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Transcript of 280A METRO 06-1bis30-1 V2.0 EN - hosa-dryer.com · METRO 06-1 to 30-1 Transport and setup 4...
Operating Manual
Hopper loaderMETRO 06-1 to 30-1
CE
02/2006 280A-00.0.EN V2.0003/06
Edition: February 2006 17
METRO 06-1 to 30-1Transport and setup 4
Mounting hopper loader
4 Transport and setup
4.1 Mounting hopper loader
Position the flange seal [3] on the machine or drying bin.
Position the hopper loader on the machine or drying bin.
Connect the hopper loader tightly to the machine or drying bin as shown above. Note the different design of discharge and machine module.
Discharge module Machine module
Fig. 4.1 – Attaching hopper loader
[1] Hexagon-headed screw[2] Washer[3] Flange seal
[4] Hexagon nut self-locking[5] Spring washer[6] Hexagonal nut
4 Transport and setupConnections METRO 06-1 to 30-1
18 Edition: February 2006
4.2 Connections
4.2.1 Compressed air connectionConnect the air hose (PU tube Ø 4x1 mm (Ø 0.16x0.04")) to the compressed air connection on the unit [1].
The operating pressure must be 0.4–0.6 MPa (4–6 bar (60–90 psi)).
[1] Compressed air connectionFig. 4.2 – Connecting compressed air METRO *C/J*
[1] Compressed air connectionFig. 4.3 – Connecting compressed air METRO *P*
Note
The operating pressure must not fall below 0.4 MPa (4 bar (60 psi)).
Edition: February 2006 19
METRO 06-1 to 30-1Transport and setup 4
Connections
4.2.2 Fastening material/vacuum hose
Note the flow direction (PU tubes only, optional), (see figure 4.4). Incorrect installation direction may influence the transport output.
Remove the wire spiral [1] from the tube and bend it inwards to make it contact the hopper loader.
Slide the material/vacuum hose on to the connection on the hopper loader and fasten the hose with a suitable hose band clip (see Figure 4.5).
CAUTION!
MATERIAL DAMAGE!Incorrectly attached material/vacuum hoses cause transport problems and damage to the hopper loader.
Lay out material/vacuum hose to the hopper loader with a sufficiently wide curve.Ground the hose.
[1] Flow direction with PU tubesFig. 4.4 – Flow direction
[1] Wire spiralFig. 4.5 – Ground material tube
4 Transport and setupConnections METRO 06-1 to 30-1
20 Edition: February 2006
4.2.3 Electrical connection
Connecting the control cable
The electrical power is supplied from the controller via the controller cable (see figure 4.64.7).
CAUTION!
MATERIAL DAMAGE!Radiant heat and hot surfaces may damage the controller cable.
Lay out the controller cable so it will not be damaged by the heat of downstream units (hot surfaces or radiant heat)!
[1] Control cable connectionFig. 4.6 – Connecting control cable METRO *C/J*
[1] Control cable connectionFig. 4.7 – Connecting control cable METRO *P*
Edition: February 2006 21
METRO 06-1 to 30-1Structure and function 5
Function
5 Structure and function
5.1 Function
In a hopper loader system with METRO H** and/or METRO M** hopper loaders one central Motan-controller controls all units in the system.
The different hopper loaders report a material requirement to the relevant controller and are then processed in succession.
METRO H**: Material required via the Proximity switch if the discharge flap is closed
METRO M**: Material required via the demand probe if the granulate no longer covers the demand probe.
If material is required by one or more hopper loaders, the blower station starts and generates underpressure in the vacuum line. The bypass valve on the filter closes and simultaneously open the vacuum valve in the hopper loader. An underpressure forms in the vacuum line and continues through the hopper loader to the material line through to the suction point.
Fig. 5.1 – Layout of the hopper loaders
[1] Demand probe (METRO M** only)[2] Material discharge module (machine hopper
loader)[3] Unit cover[4] Implosion module[5] Material inlet module
[6] Multifunction panel METRO *C/J*[7] Glass/stainless steel[8] Material discharge module (bin loader)[9] Proximity switch (METRO H** only)[10] Multifunction panel METRO *P*
5 Structure and functionFunction METRO 06-1 to 30-1
22 Edition: February 2006
The aspirated air forms a mixture of air and granulate in the material line. The granulate falls down by gravity when it enters the hopper loader. The dust particles in the granulate pass through the screen filter and are removed by the central filter. This removes dust from the granulate at the same time.
Depending on the specified conveying time the vacuum valve closes to form an airtight seal. Because of the underpressure in the hopper loader the implosion valve now opens suddenly for a short time. The implosion cleans the screen filter after every loading cycle.
METRO H**: as a result of the implosion the underpressure in the hopper loader collapses and the weight of the granulate opens the discharge flap. The material flows into the machine bin.
The vacuum valve in the hopper loader opens at the next demand. The loading cycle starts.
Only one hopper loader at a time can be filled on a blower line.
If all hopper loaders are full and no material required is pending at the controller, the bypass valve on the filter opens, the blower aspirates fresh air and switches off after a specified run-on time. This reduces the load on the blower station.
If a hopper loader reports material required again to the controller, the blower station is switched on and a new loading cycle starts.
Fig. 5.2 – Functional diagram of the METRO H 06/10/15/30 hopper loader
[1] Vacuum line[2] Implosion valve open[3] Material tube[4] Discharge flap[5] Inlet flap open
[6] Vacuum valve open[7] Inlet flap closed[8] Vacuum valve closed[9] Proximity switch
Edition: February 2006 25
METRO 06-1 to 30-1Operation 7
Settings
7 Operation
7.1 Settings
All settings required for the function of the hopper loader are made at the central Motan controller (see corresponding operating manual).
7.2 Material feed
7.2.1 GeneralThe objective is to establish an even flow of material (air conveying) during suction. The air supply at the suction point is adjusted for an even conveyor air flow.
7.3 Operation
7.3.1 CommissioningThe system must be installed by Motan technicians and transferred to the customer when it is ready for operation.
