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
Technical File Responsible: Director of Product Development

Technische Akte, verantwortlich: Austurhraun 9
Responsable du Dossier technique :
Responsable del archivo técnico:
DECLARATION OF CONFORMITY
Konformitätserklärung
Déclaration de Conformité
Declaración de la Conformidad
Manufacturer: Marel ehf

Hersteller: Austurhraun 9
Fabricant :
Fabricante:
Product:
Produkt: WEIGHT GRADER
Produit :
Producto:
Type:
Typ:
Type :
Tipo:
Serial number:
Seriennummer:
Numéro de série :
Número de serie:
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:
 2006/42/EC Machinery. Safety of Machinery

(Maschinen, Machines, Maquinaria)
 2004/108/EC EMC Electro-Magnetic Compatibility
(Elektromagnetische Verträglichkeit, Compatibilité électromagnétique,
Compatibilidad electromagnética)
 2006/95/EC Low Voltage
(Niederspannung, Basse tension, Baja tensión)
Signature: Place/Date:
Unterschrift: Ort/Datum:
Signature : Lieu/Date :
Gardabaer,
Firma: Lugar/Fecha: September 25, 2009
Þórður Theódórsson, Senior Director of Manufacturing
Marel ehf.
STANDARD SAFETY AND WARNING NOTICE FOR ALL MAREL

EQUIPMENT
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.
Additional Safety Information

• Keep long hair tied back and covered.
• Avoid wearing loose clothing, jewelry, or accessories near moving machine parts. This includes ties,
shirtsleeves, rings, watches, and other loose fitting items.
• Disengage the machinery to avoid moving parts when cleaning and lubricating bearings.
• Avoid moving parts when lubricating with hand-sprayed lubricants.
• Never work without another person in the vicinity.
• Wear safety glasses when doing the following:
- using a hammer to drive pins, riveting, staking, etc.
- drilling, grinding, etc.
- using spring hooks or attached springs.
- soldering, cutting wire, removing steel bands, etc.
- cleaning parts with solvents, spray, or cleaners.
• After cleaning or maintenance, reinstall all safety devices such as guards, shields, signs, and grounding
wires.
• Wear ear protection when exposed to noise exceeding 90 dB, such as when using a grinder, band saw or
hammer.
• Lift items with a straight back, and push up with your leg muscles, to prevent back strain. Do not lift any
equipment or parts weighing more than 30 kg (60 lb.) without assistance.
• Use only FDA or USDA approved solvents, grease or oils.
Marel ehf.
Contents
Introduction 3
ABOUT THIS MANUAL ........................................................................................... 3

Improvements and Customer Support ......................................................................... 3
Warranty Information ................................................................................................. 4
ABOUT THE PROLINE GRADER ............................................................................ 4
Technical Specifications ............................................................................................. 7
Installation 9
SITE REQUIREMENTS ............................................................................................ 9

VERIFYING THE EQUIPMENT ................................................................................ 9
INSTALLING THE PROLINE GRADER .................................................................. 10
Electrical Installations ............................................................................................... 12
Pneumatic Installations ............................................................................................. 12
ADJUSTMENTS AFTER INSTALLATION ............................................................... 14
Legs........................................................................................................................... 14
Encoder Bearing........................................................................................................ 14
Belt Sensor ................................................................................................................ 15
Weighing Plates ........................................................................................................ 15
Gate Arms ................................................................................................................. 16
CHECK LIST ......................................................................................................... 17
Operation 19
CONTROLS AND INDICATOR LAMPS ................................................................... 19

SAFETY INSTRUCTIONS ....................................................................................... 20
Warning Labels ......................................................................................................... 20
STARTING THE PROLINE GRADER ..................................................................... 22
Power-On .................................................................................................................. 22
Maintenance 23
MAINTENANCE SCHEDULE ................................................................................. 23

MAINTENANCE PROCEDURES ............................................................................. 24
Weighing Unit Belt ................................................................................................... 24
Discharge Unit Belt................................................................................................... 25
Product Sensor .......................................................................................................... 25
Pneumatic System ..................................................................................................... 26
Hardware Manual Contents • i

Air Cylinders............................................................................................................. 27
Gate Arms ................................................................................................................. 28
Bins and Chutes ........................................................................................................ 29
Motors ....................................................................................................................... 30
Idle Shaft ................................................................................................................... 30
Emergency Stop Buttons........................................................................................... 30
Cleaning 31
CLEANING IN GENERAL ...................................................................................... 31

Materials Used in Marel Equipment ......................................................................... 32
Water and Temperature............................................................................................. 32
Detergents ................................................................................................................. 33
Daily Cleaning .......................................................................................................... 33
Sanitization ............................................................................................................... 34
Training Staff ............................................................................................................ 35
CLEANING PROCEDURES .................................................................................... 35
Preparation ................................................................................................................ 35
Rinsing the Environment .......................................................................................... 35
Rinsing the Unit ........................................................................................................ 36
Foaming .................................................................................................................... 36
Washing .................................................................................................................... 36
Sanitizing .................................................................................................................. 38
Final Inspection......................................................................................................... 38
Special Cleaning Instructions.................................................................................... 39
CLEANING SCHEDULE ......................................................................................... 40
Parts Lists 41
MECHANICAL PARTS LISTS ................................................................................ 41

WEIGHING UNIT .................................................................................................. 43
DISCHARGE UNIT................................................................................................. 53
ELECTRICAL PARTS AND DIAGRAMS – WEIGHING UNIT ................................. 71
ELECTRICAL PARTS AND DIAGRAMS – DISCHARGE UNIT................................ 73
Glossary of Terms 75
Index 77
ii • Contents ProLine Grader

Introduction
About This Manual

The ProLine Grader Hardware Manual is intended to assist you in
installing, operating, and maintaining the Marel ProLine Grader.
Note: Before you install or use the unit, make sure you read and
understand the warnings and the warranty agreement.
This manual is divided into the following chapters:

