Hardware Manual
Hardware Manual
ProLine Grader
Information in this document is subject to change without further notice, and does
not represent a commitment by Marel ehf. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any
means, electronic, mechanical, photocopying or otherwise, without the prior written
permission of Marel ehf.
Marel is a registered trademark of Marel ehf.
Printed in Iceland, November 2008.
Copyright 2007, Marel ehf. All rights reserved.
070725ENG-3
Name and Address of Manufacturer: Marel ehf
Name und Anschrift des Herstellers: Austurhraun 9
Nom et adresse du fabricant :
Nombre y dirección del fabricante:
IS-210 Gardabaer, Iceland
DECLARATION OF CONFORMITY
Konformitätserklärung
Déclaration de Conformité
Declaración de la Conformidad
Marel ehf declares that this product is in conformity with the requirements of the following EC directives and
later amendments:
Marel ehf erklärt, dass dieses Produkt in Übereinstimmung mit den Anforderungen der folgenden EC-Direktiven und späteren Änderungen ist:
Marel ehf déclare que ce produit est conforme aux conditions des directives communautaires suivantes et des amendements postérieurs :
Marel ehf declara que este producto está conforme con los requisitos de las directivas de la CE siguientes y de las enmiendas posteriores:
Signature: Place/Date:
Unterschrift: Ort/Datum:
Signature : Lieu/Date :
Gardabaer,
Firma: Lugar/Fecha: September 25, 2009
Þórður Theódórsson, Senior Director of Manufacturing
Marel ehf.
All persons involved in the use and/or installation of this machinery should be aware of the
following instructions.
Failure to follow these instructions or other safety instructions in the manual voids all warranties
and may result in malfunction of the machinery, property damage, serious personal injury, or
death.
WARNING
• The installation and use of this product must comply with all applicable national, state, and local
codes.
• Turn the electrical power off when working on the machinery. Turn the main electrical breaker,
located on the electrical cabinet, to the OFF position and lock the breaker with a padlock.
• Electrical installations and repairs must be performed by a licensed electrician, in accordance with
manufacturer's specifications and national and local electrical codes.
• Operating the machinery without the supplied guards or covers installed is a misuse of the
machinery and can cause a personal hazard.
Do Not
work on any moving parts of the machinery, such as belts, motors, belt tension adjusters, or rollers, without first
disconnecting the electrical power and closing the main air supply valve. Otherwise, a serious personal injury or
death may result.
Do Not
work on electrical or air cabinets without first disconnecting the electrical power, or a serious personal injury or
death may result.
Do Not
make any changes to the emergency stop buttons.
Introduction 3
Installation 9
Operation 19
Maintenance 23
Cleaning 31
Parts Lists 41
Glossary of Terms 75
Index 77
Note: Before you install or use the unit, make sure you read and
understand the warnings and the warranty agreement.
Note: Marel hf. will not warrant any equipment that has not been used
according to specifications.
Discharge unit
Weighing unit
Take-away conveyor
The grader consists of two basic modules, a dynamic weighing unit with
a varying number of weighing platforms with load cell sensors, and a
discharge unit with a variable number of batching bins and chutes of
various types and an optional take-away conveyor. The electrical cabinet
for both the discharge and weighing unit is located on the discharge unit.
The cabinet also houses the M3000 Controller which provides the
grader’s user interface.
Motor
Product sensor
Idle end
Gate arm
M3000
Controller
Motor
Electrical cabinet
Bin 400/600,optional
Chute 400/600, optional
7 The M3000 software calculates when a batch has reached its target
weight or piece count and that information is then used for further
discharge instructions, for example into boxes on the optional box
conveyor.
Consumption:
Air 80 l/min at 180 pieces/minute
Power:
Voltage 1x230VAC + PE
Site Requirements
The following issues are important when you choose the proper location
for the ProLine Grader:
Environment: The grader should not be placed near doorways or
where there is traffic of people passing. Neither should the grader be
placed where there is draught, for example from a ceiling fan, or in
an environment where there are vibrations.
Floor: The grader should be placed on an even and stable surface
and, for best results, it should be bolted to the floor.