7.3.2 Continuous operationRequirements:
Material line correctly connected
Correct setting of the air supply at the suction point
Electrical system correctly connected
All values input or adjusted as specified in the operating manual of the controller
Note
The air supply at the suction point must be readjusted every time the material changes because of the different flow properties of the various types of granulate.
7 OperationOperation METRO 06-1 to 30-1
26 Edition: February 2006
7.3.3 Switching hopper loaders on and off (METRO *C* only)The hopper loader controller is fully wired at the factory. The electrical power is supplied from the con-troller via the controller cable. For connection see "Electrical connection" on Page 20.
FunctionsVacuum light indicator
On: material is being conveyed.
Off: no material is being conveyed.The material conveying depends on the Motan central controller. Material cannot be conveyed until the Motan central controller enables material conveying.Only one hopper loader at a time can be filled on the conveyor line.
Illuminated On/Off button
The hopper loader controller can be switched on and off manually at every hopper loader.
Press the illuminated button.
When the illuminated button is on the hopper loader is on.
Press the illuminated button.
When the illuminated button is off the hopper loader is off.
The illuminated button flashes and an alarm is displayed,(see "Troubleshooting" on Page 29).
Level light indicator (fill level)
On: on empty signal.The minimum probe or the initiator require material.
Off: on full signal.The minimum probe or the initiator do not require material.
[1] Vacuum light indicator[2] Illuminated On/Off button[3] Level light indicator (fill level)[4] Controller connection
Fig. 7.1 – Hopper loader with METRO C multifunction panel
Note
The hopper loaders are all switched on and off centrally at the On/Off switch at the corresponding Motan central controller.
It is not necessary to switch off the hopper loaders separately.
If the hopper loaders are switched off individually, they remain switched off even after the Motan central controller has been switched off and then on again.
Edition: February 2006 27
METRO 06-1 to 30-1Operation 7Operation
7.3.4 Switching demand probe on and off (METRO *J* only)The hopper loader controller is fully wired at the factory. The electrical power is supplied from the con-troller via the controller cable. For connection see "Electrical connection" on Page 20.
Functions
Toggle switch (green light on)
OFF (toggle switch light off):The demand probe is switched off. A conveying cycle cannot be started, i. e. material is not con-veyed.
ON (toggle switch light off):The demand probe is switched on. Material is conveyed if required and a new conveying cycle is started.
7.3.5 AlarmsAlarms are displayed at the central Motan controller.
Troubleshooting: see "Troubleshooting" on Page 29.
[1] Controller connection[2] Toggle switch
Fig. 7.2 – Hopper loader with METRO J control box
WARNING!
DANGER OF INJURY.Danger of injury when working on hopper loader when not switched off. If the demand probe is switched off with the toggle switch, the controller box is still under 120 V power.
Do not carry out any maintenance, repair or other work on the hopper loader if only the demand probe is switched off.If you wish to carry out any work on the hopper loader, the unit must be discon-nected from the power supply, see "Maintenance and repair" on Page 32.
Note
The hopper loaders are all switched on and off centrally at the On/Off switch at the corresponding Motan central controller.
It is not necessary to switch off the hopper loaders separately.
If the hopper loaders are switched off individually, they remain switched off even after the Motan central controller has been switched off and then on again.
Edition: February 2006 29
METRO 06-1 to 30-1Troubleshooting 8
Troubleshooting
8 TroubleshootingFaults on the hopper loader are displayed on the central Motan controller. The meanings of the var-ious alarm messages are described in the documentation of the unit that is being controlled.
8.1 Troubleshooting
Hopper loader overfull
Demand probe LED lights "red"
Material flow (air conveying) uneven
Leak in pipe system
Meaning of error Correction
– Conveying time set too high. Correct value on controller.
Meaning of error Correction
– Demand probe incorrect adjusted. Check settings (see "Checking demand probe (METRO M** only)" on Page 37)replace demand probe if necessary.
Meaning of error Correction
– Material flow interrupted. Adjust air supply at suction point.
– Plug formation. Adjust air supply at suction point.
Check underpressure.
Meaning of error Correction
– Leak in pipe system (vacuum and material line).
Check underpressure in vacuum system.
8 TroubleshootingTroubleshooting METRO 06-1 to 30-1
30 Edition: February 2006
No material or too little material transported
Meaning of error Correction
– Conveying time set too low. Correct value on controller.
– No material at suction point. Check material feed.
– Plug in pipe system. Purge plug.
– Screen filter blocked. Clean screen filter.
Check implosion valve.
– Blower filter blocked. Clean blower filter.
– Leak in pipe system (vacuum and material line).
Check underpressure in output system.
– No compressed air at hopper loader. Check compressed air system.
– Discharge flap leaks. Check and replace worn parts.
– Demand probe defective or incorrect adjusted.
Check settings (see "Check/adjustdemand probe" on Page 37) replace demand probe if necessary.
– Inlet flap on a unit of the system does not seal.
Check inlet flap (see "Check inlet flap" on Page 36).
Edition: February 2006 31
METRO 06-1 to 30-1Maintenance and repair 9
Safety
9 Maintenance and repairThis chapter contains detailed maintenance and repair instructions and information on regular inspections.
9.1 Safety
9.1.1 Personnel qualification
9.1.2 Protective equipmentThe following protective equipment is required for maintenance and repair work:
9.1.3 Safety devices
WARNING!
DANGER OF INJURY!Maintenance and repair conducted by insufficiently qualified personnel may lead to incalculable risks with negative results for persons, machine and the environment.
All maintenance and repair work must be carried out by qualified and authorized technicians only.
Wear protective gloves
WARNING!
DANGER OF INJURY!The operator runs the risk of injury if the safety devices are not operating correctly.
Check that the safety devices function correctly after work has finished.
9 Maintenance and repairBefore starting work METRO 06-1 to 30-1
32 Edition: February 2006
9.2 Before starting work
Before starting work, the following conditions must be met.
9.2.1 Maintenance and repairObserve the following information before beginning maintenance or repair work.
Switch the hopper loader off.
Disconnect the control cable (if possible) on the hopper loader, or make sure that the hopper loader is disconnected from the power supply.
Open the hopper loader cover.