• Introduction
• Installation
• Operation
• Maintenance
• Cleaning
• Parts Lists – mechanical parts lists and electrical diagrams
The manual also contains a glossary and an extensive index.
Improvements and Customer

Support
You can help improve this manual and the equipment you purchased. If
you find errors in the manual, please let us know. You can contact us at:
Marel hf, Austurhraun 9, IS-210 Gardabaer, Iceland; phone (+354) 563-
8000, fax (+354) 563-8001, attn. Documentation & Localization,
email: documentation@marel.is.
For customer support please contact your local Marel agent or Marel’s
Service Department, Marel hf, Austurhraun 9, IS-102 Gardabaer, Iceland;
phone (+354) 563-8000, fax (+354) 563-8001, email:
service@marel.com.
Hardware Manual Introduction • 3

Warranty Information
For specific warranty information, please consult the written contract of
the purchase.
Note: Marel hf. will not warrant any equipment that has not been used
according to specifications.
About the ProLine Grader

The ProLine Grader is a flexible, modular grader designed to meet most
grading and batching needs.
Discharge unit
Weighing unit
Take-away conveyor
Figure 1 ProLine Grader, main modules.
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.
4 • Introduction ProLine Grader

Weighing platform
Motor
Product sensor
Figure 2 Weighing unit, main parts.
Idle end
Gate arm
M3000
Controller
Motor
Electrical cabinet
Bin 400/600,optional
Chute 400/600, optional
Non-stick 400 bin, optional
Take-away conveyor, optional
Figure 3 Discharge unit, main parts.
This is how the ProLine Grader works:
1 The material to be weighed and graded is transported to the

weighing unit by an infeed conveyor.
2 The weighing unit’s product sensor detects individual pieces of the

material using a light beam which is transmitted across the belt.
The load cell registers the weight of each piece.
Hardware Manual Introduction • 5

3 An encoder bearing registers the belt speed to keep track of the
position of individual pieces on the weighing unit.
4 The pieces of material are then transported on to the discharge unit.
5 The M3000 software determines through which gate a specific

piece of material is to be discharged and sends this information to
the relevant gate arm.
6 The pneumatically operated gate arms direct the material flow on

the belt to the bins on the discharge unit where the material is
collected, in batches of a certain weight or piece count.
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.

Technical Specifications
Table 1 Technical data.
Software:
Type A520
Weighing:
Load cell Flintech PC-6 20–100 kg
Temperature range +7°C to +40°C (+45°F to 104°F). With PP belt
Platform size 400 mm (16")
500 mm (20")
700 mm (27")
900 mm (35")
200+500 mm (8"+20")
200+700 mm (8"+27")
500+400 mm (20"+16")
700+400 mm (27"+16")
900+400 mm (35"+16")
Dimensions:
Height 1250 - 1650 mm (49" - 65")
Number of platforms One or two
Belt width 305 mm (12"), effective width 290 mm (11")
Minimum division 470 mm (18")
700 mm (27")
1400 mm (55")
Construction:
Material AISI 304 stainless steel and PE500 plastic
Motor type BDL TM135 drum motor
Cleaning Normal washing methods with soap/foam and
detergents are recommended
Capacity:
Throughput Up to 200 pieces per minute
Belt speed 0.8 - 1.8 m/s
Application:
Raw material Most non-sticky products
Raw material size Max. length 1100 mm (43"), max. width 280 mm (11")
Raw material weight 20 g - 20 kg (0.004 - 44 lb)
Consumption:
Air 80 l/min at 180 pieces/minute
Power:
Voltage 1x230VAC + PE
Hardware Manual Introduction  7

Installation
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.
Verifying the Equipment

Before you install the ProLine Grader, verify the following:
 Inspect the equipment for damages incurred during shipment, such as
scratches or dents. If the equipment has been damaged, report
immediately to your Marel agent.
 Compare the equipment you have received to the packing list to see
if the shipment is complete. Report any discrepancies to your Marel
agent.
Hardware Manual Installation  9

Installing the ProLine Grader
This section provides instructions on how to install the ProLine Grader.
The ProLine Grader is delivered ready for installation, tested, and with all
basic setups in place. On site the installation of the ProLine Grader
involves:
• Positioning the grader
• Adjusting the height of the grader
• Bolting down the grader
• Connecting air installations to air supply
• Connecting the electrical cord to power supply
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.
To install the ProLine Grader:
1 Position the ProLine Grader on the location of your choice,

start by positioning the weighing unit.
2 The grader must be kept free of vibrations. Therefore, make

sure that the legs on all modules are level, rigid and stable.
3 During installation, be careful not to twist or force the grader

in any way.
Until the legs have been bolted down, the grader is not
perfectly rigid. It is therefore very important that you make
sure all modules are perfectly straight and level.
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.
5 Tighten the adjustment bolts on the legs of every module.
10 • Installation ProLine Grader

6 Drill holes for the floor bolts that will keep the grader stable and
in place.
Note: The ProLine Grader must be securely fastened to the
floor. Vibrations on the grader must be avoided.
Adjustment bolts
Floor bolt 7 Position the bolts in the assigned holes, and tighten
(see Figure 4).
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).
9 It is important for correct operation that the main modules of

the grader are correctly aligned with each other:
• If an infeed conveyor is used with the grader, the speed

of the infeed conveyor must never exceed the speed of
the weighing unit and the speed of the weighing unit
must never exceed the speed of the discharge unit.
• The conveyor belt or the distance between a conveyor’s

side guides must be of the same width, or narrower,
than the next unit’s conveyor belt.
• Position the belts end to end, with center lines aligned,

as close to each other as possible, yet without the belts
touching.
• A slight drop in height between modules will ensure a

smooth transition of items from one belt to another. A
drop of 25-50 mm is commonly used, depending on the
type of product. Figure 5 shows the drop in height
between the weighing unit and the discharge unit.
Height difference
25-50 mm
Figure 5 Height difference between weighing unit and discharge unit.
Important: The conveyor belts must not touch each other. Contact may
damage the belts and impair the grader’s weighing accuracy.
Hardware Manual Installation • 11