Accessibility: There should be enough space around the grader
for easy cleaning and maintenance.
Temperature: For room temperatures below 7°C (45°F) we
recommend the use of Polyethylene or Acetal belts.
Electricity: 1x230VAC + PE power supply must be available.
Air: The air must be clean and dry and the local air pressure for the
factory must be minimum 7 bars. For more details see “Pneumatic
Installations” on page 12.
WARNING! Do not weld near the grader when it has been installed and
connected to a power supply as this may damage the grader. If welding
needs to be done near the grader, unplug the electrical cord and keep the
welding ground as close to the welding point as possible.
4 Take special care when adjusting the weighing unit. Lift the
legs until the unit is perfectly level, length- and widthwise.
Use a spirit level to verify that the weighing unit is correctly
aligned:
• Place the spirit level across each end.
• Place the spirit level lengthwise on top of the weighing
section on both sides of the unit.
• Check the area between the sides to make sure both sides
have the same height.
8 Connect electrical and air supplies, and set the air pressure
Figure 4 Leg and floor bolt. (see “Pneumatic Installations” on page 12 for more details).
Height difference
25-50 mm
Important: The conveyor belts must not touch each other. Contact may
damage the belts and impair the grader’s weighing accuracy.
Pneumatic Installations
Air cylinders in the grader are operated by compressed air. The grader
requires a supply of clean and dry air according to ISO standard 8573-1
class 3 (see Table 2).
Table 2 Quality of compressed air
ISO 8573-1
Solids Water Oil
Class
Particle Concentration
Max Pressure Concentration
size max maximum
Dew point °C mg/m3
µm mg/m3
1 0.1 0.1 - 70 0.01
2 1 1 - 40 0.1
3 5 5 - 20 1
4 15 8 +3 5
5 40 10 +7 25
6 - - + 10 -
7 - - Not Specified -
Note: The lifespan of air valves and cylinders is affected by the quality
of the air supplied. It is therefore important that you only use clean and
dry air.
• Legs
• Encoder bearing
• Belt sensor
• Weighing plates
Legs
Prior to using the ProLine Grader, check if the legs need adjusting.
The discharge unit is supposed to slope a little downwards, but it is very
important that the frame is not twisted.
Encoder Bearing
The encoder bearing is attached to the weighing and discharge unit’s
motor. The encoder bearing keeps track of the belt’s revolutions by
detecting every round made by the tooth of the gear sprocket.
Belt sensor
Encoder bearing
Belt Sensor
Belt sensor
The belt sensor is located on the weighing unit’s outfeed-plate. The sensor
keeps track of the belt’s revolutions by registering the pieces of stainless
steel, inserted in one of the links of the plastic modular belt, whenever the
metal passes the belt sensor (see Figure 7).
After installation, check that the belt sensor is functioning properly. Watch
the indicator light on the bottom of the sensor. The light blinks when the
sensor registers the metal, and should do so at every turn of the belt.
Encoder bearing
Weighing Plates
After installing, check the alignment of the weighing plates:
• Make sure there is a gradual drop in height from the infeed-plate and
weighing-plate to the outfeed-plate. This is necessary to ensure a
smooth material flow across the weighing plates and thus maximum
weighing accuracy.
0.1-0.3 mm
Infeed
Adjustable nuts 2 Adjust the plates by turning the three adjustable bolts under the
weighing plates. The plates can be adjusted up or down.
Adjustable bolt 4 Adjust the edge of the weighing plate to be approximately 0,1-0,3
mm above the edge of the outfeed-plate.
Figure 9 Weighing plate
adjustments.
5 Adjust the edge of the weighing plate to be approximately
0,1-0,3 mm below the edge of the infeed-plate (see Figure 8).
6 Tighten all lock nuts to lock the adjustment bolts in the correct
position.
Gate Arms
The gate arms must be adjusted in the following order:
1 To adjust the gate arm’s angle to the belt, loosen the adjustment
plate and move the gate arm (Figure 10).
2 To adjust the gap between the gate arm and conveyor belt, loosen
the adjustment nut and move the wear strip up and down (Figure
11).
