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IMS ROBOTICS TURBO Manual

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Summary of Contents for IMS ROBOTICS TURBO

  • Page 3 Machine specifications Designation: IMS cutter TURBO Manufacturer: IMS Robotics GmbH Am Bauhof 6 01458 Ottendorf-Okrilla Phone: +49 (0)35205 75550 Fax: +49 (0)35205 53749 E-Mail: info@ims-robotics.de Website : www.ims-robotics.de User information: As of 04/05/2022 Translation of the original instruction Article number:...
  • Page 4 Introduction This user information is meant to facilitate safe and proper operation and maintenance of IMS devices and should therefore be given the attention it deserves. Note When operating the unit, be sure to comply with accident prevention rules and general safety regulations.

  • Page 5: Table Of Contents

    Table of contents Table of contents ...................... 5 Intended Use ...................... 7 Technical data ....................8 Specifications ....................8 Main dimensions .................... 9 General safety rules ..................10 Description, setting ..................11 Modules ....................... 11 General description ..................12 Universal cable drum ................... 12 4.3.1 Manual cable drum ................
  • Page 6 5.3.2 Operation with Quick-Lock Offset Packer ..........35 Conversion to other nominal dias..............36 5.4.1 Format parts and assignment to nominal dias........37 5.4.2 Nominal width-dependent setup ............38 5.4.3 Convert pressure rail ................39 5.4.4 Installing the mount ................41 5.4.5 Extension for egg shaped profile ESP (optional) ........

  • Page 7: Intended Use

    The IMS cutter TURBO must only be used for cutting work for the restoration of pressureless pipes or lines. The device can be used to open inliners after restoration and remove obstacles (roots, protruding seals, minor offsets, or the like).

  • Page 8: Technical Data

    2 Technical data 2.1 Specifications System components: Universal carriage TURBO cutting arm Camera Add-on mount Universal control unit Universal cable drum Milling performance: Milling cutter max. dia. 120 mm for concrete Travel speed: max. 10 m/min. with wheel, dia. 140 mm Format: Pipes, nominal dia.

  • Page 9: Main Dimensions

    2.2 Main dimensions Universal carriage with milling arm: Device mounted for pipes 300 mm approx. 400 mm approx. 650 mm approx. 1050 mm...

  • Page 10: General Safety Rules

    3 General safety rules Caution! System may only be operated by persons who have been instructed in its use. A lack of information may cause damage to the unit or create hazards for the operator. Caution! Pull out mains plug before opening a unit. Caution! When lowering individual components or the robot as a whole make sure no-one is standing in the shaft or under the load.

  • Page 11: Description, Setting

    4 Description, setting 4.1 Modules Overall view Universal cable reel, motorized Electric swivel drive (optional) (optional) Universal control unit Water nozzle (optional) Universal carriage Additional lighting Oil sight glass Air connection Milling arm Electrical connection Camera with nitrogen valve reverse drive sensor Carriage nitrogen valve Water connection Swivel arm nitrogen valve...

  • Page 12: General Description

    4.2 General description The IMS universal carriage with milling arm TURBO III in conjunction with the multi- purpose control system and universal cable drum with 100 m media cable is designed for milling work in the repair of sewers. The use of format parts makes it possible to convert the basic version from nominal dia.
  • Page 13 Caution! Do not reach into the drum or its drive when in Operation. Prior to working on the drum remove the air supply. The media hose must not be overstretched, due to high tensile forces, (> 1000 N/ ca. 100 kg) because of the hose and the internal lines can be damaged or can rip.

  • Page 14: Robot

    4.4 Robot This has electric drives for travel and turning/swivel of the head. Caution! All electrical driven axes of the robot (driving movement, turning, swivelling, 4. axis), as well as the rotation movement of the camera must not be moved by hand. The couplings of the power feed line are watertight when plugged together (IP 65).

  • Page 15: Reversing Safeguard

    Caution! Under normal conditions, the milling robot may operate without a pressure rail. The latter is an auxiliary and makes it possible for the operator to deal with extreme situations such as working at greater depths or on smooth pipe walls. 4.4.1.2 Reversing safeguard This is to prevent the robot from running over media supply lines during reversing.

  • Page 16: Milling Arm

    4.4.2 Milling arm Mount this on the carriage with two screws, while at the same time making the electrical connection with plug contacts and providing an air supply by hose. In addition, connect the flushing water hose to the optional electric swivel drive on the milling motor.