Electrical Installations
The mains are to be terminated in the discharge unit’s electrical cabinet.
For more details, refer to the electrical diagrams on page 71.
The mains rating is listed on the rating plate on the electrical cabinet.
Make sure that cables are run so they do not affect the function of the
grader or disturb workers at the grader. Cables must never induce danger,
electrical or mechanical, to the workers.
Termination of cables is done after the grader has been put in its final
position. Ensure that all conduits between units are tight.
The electrical cabinet should be kept closed at all times, except when
work is being performed on it.
Warning! Electrical installations are to be performed by a licensed

electrician only in accordance with manufacturer’s specifications and
national and local electrical codes.
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 -
Pressure dew point is the temperature to

which compressed air must be cooled before
water vapor in the air starts to condense into
water particles.
Note: Recommended local air pressure is minimum 7 bars. Pressure

below the recommended 7 bar will noticeably affect the grader’s
operating speed at full flow while pressure above 10 bars may damage
the grader.

• Make sure the air supply plumbing is clean before you connect the
grader.
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.

Adjustments After Installation
Parts of the ProLine Grader may have to be adjusted after installation to
ensure proper operation. The following sections describe the adjustment
procedures for:
• Legs
• Encoder bearing
• Belt sensor
• Weighing plates
• Gate arms and pneumatic cylinders, if necessary
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.
To adjust the legs:
• Use a spirit-level to check that the conveyor belts are level,

lengthwise and across the ends.
• Use the adjustable legs to make any necessary adjustments.
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
Figure 6 Weighing unit sensors.

After installation, make sure the encoder bearing is functioning properly:
• Check the indicator light on the connection module inside the
electrical cabinet.
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
Figure 7 Sensors, detail.
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
Figure 8 Drop in height between weighing plates.

To adjust the weighing plates:
1 Loosen the three adjustable nuts under each plate.
Adjustable nuts 2 Adjust the plates by turning the three adjustable bolts under the
weighing plates. The plates can be adjusted up or down.
3 Align each weighing plate to the other plates. Use a straight-edge

along the plates to make sure they are properly aligned.
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
Figure 10 Gate arm angle. Figure 11 Wear strip adjustment.

Check List
Use this check list for the initial start of the ProLine Grader.
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.

Operation
Controls and Indicator Lamps

This chapter describes the location of controls and indicator lamps on the
ProLine Grader. It also provides basic instructions in how to operate the unit.
The mains breaker and service switch are located on the discharge unit’s
electrical cabinet.
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
Stop button (red)
Motors Overload indicator
Washing mode
Figure 12 The electrical cabinet (EC) with controls and indicators.
Table 3 Description of controls and indicators.
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.
STOP button Stops the belts.
Hardware Manual Operation • 19

Power On indicator Illuminates when the unit is running.
Overload indicator Illuminates red if there is an overload on the motor.
Mains breaker Disconnects the mains power supply to the unit.
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.
20 • Operation ProLine Grader

Figure 13 Left view
Figure 14 Right view
Figure 15 Back view Figure 16 Top view
Hardware Manual Operation • 21

Starting the ProLine Grader
Before you start the grader:
1 Check the belts carefully for dirt or foreign objects.
2 Check if the belts are properly positioned on the sprocket

wheels, and if the weighing unit’s belt is centered in relation to
the infeed-, weighing-, and outfeed-plates.
3 Check if the belts are properly positioned on the idle ends.

Make sure that the idle end is locked in down position.
4 Make sure the belts of both main modules (weighing unit and
discharge unit) do not touch each other.
5 Check for abnormal noise in the belts and motors.
WARNING! If the belts are started with objects on them, a personal

injury or damage to the equipment may result.
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:
1 Press the Start button (Figure 12) on the discharge unit’s

electrical cabinet to start the belts.
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.
22 • Operation ProLine Grader

Maintenance
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.
Table 4 Maintenance schedule

Every • Check that the weighing unit weighs correctly.
working shift: • Check for broken links in the plastic modular belt.
• Test the movement of the gate arms.
• Check if all bins are properly positioned and firmly in
place.
Daily: • Check motor and belts for abnormal noise.
• Check that the product sensor is clean and correctly
positioned.
• Check that the conveyor belts are clean and free of
dirt particles. Replace the belts, if necessary.
• Check the movement of the gate arms.
• Clean the grader.
Weekly: • Check the idle-drum for abnormal noise.
• Check the general condition of the belts.
• Check all air cylinders.
• Wipe the cylinder piston rods with an oiled cloth at
the end of the work week.
• Check the function and state of the gate arms.
Continued …
Hardware Manual Maintenance • 23

Monthly: • Check the emergency stops.
• Check the sprockets for wear.
• Check the belt tension.
• Check the belt supports for wear.
• Check the bushings of the idle end sprockets
(discharge unit).
• Remove and wash the plastic modular belts.
Yearly: • General service control by Marel’s service personnel.
Inspection of the load cell(s) and the pneumatic and
electrical system.
After 10.000 • Change the oil in drum- or gear motors.
operating
hours:
Maintenance Procedures
Procedures for maintaining individual parts of the ProLine Grader are
described in the following.
Weighing Unit Belt

The weighing unit’s belt is a modular belt, made of plastic links held
together by plastic rods.
It is very important for accurate weighing and proper operation that the
links do not stick and thus prevent the belt from rotating smoothly on the
sprocket wheels.
Store your spare belts away from dust and other debris.
If you need to replace the belt, follow the instructions in the belt
manufacturer’s instructions delivered with the grader and be sure to
check the quality of the belt as described below.
To check the belt quality:
1 Before installing the weighing unit’s new belt, place it on a

bench, pick up one link at a time, and bend the link back and
forth to check if it moves freely.
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.
24 • Maintenance ProLine Grader

3 Make sure the rods have not been damaged by tools, for
example screwdrivers or pliers.
4 There should be 312 links in the belt. The current link count is
shown on the DWU Overview screen on the M3000 display.
5 Make sure the belt index is present in the belt.
Discharge Unit Belt