Adjustment nut
Ajustment plate
Wear strip Belt
The power outlet matches the power intake as specified on the rating
plate.
All unused cable glands in the electrical cabinets are sealed.
The electrical cabinets are dry and no moisture can get in.
If the cabinet is damp, turn up the thermostat in the cabinet.
The M3000 Controller turns on when you power on the unit.
The overload protection for the motors is set according to the motors’
specifications for power consumption. 1
Rinse the grader and the belts with clean water before you start the
grader. This will make the belts run more smoothly.
There are no loose objects, for example tools, lying on the belts.
The belt quality is in order; no sticking links or dirt that can hinder the
belt from moving freely.
1 The overload protection is set by Marel service personnel during installation and normally does not require
readjustment.
Figure 12 shows the position of controls and indicators and Table 3 contains
a description of them.
Emergency stop
button
Start button (green)
Mains breaker
Power On indicator
Washing mode
Emergency STOP The emergency stop button instantly shuts the grader
button off. Do not use the button, unless there is an
emergency, because the button turns off the electrical
supply and stops the system.
START button Starts the belts.
Safety Instructions
The ProLine Grader is not a dangerous piece of equipment, but during
operation care should nevertheless be taken in these places:
• The frame
Do not put your hands through the frame holes near the motor or any
moving parts. Fingers can get crushed.
• Conveyor ends
Do not place your hands under the belts, especially not near the rollers
at the conveyor ends.
• Bins and gate arms
Do not place your hands near the gate arms or the bins.
• Motor unit
When the motor is running, do not put your hands near the motor unit.
Keep loose clothing away from the motor.
• Idle end
When the motor is running, do not put your hands near the idle shaft
and wheel. Keep loose clothing away from the idle shaft.
Warning Labels
The grader is supplied with the following warning labels:
• Electrical hazard. The label is placed on the electrical cabinets.
• Danger of hands or arms getting crushed by the bins. The label is placed
near the bin flaps.
• Danger of hands or arms getting crushed between belt roller and belt.
The label is placed near conveyor ends.
• Do not climb on the weighing unit. The label is placed on the top of the
weighing unit’s shield, near sensitive parts such as the product sensor.
4 Make sure the belts of both main modules (weighing unit and
discharge unit) do not touch each other.
Power-On
When starting the ProLine Grader for the first time, turn the power on by
turning the mains breaker on the side of the electrical cabinet to the ON-
position (see electrical cabinet, Figure 12).
Everyday start of the unit is by the following procedure:
2 Let the belts run empty until a Steady message appears on the
M3000 Controller.
To stop the unit, press the Stop button on the electrical cabinet.
Note: Do not turn the power off the unit completely (using the mains
breaker) after you stop the belt. Leave the mains breaker in ON position.
This will leave power on the M3000 Controller. A little heat will be
generated in the electrical cabinet and condensation of moisture in the
cabinet is prevented.
Maintenance Schedule
This chapter describes preventive maintenance of the ProLine Grader and
various adjustments that may have to be made.
Table 4 contains the grader’s maintenance schedule.
Continued …
Maintenance Procedures
Procedures for maintaining individual parts of the ProLine Grader are
described in the following.
2 Look for sticking rods and for dirt that makes the links stiff.
In case some of the links are stiff because of dirt, clean the belt
more thoroughly, or replace the stiff links with new ones.
4 There should be 312 links in the belt. The current link count is
shown on the DWU Overview screen on the M3000 display.
Product Sensor
The product sensor is part of the weighing unit. It is very important that the
sensor is kept clean and correctly positioned.
Do not allow dirt to build up on or around the sensor. The sensor consists of
two parts, a light transmitter/receiver and a mirror. Both parts of the sensor
and the entire area between them must be kept clean at all times, or else the
light beam may be interrupted.
If the product sensor needs to be replaced, you must adjust the light beam.
Mirror
Wedge
Belt
Direction
3 Check the height from both sides of the belt and from the
center.
Pneumatic System
To operate properly the discharge unit requires a constant level of air
pressure. This is best achieved by setting the pressure to the
recommended level while the unit is running (see Pneumatic
Installations, page 12).