  • Page 17: Swivel Head Color Camera

    4.4.3 Swivel head color camera This enables the operator to watch the milling operation in the entry direction. Use of a camera limits the angle of view in the pipe, i.e. parts of the pipe are concealed by the motor/milling cutter on entry. From a pipe diameter of DN 250/10”, the camera can be mounted so that the angle of view into the pipe is increasing.
  • Page 18 Nitrogen valve Wiper blades Halogen lamps Additionally, a water nozzle from the water equipment (optional) can be used for cleaning the screens. Clean the camera periodically, to avoid strong deposits and thereby caused damages of the wipers. To protect the electronic components, the camera is filled with nitrogen, which should be checked daily before and after work (see 6.4.1 Nitrogen charging).

  • Page 19: Additional Lighting

    4.4.4 Additional lighting The additional lighting can be used in pipes with an inner diameter from 225 mm/9“. Additional lighting Remove a headless screw on top of the cutter arm, the cover on top of the cutter arm and the cover of the cutter motor bearing to assemble the additional lighting. Headless screw Cutting arm cover Cover of cutter motor bearing...
  • Page 20 To mount the front lighting, ensure the correct seating of the seal ring (on the front lighting) and fasten the lighting with 4 countersunk screws (M3x8). Countersunk screws M3x8 To establish the electrical connection, screw together the plugs of both additional lightings.

  • Page 21: Optional Features

    4.5 Optional features 4.5.1 Circular profile mounts, nominal dia. 450-800 These may be added on to the carriage for nominal dias. from 450 to 800. 4.5.2 Analog data input with meter counting (optional) This makes it possible to fade in/out a number of data such as dates, times, meter counts, positions, etc.
  • Page 22 Keys are assigned as follows: Help Headline on/off Status line 1 on/off Cursor on/off Editing area on/off Complete fade-in on/off Reset meter count to zero Ctrl + F1 Set meter count Ctrl + F3 Set date Ctrl + F4 Set time Ctrl + F6 Set headline Ctrl + F7...

  • Page 23: Meter Counting Calibration (Optional)

    4.5.3 Meter counting calibration (optional) Press the key combination Strg + Alt + Shift + F8 and enter the value 0.1225. Press ENTER and leave the menu by ESC. Perform control measurement. For this, unreel 10 m hose from the cable reel and compare with the displayed value.

  • Page 24: Water Supply (Optional)

    4.5.5 Water supply (optional) A water nozzle is arranged behind of the milling motor, for which two insets of different dia. are supplied. While the smaller one serves to cool the milling cutter, the second nozzle may be used for cleaning and preparation of a lateral connection before rehabilitation.

  • Page 25: Vehicle Installation Kit (Optional)

    4.5.6 Vehicle installation kit (optional) 4.5.6.1 Basic kit This should be mounted as shown by the auto installation diagram/sheet (for the cable drum pan). The scope of supplies includes a remote control device for permanent installation.
  • Page 26 If this is to be used to operate the system, be sure to open the ball valve on the water tank and set the "milling/vacuum" ball valve on the universal cable drum to milling. Below the control panel of the drum shall be switched the hose to the air engine of the drum and also be switched the blind plug (see following drawings and auto installation diagram).
  • Page 27 Pan for carriage installation Pan with extended universal cable drum Pan with universal cable drum Please use transport safety bolts!

  • Page 28: Winch With Movable Arm And Electrical Winch

    4.5.6.2 Winch with movable arm and electrical winch Winch for robot Hole to lock the winch The basic set is optional extendable with the winch frame module. It consists of a frame, moveable crane arm, electrical winch for lifting the robots (see at separate manual).

  • Page 29: Drawer Module

    4.5.6.3 Drawer module Under the winch module it may be mounted a further module (drawer module), to carry the robot safety. With using the drawer you can put the robot on the winch easily. Within the drawer module is also sufficient space for mounting of the water and nitrogen supply.

  • Page 30: Controlling Desk

    4.5.6.4 Controlling desk Power access socket Pulley holder The car mounting set is extendable with a desk for fixing the mobile IMS universal controlling unit. It may be mounted in the rear of the car mounting set or somewhere else in the car. The control desk contains the power access and internal power distribution.

  • Page 31: Connection To The Quick-Lock System

    Uhrig Co. Separate operating instructions from Uhrig Co. are available for the technology of setting the collars. First the camera must be connected to the Turbo Offset Packer connector using 4 hexagon screws M4x12; the electrical connection is made next.

  • Page 32: Operating Instructions

    5 Operating instructions 5.1 Media supply Caution! Proceed in this order! Make connections from universal cable drum to multi-purpose control system Connect voltage supply to multi-purpose control system Connect pneumatic line to cable drum. Caution: Set controls to STOP! Caution! Make sure the line supplying the cable drum from the compressor is not too long and the cross section not too small (max.