The tension of the modular belt may change a little with time. If this
situation occurs, you must adjust the belt tension by removing a link from
the belt.
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.
To adjust the light beam:
1 Set the height of the light beam across the belt to

approximately 5-10 mm above the belt, depending on the
product to be weighed.
This is to make sure that a small build-up of dirt and the like
on the conveyor belt will not interrupt the light beam.
Mirror
Wedge
Belt
Sensor Beam height
Direction
Figure 17 Adjusting the light beam.
2 Adjust the light beam. Use, for example, a small wedge-

shaped piece of cardboard:
Place the wedge in front of the light beam, and check when the
beam is interrupted. The height of the light beam can now be

measured as the height of the wedge where it crosses the light
beam.
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
Air filter and

water trap
Water Exhaust
Figure 18 Air cabinet, air pressure regulator.
To maintain the pneumatic system:
1 Inspect the water ventilator daily to make sure it is operating

normally.
2 Replace the filter in the water trap when dirty.
3 Keep the operating air pressure at 6 bar.

Air Cylinders
To ensure the duration of the air cylinders, the following maintenance
procedure should be implemented at the end of every week or whenever
the discharge unit is inactive for more than a day.
To maintain the air cylinders:

• After the discharge unit has been cleaned and shut down, wipe
the piston rod in every air cylinder with an oiled cloth.
To replace and adjust the air cylinders:
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).
A=speed adjustment screw,

“in” movement
B=shock absorbing adjustment
screw, “in” movement
C=speed adjustment screw,
“out” movement
D=shock absorbing adjustment
screw, ”out” movement
E=piston length, adjustment
screw
F,G=bolt connection
H=Ball joint eye
Figure 19 Adjusting the shock mechanism.
• 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.

• Check the operation of the cylinders by selecting the Adjust
gates function on the M3000 Controller.
The gate(s) will now open and close continuously while you
check the cylinders.
To adjust air cylinder speed:
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.
3 Check for abnormal noise in the arm joint.
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.

Gate arm
1-2 mm 1-2 mm
Bearing house
Figure 20 Spacing between arm and belt, 1-2 mm.
Testing the Gate Arms

There are four main issues which you should be aware of when testing
the gate arms:
• The speed of the “open” movement should be just enough for
the arm to catch the piece of product assigned to the gate.
• The speed of the “close” movement should be just enough for
the arm to catch only the assigned piece and not the piece that
follows next.
• You must make sure that opposite arms do not strike each
other (“clap” together).
Bins and Chutes

Before each working shift you should make sure all batching bins and
chutes are properly positioned and firmly in place.
Figure 21 Chute in locked position. Figure 22 Chute in unlocked position.

Motors
The motors in the ProLine Grader are maintenance-free. Nevertheless,
the following should be observed:
• Inspect the motors every day of operation. This is necessary to ensure
that the motors run normally and that there is no abnormal noise from the
motors.
• Change the oil after every 10.000 operating hours.
For refill, use EG gear oil SAE 90. For further details see the motor
manufacturer’s instructions.
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.
Shaft with sprockets Sprocket

Shaft
Figure 23 Idle end, weighing unit Figure 24 Idle end, discharge unit
Emergency Stop Buttons

Press the emergency stop buttons at least once every month to test if the
buttons function as designed.

Cleaning
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.
• It is very important that the ProLine Grader is thoroughly cleaned

every day after operation.
• In general, do not use excessively strong solutions of detergent.
Chlorine disintegrates belts and strong base solutions (pH>13) corrode
aluminum parts, air cylinders for example. The use of chlorine may
cause rust spots to appear on the stainless steel.
• High-pressure water jets can easily damage sensitive mechanisms in
the equipment. Therefore, do not use high-pressure water jets on the
M3000 Controller display, product sensor and load cell, the electrical
cabinets, or motor.
Instead, use low water pressure, or clean these parts by hand and pour
water over to rinse.
Hardware Manual Cleaning • 31

Materials Used in Marel Equipment
The materials listed here are common in Marel equipment. Use the list to
determine the chemical tolerance of individual parts of the equipment.
Note: Specific recommendations on types and strength of solutions

used for cleaning or sanitization should, at all times, come from a
qualified distributor of cleaning solutions.
Table 5 List of Materials

Material Used in Resistance to detergents
Metals:
Stainless steel Frames, various parts High (in normal conditions, for
example temperatures between
-20 to +30°C/-4 to 86°F )
Aluminum Load cell brackets and Low, to strong base solutions
spacers, load cells,
pneumatic cylinder ends
Plastics:
Polyethylene Guides High
(PE)
Polycarbonate Displays and keyboards Limited, to strong base solutions
(PC)
Polypropylene Modular conveyor belts High
(PP)
Acetyl (POM) Modular conveyor belts High, may develop precipitations
caused by chlorine
Polyvinylchloride Endless belts of layered Low, especially to minimally
(PVC) PVC and PUR canvas diluted solutions
Polyurethane
(PUR)
Water and Temperature

• Water can contain a significant number of microorganisms.
Therefore, inspection of water used for cleaning should be part
of a HACCP plan. All impurities in water can influence the
effectiveness of a detergent or sanitizer.
• Water hardness is the most important chemical property which
directly effects cleaning and sanitizing efficiency. The pH value
for normal water ranges from pH 5 to pH 8.5.
• Soils soluble in water are sugars, some starches and most salts.
• Always use clean water for rinsing and cleaning. Never rinse or
clean with seawater.
• Rinse with cold water, except when working with fat products.
In that case use 40-55°C (104-131°F) hot water to dissolve the
32 • Cleaning ProLine Grader

fat. Some fats have a melting point below the recommended 40-
55°C, so you should adjust the water temperature accordingly.
• Be careful when using hot water. Some proteins denature in
high temperatures and may become difficult to remove.
• Avoid temperatures above 55°C (131°F) because of the
corrosive nature of most chemical sanitizers.
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.
• Always use detergents according to the detergent