If you increase the air pressure after the air cylinders have been adjusted,
the cylinders will move faster and the shock will be harder. If the
pressure is decreased, the opposite will happen, a slower and softer
cylinder movement.
The water trap in the air cabinet (see Figure 18) is equipped with an
automatic water ventilator.
Adjustment valve
Locking ring
Press down to lock
4 6
Air intake 2 8 Air outlet
0 10
Air pressure gauge
Water Exhaust
WARNING! Use extreme caution while adjusting the air cylinders with
air pressure and power on the unit. Always stop the belt before adjusting
the cylinders.
Due to wear an air cylinder may have to be replaced from time to time. In
that case, note the following:
• After replacing a cylinder, you must adjust it. Before you do,
make sure the air pressure for the unit is at the correct level.
• After the cylinder has been replaced, make sure the piston
does not knock against the enclosure.
• Adjust the shock absorbing mechanism in the cylinder by
turning the small adjustment screws on both ends of the
cylinder (see Figure 19, B and D).
• Make sure the bolt connection F (to the frame) has room to
rotate.
• Tighten bolt connection G (to the gate arm). If a plastic ball
joint eye (H) without a steel insert is used, do not fasten the
bolt too tightly. Steel ball joint eyes, however, should be
tightened firmly.
1 To adjust the “out” speed of the piston rod, adjust the speed
adjustment screw at the front end of the cylinder
(see Figure 19, C).
2 To adjust the “in” speed of the piston rod, adjust the speed
adjustment screw at the rear end of the cylinder
(see Figure 19, A).
3 You can test the speed of the cylinder by selecting the Adjust
gates function on the M3000 Controller.
The gates will now open and close continuously and the arms
will catch objects that are passed over the weighing unit.
Gate Arms
WARNING! Always show great caution when working on the gate arms
and the air cylinders. You cannot test the arms unless the discharge unit
is in run mode. To stop the belt while adjusting the arms, press the Stop
button.
Check the function and state of the gate arms every week.
1 Move the gate arms manually and check for abnormal friction in
the bearings or the air cylinders.
2 Check for play in the joints and whether the arm is badly worn.
4 Check if the arm rubs against the belt or if the space between arm
and belt is too large. The appropriate space between arm and belt
is 1-2 mm.
1-2 mm 1-2 mm
Bearing house
Idle Shaft
Inspect the idle shafts daily to ensure the shaft, wheels, and sprockets run
freely. Also check that there is no abnormal noise from the bearings and
that seals are in good order.
Figure 23 Idle end, weighing unit Figure 24 Idle end, discharge unit
Cleaning in General
The following sections contain general instructions for good cleaning
practices which Marel considers appropriate for Marel equipment. The
instructions are not a proposal for a complete cleaning plan for the user.
The best available practices should be used at all times.
We recommend that you request an introduction to recommended
cleaning agents and their use from a qualified distributor of cleaning
solutions. Selecting a sanitizer depends on the type of equipment to be
sanitized, the hardness of the water, the application equipment available,
the effectiveness of the sanitizer under site conditions, and cost.
Only approved sanitizers should be used in food processing plants. Lists
of approved sanitizers are published by the authorities in most countries,
see for example the Code of Federal Regulations in USA.
Request technical advice from a reputable sanitizer manufacturer, if you
have questions on which sanitizer to use as well as questions on the
appropriate solution strength.
Detergents
The pH value of detergents used on Marel equipment should preferably
be pH 12-13.
Strong base solutions are the main ingredients in most cleaning agents,
for example potassiumhydroxid (KOH) or caustic soda (NaOH). Because
of its corrosive effects, caustic soda is not a desirable detergent for Marel
equipment.
If possible, use detergent solutions with KOH instead.
Daily Cleaning
Cleaning is the complete removal of food soils using appropriate
detergent chemicals according to instructions. It is important that
cleaning personnel have an understanding of the nature of the different
types of food soils and the chemistry of their removal.
