280A METRO 06-1bis30-1 V2.0 EN - hosa-dryer.com · METRO 06-1 to 30-1 Transport and setup 4 Mounting hopper loader 4 Transport and setup 4.1 Mounting hopper loader ... Toggle switch

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)).


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


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*


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


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


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


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.


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.


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.


– Demand probe incorrect adjusted. Check settings (see "Checking demand probe (METRO M** only)" on Page 37)replace demand probe if necessary.


– Material flow interrupted. Adjust air supply at suction point.

– Plug formation. Adjust air supply at suction point.

Check underpressure.


– Leak in pipe system (vacuum and material line).

Check underpressure in vacuum system.

8 TroubleshootingTroubleshooting METRO 06-1 to 30-1


No material or too little material transported


– 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).


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


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.



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


Demand probe demand probe See "Checking demand probe (METRO M** only)" on Page 37

Operator


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


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



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


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



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


9.5 Repair work

9.5.1 Disassemble METRO 06-1 to 30-1 hopper loader into its modules

Separating modules


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!





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!



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



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.



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



9.5.4 Adjusting proximity switch (METRO H** only)


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



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.


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


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


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


11.1.3 Maintenance work


Check the discharge flap [2] for wear and cracking.

Check the discharge [3] for damage

CAUTION!



[1] Pneumatic cylinder[2] Discharge flap[3] Discharge

Fig. 11.1 – 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



11.1.5 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




11.1.6 METRO 15/30 spare parts




3 1 O-ring 4078370




7 1 Fastener t= 3.0 4117370


9 1 Flap t=1.0 4117360


11 1 Tension pini


4076640 ISO 8752

12 1 Flap lever positive closure 4117090

13 1 Positive closure advance group 5089500



11.1.7 METRO 06-1 to 30-1 spare parts


1 2 Throttle non-return valve 4104370

2 1 Pneumatic cylinderi


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



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.


Monthly


Fill level probe fill level probe See "Maintenance work" on Page 54

Operator



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.


Monthly



Check the implosion filter (visual check) for damage.

Check the cable passage gland for damage.

Check the seal for damage.


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


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



Implosion filter option

11.3.4 Spare parts


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


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


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.


Monthly



Check the Marathon valve [1] for wear, cracking and destruction.

Check the pipe to the Marathon valve [2] for wear.


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!



[1] Marathon valve[2] Pipe to Marathon valve

Fig. 11.7 – Marathon valve



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


11.4.4 Spare parts


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


METRO 06-1 to 30-1Appendix 12

METRO 06/10-1

12 Appendix

12.1 METRO 06/10-1


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


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



11 1 Screen filter 500 µ 4114550

1 Screen filter 1200 µ 4158740

12 1 Filter fastener 4114560

13 3 Cap 4158590



METRO 06/10-1


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



12.1.1 Implosion module METRO 06/10


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


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



METRO 06/10-1

12.1.2 Discharge module METRO 06/10






5 1 Bearing plate 4083770

6 1 Weight 4070150

7 1 Thread pin M5i


4063030

8 1 Thrust pad M8 spring-loaded 4069230


10 2 Philips-head screw M4 4050900

11 2 Spring washer A4 1210880


13 1 Fastener t= 1.5 4117310



16 1 Flap t=0.5 4117330

17 1 O-ring 4078360



12.2 METRO 15/30-1


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



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



METRO 15/30-1


11 1 Screen filter 500 µ 4115350

1 Screen filter 1200 µ 4158750

12 1 Filter fastener 4115360

13 3 Cap 4158590




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



METRO 15/30-1

12.2.1 Implosion module METRO 15/30


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


9 1 Vacuum seali


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


17 2 Spring clip 4158310

1 1 Seal for cover 4115490



12.2.2 Discharge module METRO 15/30






5 1 Bearing plate 4083770

6 1 Weight 4078410

7 1 Thread pin M5i


4063030

8 1 Thrust pad M8 spring-loaded 4064980



11 2 Spring washer A4 1210880


13 1 Fastener t= 1.5 4117390



16 1 Flap t=0.5 4117380

17 1 O-ring 4078370



Multifunction panel METRO *C/J/P*

12.3 Multifunction panel METRO *C/J/P*


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


12.3.1 Multifunction panel METRO C basic


A 1 Multifunction panel METRO C basic 5089620 complete

1 5 Cable passage M25 4110280

2 1 MFP cover 4116720



5 1 4/2 directional control valve 4158580

6 1 Valve cable 4158600

7 1 MFP component carrier 4116750



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



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


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


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

Documents

280A METRO 06-1bis30-1 V2.0 EN - hosa-dryer.com · METRO 06-1 to 30-1 Transport and setup 4 Mounting hopper loader 4 Transport and setup 4.1 Mounting hopper loader ... Toggle switch