manufacturer’s instructions.
• Do not use a detergent containing sodium hypochlorite for
daily cleaning. Sodium hypochlorite is a common ingredient in
detergents, but as it contains chlorine it should be used with
great care because of chlorine’s corrosive effect on stainless
steel.
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.
• Use high alkaline foaming detergent, 1% solution, pH 12-13, for

regular daily cleaning. Avoid using a detergent containing a
high amount of sodium hypochlorite for daily cleaning. The
foaming detergent must be selected carefully and should contain
some corrosion inhibitors and preferably potassium hydroxide
(KOH) instead of sodium hydroxide (NaOH).
• Spray the detergent on all surface areas and leave to work for a
time specified by the cleaning agent’s manufacturer. Then rinse
the detergent off with clean, cold water.
• To kill any remaining bacteria, you must finish the daily
cleaning procedure by spraying the surface with an approved
chemical sanitizer.
Note: Quaternary ammonium compounds (QACs) are widely

used in the food processing industry. Keep in mind, however,
that while these are effective against most bacteria, they act

slowly against some common spoilage bacteria. Many common
bacteria may also develop tolerance against QACs, which
should therefore not be used for an extended period of time
unless they are rotated with compounds of a different type.
• QACs may leave an undesirable film on the surface of the

equipment and, as they should not come in contact with food,
they should always be rinsed off before processing is resumed
with cold and, most importantly, clean water.
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:
• Spray the sanitizer on surfaces and leave to work according to

manufacturer’s instructions. Make sure you spray into all
corners and hard-to-reach areas.
• After sanitizing, always rinse the equipment carefully with cold
and clean water before resuming processing.
• Use chlorine or a comparable sanitizer on the equipment once a
week after performing the regular cleaning procedure with a
high alkaline foaming detergent.
• Make sure the strength of chlorine, if used, does not exceed
200 ppm.
• On days when chlorine or a comparable sanitizer is not used,
use other sanitizers recommended for food processing instead.
Note: Rotating different sanitizers (for example chlorine, peracid or

acid-anionic) in your sanitization program may ensure more effective
sanitization.
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.

Training Staff
It is important that new cleaning personnel receive the proper training
and are made aware of the proper cleaning procedures for this machine.
Demonstrate the cleaning procedures for new personnel using the
instructions in the following sections. Make sure the cleaning personnel
is familiar with safety rules concerning the use of cleaning agents.
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.)
Rinsing the Environment

1 Thoroughly rinse nearby walls and floor to prevent cross-
contamination from the environment after the ProLine Grader
has been cleaned.
2 If possible, do not use water temperatures over 55°C (131°F) to
avoid heat denatured proteins.

Rinsing the Unit
1 During the entire cleaning process make sure the air cylinders
are in closed position.
2 Rinse soils off the machine using water jets or a brush. Rinse
thoroughly from the top down with clean water.
3 Avoid high water pressure in order not to spread the soils all
over the machine.
4 If possible, do not use water temperatures over 55°C (131°F) to
avoid heat denatured proteins.
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.
3 2 Use a brush on solid dirt and not easily accessible surfaces.

1 3 To clean the belts, press the Stop button to turn the grader off
(see Figure 25 arrow 1), and then turn the Washing control to
stage 1 (Figure 25, arrow 2) to put the grader in washing
mode.
2 A graphic appears on the M3000 screen indicating a washing
procedure.
Figure 25 Start and Stop
buttons, Washing control. 4 Turn the grader on (Figure 25, arrow 3). The belts are now
running at reduced speed which makes the cleaning easier.
Wash the belt thoroughly every day of operation. For a more
thorough cleaning, remove the modular belts at least once a
month and soak in a detergent bath. 2 For details on how to
remove the belt, see the belt manufacturer’s brochure
delivered with the grader.
2 The modular belt is heat resistant up to 100° C.

5 To wash the bins and chutes on the discharge unit, turn the
grader off (Figure 25, arrow 1).
6 Lift the chute up (Figure 26), and then tilt it down.
7 Raise the handle (Figure 27) to unlock the bin.
8 Lift the bin up (Figure 27) and tilt it down.
9 Move the belt side guards (Figure 28) to lift the belt up.
10 Fold the side guards (Figure 29) away from the belt and lift
the idle end up.
Figure 26 Tilting the chute.
Figure 27 Non-sticky bin (left) and 405/600 bin (right), tilted, lock handle.
Figure 28 Moving the side Figure 29 Folding the side guards

guards. down and lifting the idle end.
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
12 Clean the electrical cabinets as described on page Error!

Bookmark not defined. (once a month).
13 Let the machine dry as much as possible before sanitizing.
Note: Do not allow dirt to build up underneath the weighing platform,

this could affect the grader’s weighing accuracy.
Do not allow dirt to build up on or around the product sensor. Both

transmitter and mirror and the entire area between them must be kept
clean at all times, or else the light beam may be interrupted.
Note: Cross-contamination can easily occur if clean surfaces come in

contact with other less clean surfaces, for example when you replace
belts.
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:
• By stroke of hands make sure that places where visual control is

difficult are clean.
• Regularly measure cleaning results by counting the
microorganisms, for example using RODAC cups or ATP
measurements.
• After cleaning and sanitizing, make sure that all surfaces dry as
well as possible.

Special Cleaning Instructions
Some parts of the ProLine Grader require special care during cleaning:
the conveyor belt (see page 36), the M3000 display, and the electrical
cabinets.
Cleaning the M3000 Display
 Rinse the M3000 display thoroughly every day of operation.

 Do not use high-pressure jets on the display. Instead, use low
water pressure, or clean by hand and pour water over to rinse.
WARNING: Before you start cleaning the display, press the

emergency stop button to prevent an accidental start of the
conveyor.
Cleaning the Electrical Cabinets

Open the electrical cabinets once a month and check for soils.
• Turn the Mains switch to Off.