9.2.2 Additional information for repair work
Remove the pressure tubes.
Remove the hopper loader from the machine or drying bin.
Fig. 9.1 – Safety stickers on the hopper loader
CAUTION!
Material damage!Parts which fall into the unit may cause operational faults.
Make sure that no parts fall into the unit.Cover the opening of the machine and bin.
CAUTION!
DANGER OF INJURY!If the compressed air hose is disconnected while it is under pressure it may cause impact injuries.
Make sure that the compressed air hose has no pressure before disconnecting it.
Edition: February 2006 33
METRO 06-1 to 30-1Maintenance and repair 9
Intervals for inspections, maintenance and cleaning work
9.3 Intervals for inspections, maintenance and cleaning work
Weekly
Monthly
Annually
Component Activity Target value/Meaning Qualification
Screen filter cleaning See "Clean screen filter" on Page 34
Operator
Component Activity Target value/Meaning Qualification
Demand probe demand probe See "Checking demand probe (METRO M** only)" on Page 37
Operator
Component Activity Target value/Meaning Qualification
Check inlet flapi
i monthly with abrasive plastic granulates
for wear See "Check inlet flap" on Page 36
Operator
Check discharge flapi for wear See "Adjusting discharge flap (METRO H** only)" on Page 42
Operator
Check vacuum and implosion valve
for leaks Visual check Operator
9 Maintenance and repairMaintenance and cleaning METRO 06-1 to 30-1
34 Edition: February 2006
9.4 Maintenance and cleaning
9.4.1 Clean screen filter
Prepare the hopper loader for maintenance (see "Maintenance and repair" on Page 32).
Open the spring clips on the top of the unit.
Open the cover.
Remove the screen filter.
Tap the screen filter to clean it and clean the screen filter with a vacuum cleaner.
Check its condition and if necessary replace the screen filter.
WARNING!
Danger of injury by dust, granulate, etc.Dust, granulate, etc. may cause eye injuries and injuries to breathing passages.
Always wear protective glasses.Always wear a respirator.
CAUTION!
DANGER OF SLIPPING!Material pellets can fall on the floor and there is a risk of people slipping on the material and injuring themselves.
Keep the floor free of material pellets.
[1] Screen filter[2] Filter fastener rods
Fig. 9.2 – Screen filter
Edition: February 2006 35
METRO 06-1 to 30-1Maintenance and repair 9
Maintenance and cleaning
Structure
Insert the screen filter so the screen filter seal contacts the fastener ring [2].
Check that the screen filter [1] is correctly positioned, i.e. the rods of the filter fastener (see figure 9.2) are not in the vicinity of the vacuum valve.
Close the cover and lock it with the spring clips.
[1] Screen filter[2] Fastener ring
Fig. 9.3 – Replace screen filter
CAUTION!
MALFUNCTION!The required vacuum may not be generated if the rods of the filter fastener project above the hopper housing.
Never force the cover closed.Make sure that the screen filter is precisely positioned and that the rods do not project above the hopper housing.
Note
The screen filter clogs up faster when regrind material is transported.
Reduce cleaning intervals appropriately.
9 Maintenance and repairMaintenance and cleaning METRO 06-1 to 30-1
36 Edition: February 2006
9.4.2 Check inlet flap
Prepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Remove the screen filter (see "Clean screen filter" on Page 34).
Check the inlet flap [1] for wear (see arrows in the magnified view).
[1] Check inlet flapFig. 9.4 – Check inlet flap
Edition: February 2006 37
METRO 06-1 to 30-1Maintenance and repair 9
Maintenance and cleaning
9.4.3 Checking demand probe (METRO M** only)
Check/adjust demand probe
Setting demand probeUnlock: press and hold the programming key [1] for at least 10 s with a blunt object until the green LED [3] goes out.
Position the probe as desired and make sure that the probe is in contact with the glass.
Run-empty adjustment: Press and hold the programming key [1] (1-5 sec) until the green LED flashes. The green and yellow LED [2] now indicate ready for operation.
Lock: press and hold the programming key for at least 10 s. The green LED flashes slowly at first, then faster after 5 s and then goes out.
Conducting full adjustment
First unlock, then the run-empty adjustment
Then with the hopper full press and hold the programming key for 5 to 10 s until the green LED flashes twice as fast as in the first 5 s.
Now the green LED lights. Then lock the probe again.
[1] Programming key[2] LED, yellow[3] LED, green
Fig. 9.5 – Demand probe
Note
The probe is locked at the factory
The probe must be reset for specific material or after a position change.
Note
In rare cases it is necessary to conduct a full adjustment
9 Maintenance and repairRepair work METRO 06-1 to 30-1
38 Edition: February 2006
9.5 Repair work
9.5.1 Disassemble METRO 06-1 to 30-1 hopper loader into its modules
Separating modules
Prepare the hopper loader for maintenance (see "Before starting work" on Page 32).
To separate the module, slacken the screw [4] and remove the profile clamp [1] (also the ground for glass units [6]).
Disengage the module.
Remove the seal [3].
Remove the two ground terminals [2].
Fig. 9.6 – METRO H** hopper loaders
[A] METRO HC/HJ*[B] METRO HP*[1] Profile clamp[2] Ground terminal
[3] Seal[4] Screw[5] Multifunction panel[6] Ground (glass units only)
CAUTION!
Material damage!Parts which fall into the unit may cause operational faults.
Make sure that no parts fall into the unit.Cover the opening of the machine and bin.
Edition: February 2006 39
METRO 06-1 to 30-1Maintenance and repair 9
Repair work
Assembling modulesPlace the two ground terminals [2] at opposite ends.
Place the seal [3] on the contact surface of the bottom module.
Position the module.
Position the profile clamp [1] and fasten the clamp with screw [4] (also the ground for glass units [6]).
9.5.2 Replacing vacuum valve
RemovalPrepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Note
Always place the profile clamp screws behind the controller [5].
CAUTION!
Material damage!Parts which fall into the unit may cause operational faults.
Make sure that no parts fall into the unit.Cover the opening of the machine and bin.
