator tab on the bottom of the brush mechanism into the corresponding hole on the top of the commutator end bracket and secure the brush mechanism with the brush clamp and screws that were earlier removed.
4.
To properly seat the new brushes to the commutator face and enhance the performance and overall life to the brush, the motor must be run at half voltage for 30 minutes with an orifice plate.
If a variac or other voltage control device is not available, two motors may be run in electrical series. This reduces the voltage to each motor, as each will receive approximately half of the supply voltage. Connect one lead from each motor using a wire nut. Connect the other two leads to the power source.
5.
After running the re-brushed motor for 30 minutes at half voltage, it can be run again at full voltage.
6.
Reinstall the motor shelter.
Note: The estimated brush life is approximately 250 hours under normal operating conditions.
Warning: On reassembly and handling, the lead wires must be kept away from rotating parts.
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LOADER OPERATING MANUAL
NOTE: To achieve best performance, new brushes should be seated on the commutator before full rated voltage is applied.
The motor manufacturer recommends the following procedure:
After brush change, apply 50% to 75% of rated voltage for 30 minutes to accomplish this seating.
The motor will return to full performance after 30-45 minutes of running at full rated voltage. The motor must not be run with the vacuum air inlet sealed off.
Warning: Direct application of full rated voltage after changing brushes will cause arcing, commutator pitting, and reduced overall life.
Note: If reduced voltage is unavailable, connecting two motors of similar rating in series for 30 minutes will accomplish brush seating.
17
8.
EXPLOADED VIEW AND PARTS LIST
8.1 Model 200 LOADER EXPLOADED VIEW
LOADER OPERATING MANUAL
18
8.2 Model 400 LOADER EXPLOADED VIEW
LOADER OPERATING MANUAL
19
8.3 Model 800 LOADER EXPLOADED VIEW
LOADER OPERATING MANUAL
20
8.4 Model 200JT LOADER EXPLOADED VIEW
LOADER OPERATING MANUAL
21
8.5 Model 300JT LOADER EXPLOADED VIEW
LOADER OPERATING MANUAL
22
8.6. Circuit diagram
LOADER OPERATING MANUAL
23
8.7 Control box explosion figure
LOADER OPERATING MANUAL
24
NO.
specification
01 Control box
02 power switch
03 PG11 Cable fixed head
04 fuse
05 fuse seat
06 PG7 Cable fixed head
07 NM1069B ( I /O floor )
08 NM1069A ( control panel )
09 Panel bracket
10 Thin film panel
11 PG11 Cable fixed head
12 buzzer
LOADER OPERATING MANUAL
Shipping number number
TM-E03007
TV-B02-4004302230
TV-B15-000000PG11
TV-B10-1200150030
1
1
1
1
TV-B10-12020FH015
TV-B15-000000PG07
TV-B01-00010E0001
TV-B01-00010E0000
TM-E03009
TV-B01-10000000E0
TV-B15-000000PG11
TV-B12-0000000012
1
1
1
1
1
1
1
1
25
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