• Carefully wipe off the dirt with special attention to possible dirt
accumulation in door grooves and the bottom of the cabinets.
• Sanitize places where dirt has accumulated by wiping with a
sanitizing cloth.
• Secure the cabinet door and make sure the weather strip is intact
and properly in place.
• Turn the Mains switch back to On position to maintain constant
power and prevent condensation of moisture in the unit.
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.

Cleaning Schedule
Table 6 Cleaning schedule.
Frequency Action Description Comments
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.
• Let the foam work on the machine as specified by the foam

manufacturer.
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.
• Sanitze all parts of the machine after cleaning with approved

sanitizers.
• Pay special attention to surfaces in direct contact with the raw

material or products.
• Rinse the machine with clean, cold water before resuming

processing.
Daily Final • After cleaning quality control personnel should check and Count micro-
inspection evaluate cleaning results. organisms
regularly.
Weekly Extra • Sanitize with chlorine or a comparable sanitizing agent once a

cleaning 1 week.
• If chlorine is used, do not leave it on the machine for long

(max. 30 minutes).
• On the day when chlorine is used, you can leave out sanitizing
with other agents.
Monthly Extra Note: This action is performed by a certified electrician. Electrical

cleaning 2 hazard. Turn
• Open the electrical cabinets and check for soils. off the Mains
switch.
• Wipe off the soils and sanitize.

Parts Lists
Mechanical Parts Lists
The parts lists in this chapter apply to a typical ProLine Grader.
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
Hardware Manual Parts Lists • 41

42 • Parts Lists ProLine Grader
Weighing Unit
The weighing unit shown in this parts list is the ProWeigher, the standard weighing unit for the ProLine
Grader.
Figure 30 ProLine weighing unit, item overview.
Item: Figure number: Description:

1 See Figure 31 Main and support frames
2 See Figure 32 Weighing platform and infeed/outfeed plates
3 See Figure 33 Drive unit and idle end
4 See Figure 34 Shield
5 See Figure 35 Drip pan
6 See Figure 36 Wear strip support under belt
7 See Figure 37 Electrical cabinet
8 See Figure 38 Belt
Hardware Manual Parts Lists  43

Figure 31 Main and support frames.
Number: Stock number: Qty: Description:

1 007-0014-a0570001 1 Grounding frame, range: 1250 - 1450
007-0014-a0570002 1 Grounding frame, range: 1450 - 1650
007-0014-a0570003 1 Grounding frame, range: 950 - 1150
2 007-0014-a0310002 1 Main frame 305 x 1900
3 744-0ngi-m07630330 4 Adjustable foot base M76-30-330
4 740-0705-30000 8 Adjustment ring with socket set screw
5 740-0933-08020 8 Hexagon head screw M8 x 20, stainless steel A4-70
44  Parts Lists ProLine Grader

Figure 32 Weighing device, and infeed/outfeed plares.

1 007-0014-22880200 1 Weighing platform L=200, for 700/200 platform
007-0014-23010200 1 Weighing platform L=200, for 500/200 platform
007-0014-23010400 1 Weighing platform L=400, for 400 and 400/500 platform
007-0014-22880700 1 Weighing platform L=700, for 700, 700/200 and 700/400 platform
2 720-5300-1510k0100 1-2 Load cell,100 kg. stainless steel 1510 ip 68

For weighing platform 700, 900, 200/700, 400/700 and 400/900
720-5300-pc6k0100 1-2 Load cell PC6 100 kg C3, MI6 (M6 threads) stainless steel
For weighing platform 400, 500, 200/500 and 400/500
3 007-0014-20970160 1 Plate L=160, infeed end for L=1300 weighing platform
007-0014-20970360 1 Plate L=360, infeed end for L=1100 weighing platform
4 007-0014-a064 1 Bracket for mirror, cat’s-eye
5 717-3407-e39-r1 1 Mirror
6 717-3407-e3z-r81-5 1 Sensor photoelectric, 5 m cable pre-wired
7 007-0014-a063 1 Bracket for sensor, adjustable
8 740-0934-03 2 Hexagon full nut, stainless steel A4-70
9 740-125a-05 2 Medium washer, stainless steel A4-7
10 007-0014-a062 1 Cover for sensor
11 740-7985-03016 2 Cross-recessed raised cheese head screw M3 x 16
12 740-0985-05 2 Self-locking hexagon nut M5, stainless
13 740-125a-08 2 Medium washer M8 stainless steel A4-70

15 007-0014-20961285 1 Plastic plate, outfeed end, L=285 mm
16 018-0013-22320030 1 Adapter for 30 mm sensor
17 717-3407-0008 1 Belt sensor, weighing unit
18 721-3900-1016 1 Cable gland, M16 HSK-M, brass

Figure 33 Drive unit.

Idle end
1 740-0933-08025 2 Hexagon head screw M8 x 25, stainless steel
2 007-0014-2100 2 15 mm axle for bearing l=20
3 732-1501-6002 2 Ball bearing
4 007-0014-20990305 1 Axle, 12 teeth b=300
Drive end
5 740-0933-06010 4 Hexagon head screw M6 x 10, stainless steel
6 007-0014-2098 2 Fastener for drum motor
7 727-e082-30010015gd2 2 Drum motor

Figure 34 Shield.

1 007-0014-2174 1 Side panel
2 007-0014-a047 1 Shield handle
3 007-0014-a030 1 Hinge bracket
4 007-0014-2154 2 Spacer handle
5 007-0014-22260002 1 Spring bracket, left
6 007-0014-22260001 1 Spring bracket, right
7 007-0014-2196 2 Rod for spring
8 743-2331-7177 1 Torsion spring, right
9 743-2331-7392 1 Torsion spring, left
11 740-0985-08 2 Self-locking nut M8 A4-70
12 732-1494-mfm121810 2 Lock

Figure 35 Drip pan.