Fig. 9.7 – Vacuum valve
[1] Hexagonal nut[2] Implosion valve[3] Spacer rod[4] Contact surface of the spacer rod[5] Sealing disk
[6] Vacuum seal[7] Hexagon-headed screw M6[8] Spring[9] Piston rod[10] Contact surface of the piston rod[11] Pneumatic cylinder
9 Maintenance and repairRepair work METRO 06-1 to 30-1
40 Edition: February 2006
Unscrew the M6 hexagon-headed screw [7]. Using a forked wrench (WAF 9), push against the contact surface of the piston rod [4].
Press the spacer rod [3] back manually and pull the sealing disk [5] out.
Remove the spring [8].
Slacken the hexagon nut [1] on the pneumatic cylinder [11].
Unscrew the pneumatic cylinder [11] and remove the implosion valve [2].
Loosen the spacer rod with forked wrench (WAF 9). Using a forked wrench (WAF 9), push against the contact surface of the piston rod [10].
Unscrew the spacer rod [3].
InstallationAssemble in reverse order.
Make sure that the sealing disk [5] contacts the seal [6] after assembly.
Lock the thread of the piston rod [9] and the hexagon-headed screw [7] with Loctite 270.
Tighten the screw to 10 Nm. The Loctite must harden for at least 6 hours, i.e. the hopper loader should not be operated again during this period.
Note
Make sure that no parts fall into the unit.
Cover the opening of the machine and bin.
Edition: February 2006 41
METRO 06-1 to 30-1Maintenance and repair 9
Repair work
9.5.3 Replacing demand probe (METRO M** only)
Removing demand probe Prepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Unscrew the sensor cable [1].
Slacken the hexagon nuts [2].
Unscrew the demand probe [3].
Installing demand probeAssemble in reverse order.
After replacement adjust the new demand probe(see section "Check/adjust demand probe" on Page 37)
Conduct a test run.
[1] Sensor cable[2] Hexagonal nut[3] Demand probe
Fig. 9.8 – Removing demand probe
9 Maintenance and repairRepair work METRO 06-1 to 30-1
42 Edition: February 2006
9.5.4 Adjusting proximity switch (METRO H** only)
Prepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Close the discharge flap.
Set the clearance as shown in the diagram 9.9.
Lock the proximity switch [1] with the hexagon nuts [2].
9.5.5 Adjusting discharge flap (METRO H** only)
Slide the weight on to the tension pin and fix the weight. Installation position: see diagram 9.10.
Tighten the set screw and lock it with Loctite 242.
[1] Proximity switch[2] Hexagon nuts
Fig. 9.9 – Adjusting proximity switch
2
1
[1] WeightFig. 9.10 – Positioning weight
Edition: February 2006 43
METRO 06-1 to 30-1Maintenance and repair 9
Repair work
Screw the spring-loaded thrust pad [1] (see figure 9.11) up until the gap between the discharge [3] and the discharge flap [2] is 5-8 mm.
[1] Spring-loaded thrust pad[2] Discharge flap[3] Discharge
Fig. 9.11 – Adjusting discharge flap
Note
The air gap at the discharge flap ensures that particles of granulate on the discharge flap are sucked in by the vacuum at the start of transport.
The discharge flap is pulled up by the vacuum and forms an airtight seal.
Edition: February 2006 45
METRO 06-1 to 30-1Decommissioning and disposal 10
Disposal of unit parts
10 Decommissioning and disposalDecommissioning the unit
Switch the unit off.
Remove the controller cable.
Remove the hose for the compressed air supply.
10.1 Disposal of unit parts
Dispose of unit parts as follows:
CAUTION!
PERSONAL INJURY AND ENVIRONMENTAL DAMAGE.Through incorrect disposal of operating fluids.
Incorrect disposal of operating fluids endangers people and damages the environ-ment.
Dispose of the unit parts and operating fluids sorted and correctly.Follow the manufacturer's directions.
Part Disposal
Hoses Plastic waste
Multifunction duct cover Plastic waste
Seals Plastic waste
Cables and electrical parts Electrical waste
Controller Electronic waste
Glass module Scrap glass
Remainder of hopper loader Scrap iron
Edition: February 2006 47
METRO 06-1 to 30-1Option 11
Option: Pneumatically actuated discharge flap
11 Option
11.1 Option: Pneumatically actuated discharge flap
The pneumatically actuated discharge flap is for positive opening and closing of the discharge flap and requires a demand probe under the discharge flap.
11.1.1 Before starting workBefore starting work read the safety notices "Safety" on Page 7.
11.1.2 Intervals for inspections, maintenance and cleaning work
Annually
Component Activity Target value/Meaning Qualification
Check discharge flapi
i monthly with abrasive plastic granulates
for wear See "Maintenance work" on Page 48
Operator
11 OptionOption: Pneumatically actuated discharge flap METRO 06-1 to 30-1
48 Edition: February 2006
11.1.3 Maintenance work
Prepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Check the discharge flap [2] for wear and cracking.
Check the discharge [3] for damage
CAUTION!
Material damage!Parts which fall into the unit may cause operational faults.
Make sure that no parts fall into the unit.Cover the opening of the machine and bin.
[1] Pneumatic cylinder[2] Discharge flap[3] Discharge
Fig. 11.1 – Pneumatically actuated discharge flap
Edition: February 2006 49
METRO 06-1 to 30-1Option 11
Option: Pneumatically actuated discharge flap
11.1.4 Maintenance
Removing the pneumatic cylinderPrepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Fold the pin [8] down out of the way and pull the pin [8] out of the yoke [7].
Remove the bayonet clip [2] and remove the cylindrical roller-bearing [3] with the pneumatic cylinder [1].
Slacken the hexagon nut [6]. Using a forked wrench (WAF 9), push against the contact surface of the piston rod [5].
Unscrew the yoke [7] and the hexagon nut [6].
Slacken the hexagon nut [4] using the fork wrench (WAF 32).
Unscrew the pneumatic cylinder [1] out of the cylindrical roller-bearing [3].
Installing the pneumatic cylinderAssemble in reverse order.
Lock the two hex nuts [4] [6] with Loctite 242.