Sanitization
When choosing a sanitizing agent, please note that chlorine corrodes the
stainless steel and disintegrates PVC and PUR belts, especially at higher
temperatures. Chlorine is, however, an effective sanitizer, so occasional
use of chlorine may be necessary to control the growth of
microorganisms.
Marel recommends the following sanitization procedure:
As chlorine evaporates very quickly, its sanitizing effect will fade soon
after it is sprayed on the equipment. Letting chlorine stay on the
equipment will not improve the sanitizing effect, but only damage the
equipment. Quaternary ammonium compounds are considerably more
stable than chlorine and are active for a much longer time. Therefore, the
benefit of leaving QACs on the equipment for an extended period of time
is much greater.
Cleaning Procedures
Before you start cleaning the ProLine Grader, follow the instructions
below to ensure maximum safety during the cleaning.
Cleaning the grader is a procedure in 7 steps:
• preparation
• rinsing the nearby environment
• rinsing the grader
• foaming
• washing
• sanitizing
• final inspection
Preparation
1 Secure the machine by turning the Motors switch Off.
(Optionally, lock the switch with a padlock for additional
safety.)
Foaming
1 Keep the conveyor belt running and spray the machine with
detergent foam or other appropriate type of detergent. Make
sure the foam reaches all corners and hard-to-reach areas.
2 Let the detergent work as specified by the manufacturer.
Washing
1 Keep the conveyor belt running while you rinse off dirt
dissolved by the foaming, working from the top down using
water jets.
Figure 27 Non-sticky bin (left) and 405/600 bin (right), tilted, lock handle.
11 When you have finished cleaning the belts, put the idle end
down.
Note: Never start the grader with the idle end lifted in
upward position
Sanitizing
• All surfaces in contact with the product should be sanitized
every day of operation.
• Make sure the surface is as dry as possible before sanitizing,
because water remaining from the washing process will dilute
the sanitizing agent.
• For the daily sanitization, use sanitizing agents containing, for
example, quaternary ammonium compounds. Once a week,
sanitize with chlorine (≤ 200 ppm) or a comparable sanitizing
agent.
• After sanitizing, rinse the ProLine Grader thoroughly with clean
water to eliminate contact between sanitizer and raw material or
products in the next production round. This also helps prevent
corrosion of the stainless steel by aggressive sanitizers and
prevents the forming of an undesirable chemical film.
Final Inspection
After cleaning, quality control personnel should evaluate the result of the
cleaning process:
WARNING: Do not use water for cleaning the electrical cabinets. The
electrical components in the cabinets must never become wet. If they
do, you must make sure they are completely dry before the ProLine
Grader is powered on again.
Daily Preparation • Remove any raw material, products or packing material. After
preparation the
• Put the machine in Washing mode to keep the conveyor machine should
running while you rinse soils off. be ready for
cleaning.
Daily Rinsing • Rinse off loose soils using water jets or brushes. Do not use After rinsing
high water pressure. the machine
should be free
of loose soils.
Daily Foaming • Foam the machine and make sure the foam reaches into all
corners and hard-to-reach places.
Daily Washing • Use a brush to scrub difficult places and wash with a water jet. Do not use
water pressure
• Wash the conveyor. on the M3000
display.
Daily Sanitizing • Make sure the surface is as dry as possible before sanitizing.
Daily Final • After cleaning quality control personnel should check and Count micro-
inspection evaluate cleaning results. organisms
regularly.
• On the day when chlorine is used, you can leave out sanitizing
with other agents.
Note: Before contacting our service personnel or placing an order for spare
parts, please note the serial number on the rating plate located on the side of
the electrical cabinet.
Serial number
Controller
See M3000 Controller.
L/min
Capacity measure liters per minute.
M3000 Controller
A computer with a display unit that controls Marel equipment.
Motors
Motors that drive the belts.
Operator panel
An operator panel with indicators to start and stop the ProLine Grader.
Product sensor
On the weighing unit. A light transmitter and receiver. Detects when
objects enter the weighing plate.
Psi
Pounds per square inch.
Weighing plate
Part of the weighing unit where the weight is registered. Attached to the
load cell.
R
Replacing air cylinders 27