1 007-0014-2178 1 Drip pan bottom pan
2 007-0014-2182 2 Drip pan top piece
3 740-0603-08040 4 Mushroom head bolt M8 x 40 A4-70
4 012-0001-2383 8 Spacer ø20 / ø8 L=6 POM
7 740-0933-06016 8 Hexagon head screw M6 x 16 A4-70
8 007-0014-2201 2 Bracket on drip pan
9 007-0014-2200 2 Bracket on drip pan
11 007-0014-2178 1 Drip pan bottom pan

Figure 36 Wear strip support under belt.

1 007-0014-21631125 1 Pin for wear strip under belt
2 740-0705-08000 6 Steel ring Ø8 A2
3 007-0014-2162 2 Wear strip under belt, idle end
4 007-0014-2164 1 Wear strip under belt, motor end
5 007-0014-2112 2 Round bar support for wear strip
8 742-0106-08 4 Hexagon connection nut M8 A4
9 740-0933-08016 4 Hexagon head screw M8 x16 A4-70
10 740-0931-08110 2 Hexagon head bolt M8 x 110 A4-70

Figure 37 Electrical cabinet.

1 007-0014-A033 1 Electrical cabinet 190 x 300 x 190, body
2 001-0006-1152 2 Assembled drain nozzle
3 740-0934-06 8 Hexagon nut M6 A4-70
4 007-0014-2121 1 Cabinet door
5 007-0014-2168 1 Bottom plate for electrical component
6 007-0014-2167 2 Hinge/bracket for electrical cabinet
7 020-0002-2216 4 Bushing
9 740-125a-06 4 Medium washer M6, stainless steel A4-7
10 740-0985-06 4 Self-locking nut A4-70
11 740-0933-08025 2 Hexagon head screw M8 x A4-70
12 740-0985-08 2 Self-locking nut A4-70

Figure 38 Belt.

1 730-1500-fgpp0305 2 Conveyor belt W=305
2 004-0056-2001 3 Belt index

Discharge Unit
The discharge unit shown in this parts list is the ProLine Grader.
Figure 39 ProLine discharge unit, item overview.
Item: Figure number: Description:

1 See Figure 40 Grader main parts
2 See Figure 41 Motor end
3 See Figure 43 Idle end
4 See Figure 44 Gate arms
5 See Figure 45 Air control box
6 See Figure 46 Electrical cabinet
7 See Figure 47 Non-stick 400 bin, optional
8 See Figure 48 Opening bracket for Non-stick bin
9 See Figure 49 Bin 400/600, optional
10 See Figure 50 Chute, optional
11 See Figure 51 Outfeed, optional parts
12 See Figure 52 Take-away conveyor, optional

Figure 40 Grader main parts.

1 Variable, depends on length 1-2 Support frame
2 Variable, depends on length 1 Drip pan 300-2035
3 004-0200-228800006 2 Support axle, 490 division, for first gate
4 004-0200-228800001 6 Support axle, 470 division
5 004-0200-228800005 2 End support axle, L = 49 mm
6 730-1008-32201 4 Molded wear strip with stainless flat bar
7 730-1650-ftpp0305 1 Conveyor belt
8 See Figure 41 1 Motor end
9 See Figure 43 1 Idle end
10 See Figure 44 variable Gate arms
11 See Figure 45 variable Air control box

Figure 41 Motor end.

1 004-0201-2161 1 Right side guard for motor support
2 004-0201-2164 1 Left side guard for motor support
3 003-0024-2689 4 Spacer ø25/8,5 L=20
4 004-0201-2298 2 Bracket for drum motor (20 mm)
5 004-0201-2299 2 Adjustment bracket for drum motor
6 004-0201-2314 1 Bracket for scraper
7 004-0201-2216 1 Scraper for motor end
8 727-e135-35010016ta2 1 Drum motor
11 740-0931-10030 3 Hexagon head bolt M10 x 30 A4-70
14 See Figure 42 1 Sprinkler unit

Figure 42 Sprinkler unit.

1 755-0060-63240630CC 2 Sprinkler
2 718-3703-0037 1 Power cable with fixed connection
3 753-2020-0028 1 Cable gland knee
4 717-3406-0043 1 2 port solenoid valve for water, direct
5 753-2500-0028 1 Nipple 1/4" BSP taper
6 753-6521-0828 2 Swivel elbow adaptor Ø8 - thread 1/4" BSP par
7 750-6021-12128 1 Ball valve 1/4"
8 753-6430-1028 1 Tee Ø10 tube - 1/4" BSP
9 753-6521-0828 2 Swivel elbow adaptor Ø8 - thread 1/4" BSP par

Figure 43 Idle end.

1 004-0201-1174 1 Idle end for conveyor belt
2 004-0201-2172 1 Left side guard
3 004-0201-2173 1 Right side guard
4 740-0705-16000 2 Steel ring Ø16 A2
5 004-0201-2171 2 Guide for chain
6 732-1494-jfm202321 4 Bushing JFM-2023-21
7 004-0201-2151 2 Sprocket S1600 z=10
8 004-0201-2155 1 Axel for idle-end
9 004-0201-2178 1 Scrape on idler-end
12 004-0200-21880002 2 Belt return support with side gude 20 x 140 mm
13 004-0200-21880001 1 Belt return support 20 x 140 mm
14 004-0201-2187 1 Bracket for side guard
15 740-0705-16000 2 Steel ring Ø16 A2
17 004-0201-2405 1 Support for wear strip
22 704-psk3-sk4520075/0014 2 Side guard 20 x 75 PE 300

Figure 44 Gate arms.

1 004-0201-a1030001 1 Crossbeam for two bearing houses
004-0201-a1030002 1 Crossbeam for one bearing house
004-0201-a1030003 1 Crossbeam without bearing house
6 018-0013-2229 2 Cylinder bolt
7 740-1250-08 4 Washer M8 740-1250-08
8 740-0985-06 2 Self-locking hexagon nut M6 A4-70
9 751-6432-7026050 2 Stainless SMC cylinder ø25 x 50 mm
11 751-8139-802532 2 Rod eye M10 x 1.25

12 004-0200-a067 2 67 mm pivot arm for discharge unit
13 004-0200-2007 2 Spacer ø30 x ø20,5 L=8
14 732-1494-jfm202321 4 Bushing JFM-2023-21
15 018-0009-2755 2 Bolt in pivot arm
16 004-0201-2405 1 Support for wear strip
17 004-0200-2004 2 Shaft for pull-off gate arm
18 004-0008-2411 1 Right arm without shaft
19 004-0008-2412 1 Left arm without shaft
20 004-0200-2316 2 Side guide 80 x 25 t=5
21 004-0200-21880002 2 Belt return support with side guide 20 x 140 mm
22 004-0200-21880001 1 Belt return support 20 x 140 mm
23 004-0200-2285 2 Adjustment nut for wear strip support

Figure 45 Air control box.