[1] Pneumatic cylinder[2] Bayonet clip[3] Cylindrical roller-bearing[4] Hexagonal nut[5] Contact surface of the piston rod[6] Hexagonal nut[7] Yoke[8] Pin[9] Panel
Fig. 11.2 – Pneumatically actuated discharge flap
11 OptionOption: Pneumatically actuated discharge flap METRO 06-1 to 30-1
50 Edition: February 2006
11.1.5 METRO 06/10 spare parts
Spare parts listItem Unit Designation Article no. Remarks
1 2 Silencer 4063970
2 2 Sealing ring 4044670
3 1 O-ring 4078360
4 1 Discharge module welded 4116870
5 1 Flap shaft 4116960
6 1 Screw M6i 4083720 Verbus Ripp
7 1 Fastener t= 3.0 4117300
8 2 Hexagon nut M6 with clamp sectioni 1902350 ISO 7042
9 1 Flap t=1.0 4117320
10 2 Lens flange flat-head screw M6 4073190
11 1 Tension pini
i Secured with Loctite 242
4076640 ISO 8752
12 1 Flap lever positive closure 4117090
13 1 Positive closure advance group 5089500
Edition: February 2006 51
METRO 06-1 to 30-1Option 11
Option: Pneumatically actuated discharge flap
11.1.6 METRO 15/30 spare parts
Spare parts listItem Unit Designation Article no. Remarks
1 2 Silencer 4063970
2 2 Sealing ring 4044670
3 1 O-ring 4078370
4 1 Discharge module welded 4117150
5 1 Flap shaft 4117010
6 1 Screw M6i 4083720 Verbus Ripp
7 1 Fastener t= 3.0 4117370
8 2 Hexagon nut M6 with clamp sectioni 1902350 ISO 7042
9 1 Flap t=1.0 4117360
10 2 Lens flange flat-head screw M6 4073190
11 1 Tension pini
i Secured with Loctite 242
4076640 ISO 8752
12 1 Flap lever positive closure 4117090
13 1 Positive closure advance group 5089500
11 OptionOption: Pneumatically actuated discharge flap METRO 06-1 to 30-1
52 Edition: February 2006
11.1.7 METRO 06-1 to 30-1 spare parts
Spare parts listItem Unit Designation Article no. Remarks
1 2 Throttle non-return valve 4104370
2 1 Pneumatic cylinderi
i Secured with Loctite 242
4158440
3 1 Cylindrical roller-bearing 4114600
4 2 Cam 4012830
5 1 Base panel 4117070
6 4 Spring washer 1210880
7 4 Slotted panhead screw 4050900
8 1 Yoke 4004550
9 1 ES Pin 1095250
10 1 Hexagon nut M10x1.26i 4150880
11 1 Bayonet clip 1095090
Edition: February 2006 53
METRO 06-1 to 30-1Option 11
Optional fill level probe
11.2 Optional fill level probe
The fill level probe switches when granulate passes before the active surface. The fill level probe adjustment depends on the type of granulate and must be adjusted accordingly.
11.2.1 Intervals for inspections, maintenance and cleaning work
Monthly
Component Activity Target value/Meaning Qualification
Fill level probe fill level probe See "Maintenance work" on Page 54
Operator
Edition: February 2006 57
METRO 06-1 to 30-1Option 11
Implosion filter option
11.3 Implosion filter option
The implosion filter prevents the entry of dust into the unit and prevents the release of dust into the environment.
11.3.1 Intervals for inspections, maintenance and cleaning work
Monthly
11.3.2 Maintenance work
Prepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Check the implosion filter (visual check) for damage.
Check the cable passage gland for damage.
Check the seal for damage.
Component Activity Target value/Meaning Qualification
Implosion filter for damage and clean See "Maintenance work" on Page 57
Operator
Seal for damage See "Maintenance work" on Page 57
Operator
[1] Nut[2] Sealing ring[3] Cover plate of implosion filter[4] Implosion filter[5] Spacer[6] Seal[7] Cable passage[8] Plug connector
Fig. 11.5 – Implosion filter
11 OptionImplosion filter option METRO 06-1 to 30-1
58 Edition: February 2006
11.3.3 Maintenance
Removing implosion filterPrepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Label the PU tubes to the implosion filter and undo the PU tubes.
Remove the plug connector [8].
Slacken the nut [1] and remove the sealing ring [2].
Remove the cover plate of the implosion filter [3] and pull the implosion filter [4] off.
Remove the spacer [5] and the seal [6].
Installing implosion filterAssemble in reverse order.
Make sure that the PU tubes are correctly installed.
[1] Nut[2] Sealing ring[3] Cover plate of implosion filter[4] Implosion filter[5] Spacer[6] Seal[7] Cable passage[8] Plug connector
Fig. 11.6 – Implosion filter
Edition: February 2006 59
METRO 06-1 to 30-1Option 11
Implosion filter option
11.3.4 Spare parts
Spare parts listItem Unit Designation Article no. Remarks
1 1 Bend 4119050
2 2 Screw-plug connector straight M5 4110160
3 rm PU tube Ø 4x1 mm (Ø 0.16x0.04") 4037050 Calibrated
4 1 Pressure connection for implosion filter 4119040
5 1 Seal for implosion filter METRO 06/10 4119060
1 Seal for implosion filter METRO 15/30 4119000
6 1 Spacer for implosion filter METRO 06/10 4119070
1 Spacer for implosion filter METRO 15/30 4118990
7 1 Implosion filter 4119100
8 1 Cover plate of implosion filter 4119110
9 1 Sealing ring 4044270
10 1 Nut 4072970
11 1 Plug connector 4070220
12 1 Cable passage 1168150
11 OptionMarathon valve option (for abrasive materials) METRO 06-1 to 30-1
60 Edition: February 2006
11.4 Marathon valve option (for abrasive materials)
The Marathon valve prevents wear in hopper loaders on components that come into contact with the granulate during conveying.
11.4.1 Intervals for inspections, maintenance and cleaning work
Monthly
11.4.2 Maintenance work
Prepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Check the Marathon valve [1] for wear, cracking and destruction.
Check the pipe to the Marathon valve [2] for wear.