  • Page 33: Startup

    Check nitrogen pressure (see 6.4.1 Nitrogen charging) Caution! Nitrogen shortages may destroy the TURBO cutter. Pay out the required length of media supply line from cable drum (for overall length make allowance for shaft height, lock cable drum after paying out)

  • Page 34: Operation

    5.3 Operation 5.3.1 Operation cutting robot Lower robot with crane connection into shaft. Take off crane connection and insert TURBO miller into chuter. Do not use media hose to position robot, instead use separate rope (risk of cable break)! Crane connection...

  • Page 35: Operation With Quick-Lock Offset Packer

    5.3.2 Operation with Quick-Lock Offset Packer The Quick-Lock manual must be absolutely studied for operation. This present information serves as supplement. Two directional valves are installed in the connector. One directional valve is used to inflate the packer and the second one to release the air from the packer. The second directional valve is normally open to ensure the release of the packer air in case of damages (e.g.

  • Page 36: Conversion To Other Nominal Dias

    Now the entry and positioning at the renovation site is possible. The attachment pressure must be monitored during entry and adjusted with the switch “cylinder” if necessary. Cylinder switch ON (directional valve 1 for filling): applies air to the packer (packer is inflated as until cylinder switch is OFF).

  • Page 37: Format Parts And Assignment To Nominal Dias

    5.4.1 Format parts and assignment to nominal dias. The system of axle add-ons has 6 sizes. The add-on parts have holes for attaching the wheels to the axles. The following add-ons are available: Extension plate 3 3 mm Extension plate 6 6 mm 16 mm 20 mm...

  • Page 38: Nominal Width-Dependent Setup

    5.4.2 Nominal width-dependent setup Internal Axis Extension Wheels Adapters for Pressure Side pipe extension carriage pressure rail rail plates diameter (mm) M6x12 small screw head Extension plate M6x12 small screw head Extension plate M6x16 small screw head AW 0 M6x16 M6x12 small screw head...

  • Page 39: Convert Pressure Rail

    These are 1 (85 mm) and 2 (135 mm) adapters. Instead of the pressure rail, a rubber pad is used for nominal dias. between 180 mm and 200 mm. At low DNs it serves to brace the TURBO for milling work. Caution!
  • Page 40 Unscrew fork head Screw on adapters and mount pressure rail...

  • Page 41: Installing The Mount

    5.4.4 Installing the mount Remove cover panels, axle supports and V-belts as described in “6.4.3 Change V- belts” and mount the A-19 V-belt. Place the rear section onto the mount so that the rear plate rests against the clamping screw seat. Place the V-belt onto the lower rear V-belt pulley. Clamping screw seat...
  • Page 42 Push the carriage forward and tighten via V-belt clamping screw. Mount the A42 V-belt on the front V-belt pulley. Position the V-belt around the V-belt pulley for this purpose. Slightly screw down the V-belt pulley through the elongated hole in the V-belt pulley on the mount using the hexagon socket screws. Tighten the V-belt with a face spanner and fasten the second hexagon socket screw.

  • Page 43: Extension For Egg Shaped Profile Esp (Optional)

    5.4.5 Extension for egg shaped profile ESP (optional) Egg shaped profile 250/375 Support rail 0 with 1 screw M10x20 (front) 1 screw M10x30 (back) and 1 flat washer per screw ESP above with 3 screws M10x30 Wheel 90...
  • Page 44 Egg shaped profile 300/450 rriage for circular section Belt 1=1060 mm (A42) Pressure wheel with distance part 1 Support rail 1 (mounted39 mm) with 2 x M10 x 30 and 1 flat washer per screw ESP above with 3 screws M10 x 30 Belt 1 = 480 mm (A19) Wheel 140...
  • Page 45 Egg shaped profile 350/525 Distance part 0 Guide bushing Carriage for circular section Belt 1 = 1060 mm (A42) Distance part 2 with pressure wheel Support rail 1 mounted 40mm with 2 screws M10x30 and 1 flat washer per screw Distance sheet metal Extension ESP above with 3 screws M10x30...
  • Page 46 Egg shaped profile 400/600 Distance part 0 Guide bushing Carriage for circular section Belt 1 =1060 mm (A42) Pressure rail with distance part 3 Support Rail 2 (mounted 68mm) with 2 screws M10x30 and 1 flat washer per screw Distance metal sheet Extension ESP above with 3 screws M10x30 Extension ESP below with 2...
  • Page 47 Egg shaped profile 500/750 Distance part 0 Guide bushing Carriage for circular section Belt 1=1060 mm (A42) Pressure wheel with distance part 2+3 Support rail 3 mounted 68 mm with 2 screws M10x30 and 1 flat washer per screw Distance metal sheet Extension ESP above with 3 screws M10x30 Extension ESP below with 2 screws...