Component Activity Target value/Meaning Qualification
Marathon valve for wear, cracking and destruction
See "Maintenance work" on Page 60
Operator
Pipe to Marathon valve for wear See "Maintenance work" on Page 60
Operator
CAUTION!
Material damage!Parts which fall into the unit may cause operational faults.
Make sure that no parts fall into the unit.Cover the opening of the machine and bin.
[1] Marathon valve[2] Pipe to Marathon valve
Fig. 11.7 – Marathon valve
Edition: February 2006 61
METRO 06-1 to 30-1Option 11
Marathon valve option (for abrasive materials)
11.4.3 Maintenance
Removing Marathon valvePrepare the hopper loader for maintenance (see "Before starting work" on Page 32).
Unscrew the screw bushing [3].
Pull the Marathon valve [1] with the pipe to Marathon valve [2] out of the inlet pipe.
Installing Marathon valveAssemble in reverse order.
[1] Marathon valve[2] Pipe to Marathon valve[3] Screw bushing
Fig. 11.8 – Marathon valve
11 OptionMarathon valve option (for abrasive materials) METRO 06-1 to 30-1
62 Edition: February 2006
11.4.4 Spare parts
Spare parts listItem Unit Designation Article no. Remarks
1 1 Marathon valve D45 4153700
1 Marathon valve D60 4153710
2 1 Pipe to Marathon valve D45 4112410
1 Pipe to Marathon valve D60 4112430
3 1 Screw bushing D45 4113200
1 Screw bushing D60 4113210
2
1
3
Edition: February 2006 63
METRO 06-1 to 30-1Appendix 12
METRO 06/10-1
12 Appendix
12.1 METRO 06/10-1
Spare parts listItem Unit Designation Article no. Remarks
1 1 Implosion module complete 5084420 See Page 66
2 1 Inlet flap D45 4114910
1 Inlet flap D60 4115640
3 1 Inlet module D45 4117240
1 Inlet module D60 4117260
4 1 Glass module H184 4158410
1 Glass module H248 4158420
1 Steel module H184 4116390
1 Steel module H250 4116400
5 1 Proximity switch 24 V 4038130
1 Proximity switch 120 V 25008512
6 1 Discharge module complete 5089690 See Page 67
7 6 Ground terminal 4117720
8 3 U-profile seal 4115020
9 3 Profile clamp 4114940
10 1 Machine module 4115290
12 AppendixMETRO 06/10-1 METRO 06-1 to 30-1
64 Edition: February 2006
Spare parts listItem Unit Designation Article no. Remarks
11 1 Screen filter 500 µ 4114550
1 Screen filter 1200 µ 4158740
12 1 Filter fastener 4114560
13 3 Cap 4158590
Edition: February 2006 65
METRO 06-1 to 30-1Appendix 12
METRO 06/10-1
Spare parts listItem Unit Designation Article no. Remarks
1 1 Sensor fastener METRO M C/J G 06 4116730
1 Sensor fastener METRO M C/J G 10 4116970
2 1 Demand probe 24 V 4159620
1 Demand probe 120 V 25000065
3 1 Sensor fastener METRO MPG 06/15 4118220
1 Sensor fastener METRO MPG 10/30 4118230
4 1 Probe cable 24 V 4159630
12 AppendixMETRO 06/10-1 METRO 06-1 to 30-1
66 Edition: February 2006
12.1.1 Implosion module METRO 06/10
Spare parts listItem Unit Designation Article no. Remarks
1 1 Cover 4114520
2 1 Warning sign 4103380
3 2 Countersunk screw M4 1237810
4 1 Edge protector 1192960
5 1 Implosion module welded 4115840
6 2 O-ring 1110660
7 1 Axis at cover 4114540
8 4 Hexagon nut M4 1238200
9 1 Vacuum seali
i Secured with Loctite 406
4158110
10 1 Hexagon-headed screw M6ii 1229040
11 1 Vacuum sealing disk 4115810
12 1 Spring 4115580
13 1 Spacer rod to implosionii
ii Secured with Loctite 270
4114430
14 1 Implosion mechanical components complete 4158400
15 1 Pneumatic cylinder 4158440
16 2 L-connector screw retainer 4158630
17 2 Spring clip 4158310
18 1 Seal for cover 4114530
Edition: February 2006 67
METRO 06-1 to 30-1Appendix 12
METRO 06/10-1
12.1.2 Discharge module METRO 06/10
Spare parts listItem Unit Designation Article no. Remarks
1 1 Discharge module welded 4116870
2 2 Silencer 4063970
3 2 Sealing ring 4044670
4 1 Flap shaft 4116960
5 1 Bearing plate 4083770
6 1 Weight 4070150
7 1 Thread pin M5i
i Secured with Loctite 242
4063030
8 1 Thrust pad M8 spring-loaded 4069230
9 2 Hexagon nut M8 3034630
10 2 Philips-head screw M4 4050900
11 2 Spring washer A4 1210880
12 1 Screw M6i 4083720 Verbus Ripp
13 1 Fastener t= 1.5 4117310
14 2 Hexagon nut M6 with clamp sectioni 1902350 ISO 7042
15 2 Lens flange flat-head screw M6 4073190
16 1 Flap t=0.5 4117330
17 1 O-ring 4078360
12 AppendixMETRO 15/30-1 METRO 06-1 to 30-1
68 Edition: February 2006
12.2 METRO 15/30-1
Spare parts listItem Unit Designation Article no. Remarks
1 1 Implosion module complete 5084620 See Page 71
2 1 Inlet flap 4115640
3 1 Inlet module 4117280
4 1 Glass module H200 4158380
1 Glass module H300 4158390
1 Steel module H200 4116410
1 Steel module H300 4116420
5 1 Proximity switch 24 V 4038130
1 Proximity switch 120 V 25008512
6 1 Discharge module complete 5089530 See Page 72
7 6 Ground terminal 4117720
8 3 U-profile seal 4115010
9 3 Profile clamp 4114950
10 1 Machine module 4115240
Edition: February 2006 69
METRO 06-1 to 30-1Appendix 12
METRO 15/30-1
Spare parts listItem Unit Designation Article no. Remarks
11 1 Screen filter 500 µ 4115350
1 Screen filter 1200 µ 4158750
12 1 Filter fastener 4115360
13 3 Cap 4158590
12 AppendixMETRO 15/30-1 METRO 06-1 to 30-1
70 Edition: February 2006
Spare parts listItem Unit Designation Article no. Remarks
1 1 Sensor fastener METRO M C/J G 15 4118070
1 Sensor fastener METRO M C/J G 30 4118080
2 1 Demand probe 24 V 4159620
1 Demand probe 120 V 25000065
3 1 Sensor fastener METRO MPG 06/15 4118220
1 Sensor fastener METRO MPG 10/30 4118230
4 1 Probe cable 24 V 4159630
Edition: February 2006 71
METRO 06-1 to 30-1Appendix 12
METRO 15/30-1
12.2.1 Implosion module METRO 15/30
Spare parts listItem Unit Designation Article no. Remarks
1 1 Cover 4115480
2 1 Warning sign 4103380
3 2 Countersunk screw M4 1237810
4 1 Edge protector 1192960
5 1 Implosion module welded 4158370
6 2 O-ring 1110660
7 1 Axis at cover 4114540
8 4 Hexagon nut M4 1238200
9 1 Vacuum seali
i Secured with Loctite 406
4158100
10 1 Hexagon-headed screw M6ii 1229040
11 1 Vacuum sealing disk 4158100
12 1 Spring 4115580
13 1 Spacer rod to implosionii
ii Secured with Loctite 270
4114430
14 1 Implosion mechanical components complete 4158370
15 1 Pneumatic cylinder 4158440
16 2 L-connector screw retainer 4158630
17 2 Spring clip 4158310
1 1 Seal for cover 4115490
12 AppendixMETRO 15/30-1 METRO 06-1 to 30-1
72 Edition: February 2006
12.2.2 Discharge module METRO 15/30
Spare parts listItem Unit Designation Article no. Remarks
1 1 Discharge module welded 4117150
2 2 Silencer 4063970
3 2 Sealing ring 4044670
4 1 Flap shaft 4117010
5 1 Bearing plate 4083770
6 1 Weight 4078410
7 1 Thread pin M5i
i Secured with Loctite 242
4063030
8 1 Thrust pad M8 spring-loaded 4064980
9 2 Hexagon nut M8 3034630
10 2 Philips-head screw M4 4050900
11 2 Spring washer A4 1210880
12 1 Screw M6i 4083720 Verbus Ripp
13 1 Fastener t= 1.5 4117390
14 2 Hexagon nut M6 with clamp sectioni 1902350 ISO 7042
15 2 Lens flange flat-head screw M6 4073190
16 1 Flap t=0.5 4117380
17 1 O-ring 4078370
Edition: February 2006 73
METRO 06-1 to 30-1Appendix 12
Multifunction panel METRO *C/J/P*
12.3 Multifunction panel METRO *C/J/P*
Spare parts listItem Unit Designation Article no. Remarks
A 1 Multifunction panel METRO C basic 5089620 See Page 74
B 1 Multifunction panel METRO J 5062360 See Page 75
C 1 Multifunction panel METRO P 5001060 See Page 76
12 AppendixMultifunction panel METRO *C/J/P* METRO 06-1 to 30-1
74 Edition: February 2006
12.3.1 Multifunction panel METRO C basic
Spare parts listItem Unit Designation Article no. Remarks
A 1 Multifunction panel METRO C basic 5089620 complete
1 5 Cable passage M25 4110280
2 1 MFP cover 4116720
3 1 L-connector screw retainer 4158630
4 2 Philips-head screw M4 1206930
5 1 4/2 directional control valve 4158580
6 1 Valve cable 4158600
7 1 MFP component carrier 4116750
8 8 Philips-head screw M4 4050900
9 1 Philips-head screw M4 4050900
10 1 Plug connector 4070220
11 rm PU tube Ø 4x1 mm (Ø 0.16x0.04") 4037050 Calibrated
12 1 Controller METRO C basic 4158010
Edition: February 2006 77
METRO 06-1 to 30-1Appendix 12
Pneumatics diagram
12.4 Pneumatics diagram
12.4.1 METRO 06-1 to 30-1
12.4.2 METRO H** with pneumatically actuated discharge flap
[1] Vacuum valve
[1] Vacuum valve[2] Discharge flap closed
�nderung
Datum
Name
Datum
Bearb.
Gepr.
Norm
Blatt
Gr.:
Kommission:
Zeichng.Nr.:
Projekt:
Urspr.
Ers. f.
Ers. d.
Vers.
A B C D E F2
1
1
09.01.2006
EKA
2
2
METRO C basic
SPS (PLC)/SELVAC
27.11.2001
3
3
REG4
4
Motan GmbH
Max-Eyth-Weg 42
88316 Isny
Steuerung
Control (unit)
5
5
6
6
Convey
280A-90.0.00
7
7
= +F1F1
8
8 +KAUE/1
2.0
5
A B C D E F
A1+ZSW
+KK
W5F1
PVC Steuerleitung
12x1mmý
PE P
E
GNYE
+F13
-XS
12PE
-X41
3PE
+ 24V
1
1 1
W5Y1
H05VV-F/F
3x0,75
Vakuum Ventil
Vacuum Valve
2 BU
M 2
2 2
VACV
3
3 3 1 BN
-5Y1
1 2
GNYE
PE Vakuum
Vacuum
+F16
-5H11 2
Niveau
Level-5H21 2
Anforderung Material
Demand Material
W5B1
SENSOR
3x0,34
ANFO
6
6 6 6 BK
4 BN
+FH-LOADER
-5B1
BN
BK
BU +F
MCS-LOADER
-5B1
BN
WH
BU +FMCG-LOADER
-5B1
BU
BK
BN5 BU
+F
7PE
Ï
+F16
ONLP
5
5 5
-5H31 2
Ein Aus Alarm
On Off Alarm
ONTS
7
7 7
-5S1
3 4
W5B2
SENSOR
4x0,34
Niveau Beh„lter
Level Hopper
NIBE
4
4 4 10
BK
8 BN
-5B2
BN
BK
BU9 BU
*
W5Y2
H05VV-F/F
3x0,75
Zwangsverschluss
Operated flap
12
BUZWVV
8
8 8 11
BN
-5Y2
1 2
**
GNYE
14RES 9
9 9 13
* Option 1
** Option 2
RES
10
10
10
15PE
16PE
RES
11
11
11
�nderung
Datum
Name
Datum
Bearb.