  • Page 48: Nominal Diameter Extension Dn800 (Optional)

    5.4.6 Nominal diameter extension DN800 (optional) Caution! If the milling robot with the selected nominal width extension is used in a larger nominal width than the specifications (see table Nominal width- dependent setup), there is an increased risk of it tipping over during travel.
  • Page 49 Extension plates with wheels for pressure rail Distance part 1 (85mm) for pressure rail A/13 V- belts l=775mm (A31) Extension plate AW 5 (90 mm) Extension plate AW 3 (40 mm) Fork head with Distance part 1 (85 mm) for pressure rail Extension ESP below with 2 screws M10x16 Distance part Nr.

  • Page 50: Cutting Tools

    5.5 Cutting tools The air motor of the miller idles at a speed of approx. 9,000 rpm so that extremely true running of the milling cutter is required. Cutter unbalances may cause extreme vibration destroying electrical, mechanical and electronic components of the unit. Caution! We recommend the use of original IMS cutting tools for operating the cutter.

  • Page 51: Pressure Control

    Continuing to work with a leaking robot may cause serious damages and result in high repair costs! With the TURBO cutter, the nitrogen-filled cavities of cutting head and camera are connected via the cable. An error may therefore be located in the head itself or in the camera.

  • Page 52: Inspection After Completion Of Work

    5.6.3 Inspection after completion of work The function of the pressure control unit must be checked once more after the cutting work has been finished. Fill the carriage with approx. 1.5 bar of nitrogen. The lights must flash 6 x. The nitrogen must first be removed from the carriage (push on the valve until the nitrogen has escaped and repeat after 1 minute).

  • Page 53: Repairs And Maintenance

    6 Repairs and maintenance 6.1 Cleaning Clean the outside of the milling robot after use. Caution! Do not use high-pressure equipment, simply wipe off air motor or hose down at low pressure when motor is running so that no dirt may enter through exhaust openings and possibly destroy the motor.

  • Page 54: Nitrogen Charging

    (IMS order number 015 04 000 – includes a nitrogen bottle with pressure reducer and IMS charging apparatus). Nitrogen must be charged at a dry location. There are 3 nitrogen valves at the IMS cutter TURBO. The valves are installed in the carriage, the cutting arm and the swivel color camera.
  • Page 55 Valve 1 Carriage Valve 2 Cutting arm Valve 3 Swivel color camera...

  • Page 56: Oiling The Air Motor

    6.4.2 Oiling the air motor The carriage of the TURBO accommodates an oiler and storage tank with a capacity of approx. 0.175 liters. Check the oil level in the carriage daily, prior to starting work, and every two operating hours and top up if necessary.
  • Page 57 Oil is available from specialized dealers, use: BP – Biohyd SE-S 46 or equivalent types. Absorb spilled oil at once in keeping with environmental protection regulations. Take off pressure rail: Remove oil screw, fill in oil: Sight glass...
  • Page 58 It is necessary to check weekly or if you do not waste any oil to check the oil nozzle. Please see the following instructions. Cover screw 2.) Remove nozzle 1.) Remove cover screw Clean the nozzle Put back the nozzle inside the cutter Screw the cover screw back again.

  • Page 59: Change V-Belts

    6.4.3 Change V-belts The TURBO drive acts on the front wheels via V-belts. These are wearing parts and need to be replaced when worn out. Position robot sideways so that wheels can rotate freely. Unscrew all wheels and axle add-ons until axle seats are visible...
  • Page 60 In the front section there are axle seats with eccentric clamps. Loosen these with an Allen key and remove the V-belt pulley. Rotate rear V-belt pulley using multi-purpose control system until V-belt can be threaded out via the groove. Put on new V-belt.
  • Page 61 Place V-belt at the travel drive in the groove of the V-belt pulley and rotate the latter using the multi-purpose control system until V-belt is in place. Insert front V-belt pulley and fix with a screw. Tension V-belt with a face wrench and fix with another screw.

  • Page 62: Change Air Motor

    6.4.4 Change air motor The air motor of the TURBO miller has a rotating piston drive. This and the air motor bearing are subject to high loads and therefore classified as wearing parts. For replacement, dismantle the air motor set and install a set which has been reconditioned by the manufacturer.
  • Page 63 Loosen two screws on air cover and take off cover To install the reconditioned air motor set, screw a threaded rod into one of the lower threads for easier insertion. Place the air motor set with the exhaust valve showing forward into the housing under help of the threaded bolt , remove the threaded bolt and retighten the three lower screws.
  • Page 64 Put cover back on and screw down. Check rotor for easy movement.

  • Page 65: Additional Regulations To Be Observed

    7 Additional regulations to be observed In keeping with the scope of supplies observe the following separately delivered operating and maintenance instructions: Monitor instructions Data input (analog) Instructions universal control unit...

  • Page 66: Accessory Overview

    8 Accessory overview...

  • Page 67: Ec-Declaration Of Conformity

    9 EC-Declaration of Conformity...

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