Gepr.
Norm
Blatt
Gr.:
Kommission:
Zeichng.Nr.:
Projekt:
Urspr.
Ers. f.
Ers. d.
Vers.
A B C D E F2
1
1
09.01.2006
EKA
2
2
METRO C METROMIX
SPS(PLC)/SELVAC-METROMIX
27.11.2001
3
3
REG4
4
Motan GmbH
Max-Eyth-Weg 42
88316 Isny
Steuerung
Control (unit)
5
5
6
6
Convey
280C-90.0.00
7
7
= +F1F1
8
8 +KAUE/1
1.0
5
A B C D E F
A1+ZSW
+KK
W5F1
PVC Steuerleitung
8x1mmý
PE PE GNYE
+F13
-XS
12PE
-X41
3PE
+ 24V
1
1 1
W5Y1
H05VV-F/F
3x0,75
Vakuum Ventil
Vacuum Valve
2 BU
M 2
2 2
VACV
3
3 3 1 BN
-5Y1
1 2
GNYE
PE
+F16
Vakuum
Vacuum
-5H11 2
Niveau
Level
-5H21 2
W5B1
SENSOR
3x0,34
Anforderung Material
Demand Material
ANFO
6
6 6 6 BK
4 BN
+FH-LOADER
-5B1
BN
BK
BU
+F
MCS-LOADER
-5B1
BN
WH
BU
+FMCG-LOADER
-5B1
BU
BK
BN5 BU
+F
7PE
Ï
+F16
ONLP
5
5 5
-5H31 2
Ein Aus Alarm
On Off Alarm
ONTS
7
7 7
-5S1
3 4
W5B2
SENSOR
4x0,34
Niveau Beh„lter
Level Hopper
NIBE
4
4 4 10
BK
8 BN
-5B2
BN
BK
BU9 BU *
12
+EX
RES
8 11
AWG20
BU
+F12
-XS2
1
9
AWG20
BU/WH
METROMIX
5 Ventil Material
Valve material
14
2
8
AWG20
BU
6
-5Y2
1 2
3
10
PE
7
RES
9 13 4
PE
AWG20
GNYE
15PE
RES
10
16PE
* Option
RES
11
�nderung
Datum
Name
Datum
Bearb.
Gepr.
Norm
Blatt
Gr.:
Kommission:
Zeichng.Nr.:
Projekt:
Urspr.
Ers. f.
Ers. d.
Vers.
A B C D E F2
1
1
09.01.2006
EKA
2
2
METRO C DUOMIX
SPS(PLC)
27.11.2001
3
3
REG4
4
Motan GmbH
Max-Eyth-Weg 42
88316 Isny
Steuerung
Control (unit)
5
5
6
6
Convey
280D-90.0.00
7
7
= +F1F1
8
8 +KAUE/1
1.0
5
A B C D E F
A1+ZSW
+KK
W5F1
PVC Steuerleitung
12x1mmý
PE PE GNYE
+F13
-XS
12PE
-X41
3PE
+ 24V
1
1 1
W5Y1
H05VV-F/F
3x0,75
Vakuum Ventil
Vacuum Valve
2 BU
M 2
2 2
VACV
3
3 3 1 BN
-5Y1
1 2
GNYE
PE
+F16
Vakuum
Vacuum
-5H11 2
Niveau
Level-5H21 2
W5B1
SENSOR
3x0,34
Anforderung Material
Demand Material
ANFO
6
6 6 6 BK
4 BN
+FH-LOADER
-5B1
BN
BK
BU +FMCS-LOADER
-5B1
BN
WH
BU +FMCG-LOADER
-5B1
BU
BK
BN5 BU
+F
7PE
Ï
+F16
ONLP
5
5 5
-5H31 2
Ein Aus Alarm
On Off Alarm
ONTS
7
7 7
-5S1
3 4
W5B2
SENSOR
4x0,34
Niveau Beh„lter
Level Hopper
NIBE
4
4 4 10
BK
8 BN
-5B2
BN
BK
BU9 BU *
12RES 8
8 8 11
+EX
AWG20
BU/WH Ventil Material
Valve material
14
+F12
-XS2
2
AWG20
BU
DUOM
9
9 9 13
1
-5Y21 2
3
DUOMIXAWG20
GNYE
15PE
PE
PE
RES
10 10
10
16PE
* Option
RES
11 11
11
�nderung
Datum
Name
Datum
Bearb.
Gepr.
Norm
Blatt
Gr.:
Kommission:
Zeichng.Nr.:
Projekt:
Urspr.
Ers. f.
Ers. d.
Vers.
A B C D E F2
1
1
09.01.2006
EKA
2
2
METRO P-LOADER
29.10.2002
3
3
REG4
4
Motan GmbH
Max-Eyth-Weg 42
88316 Isny
Steuerung
Control (unit)
5
5
6
6
Convey
280G-90.0.00
7
7
= +F1F1
8
8 +KAUE/1
1.0 11
A B C D E F
=ZSW
F”rdersteuerung
Conveying control
WF1
PVC Steuerleitung
5x1mmý
L+
1
-11XS1.1
1
-11XS1
1
+F
H-LOADER
-11B1
BN
BK
BU
+FMPS-LOADER
-11B1
BN
WH
BU
+FMPG-LOADER
-11B1
BU
BK
BN
Anforderung
DemandM
2 2 2
1,0 mmý
GNYE
H05V-K
+EX
-PE
Ï
WY1
PVC Steuerleitung
1m
3x1mmý
2
PE
GNYE
Ï Ï GNYE 5 VA
-11Y1
Ï1 2
Vakuumventil
Vaccum valve
VAKUUM
3 3 3 1
ANFO 4 4 4