1 004-0200-a072 1 Air control box
2 004-0201-2415 2 Cone for 38 mm cable pipe
3 732-0070-05682x262 2 O-ring NBR70 56,82 x 2,62
4 732-0070-04020x300 2 O-ring NBR 70 40,20 x 3,00 mm (38 mm)
5 004-0201-2417 2 Test flange ø38
6 001-0006-2501 1 Cover-plate for drain
7 001-0006-2493 1 Drain- nozzle
8 004-0200-2294 1 Lid for air control box
9 001-0006-2495 1 Plate for drain
12 740-7981-35130 2 Self-tapping screw PAN 3.5 x 13 A4-70
15 740-1250-06 2 Washer M6 740-1250-06
16 740-0912-04020 4 Socket head cap screw M4 x 20 A4-70
17 752-0100-000004 1 SY3140-5GZ-Q valves and manifold, 4 valves

Figure 46 Electrical cabinet.

1 004-0200-a041 1 Electrical cabinet
2 004-0200-2341 1 Electrical cabinet component plate
3 717-3405-1svb-sw-t0 2 Switch handle, lockable 25A-32A, black
4 004-0200-2226 1 Electrical cabinet door
5 743-5700-0020 2 Lock
6 001-0006-2306 2 Hinge for cabinet
7 004-0200-2227 1 Electrical cabinet control panel
8 508-0002-023 1 M3000 V2 assembly
9 004-0200-a042 2 38 mm 90° pipe with flange
10 004-0008-2475 2 Flange, inner ø38 mm
11 001-0006-1152 2 Assembled drain nozzle

Figure 47 Non-stick bin/400.

1 004-0200-2184 1 WEB PL400, Back plate
2 004-0200-2191 1 WEB PL400, axle
3 004-0200-2187 1 Flap in plastic bin
4 004-0200-2144 1 Proline Non-sticky bin
5 004-0200-2149 2 Bracket for Web, stopper
6 004-0060-2227 4 Flange bearing Ø16/Ø9/Ø6 L=6 t=2
11 004-0200-2192 2 Hinge bolt
12 740-1250-08 2 Washer M8 740-1250-08

Figure 48 Opening bracket for Non-stick bin.

1 004-0200-2214 2 Turnabout axle for lock
2 004-0201-2234 2 WEB PL400, opening bracket
3 004-0060-2243 4 Washer Ø30/Ø16,2 t=2,5
4 751-6432-7026025 2 Pneumatic cylinder Ø25 x 25 double acting cylinder with end
cushioning. Stainless Steel with speed controller
5 004-0200-2220 4 Spacer ø16/ø6 L=15 AISI303
6 740-0603-08020 8 Mushroom head square neck bolt M8 x 20, stainless steel A4-70
7 018-0013-2229 2 Cylinder Bolt
8 740-0985-10 4 Self-locking hexagon nut M10 stainless steel A4-70
9 732-1850-mfm162212 4 Bushing, MFM 1622-12
10 721-3900-0012 2 Cable gland long nipple
13 004-0200-a043 2 Handle for lock
14 004-0200-2199 2 Proline switch housing part 1
15 717-3400-0012 2 Batching button
16 004-0200-2215 4 Lock for web 400
17 740-0931-10055 2 Hexagon head bolt M10 x 30, stainless steel A4-70
19 751-8139-802532 2 Rod eye M10 x 1.25
20 004-0200-22240372 2 Axle for WEB PL300

Figure 49 Bin 400/600, Left

1 004-0200-A0770002 1 Discharge bin 400
004-0200-A0770003 1 Discharge bin 600
2 740-0473-08 2 Retaining ring 8 mm
3 004-0200-2319 1 Cover over air cylinder
4 740-0007-06036 1 Parallel pins 6 x 36
5 740-0473-06 2 Retaining ring 6 mm
6 740-0007-08036 1 Parallel pins 8 x 36
7 721-3900-1017 1 M16 cable gland short nipple
8 004-0200-2335 1 Sleeve on switch
9 751-6432-7026025 1 Stainless cylinder ø25 x 25 mm
10 732-1850-GERMK10F 1 Clevis joint
11 717-3400-0012 1 Batching button
12 020-0015-A051 1 Shutter arm 1, welded
13 740-0933-08010 2 Hexagon head screw M8 x 10
14 004-0201-24110351 1 Flap, Bin 400
004-0201-21440531 1 Flap, Bin 600
15 721-5800-0014 2 Rubber grommet 4/6
16 740-0934-08 2 Hexagon nut M8

17 004-0005-2321 2 Hinge bolt for bins
18 740-0933-06016 2 Hexagon head screw M6 x 16
19 732-1850-ASM101610 2 Bushing

Figure 50 Chute/400

1 004-0200-a054 1 Chute 400 with bracket
004-0200-a055 1 Chute 600 with bracket
2 740-0985-08 2 Self-locking hexagon nut M8, stainless steel
3 740-0912-08016 2 Hexagon socket head cap screw M8 x 16, stainless steel A4-70

Figure 51 Outfeed, optional parts.

8. Reject chute
8.1 004-0201-2220 1 Reject chute 25°
8.2 004-0201-2221 1 Beam for reject chute
8.3 004-0201-2222 1 Beam for reject chute
8.4 004-0201-2219 1 End plate for reject chute
8.5 022-0000-2230 8 Spacer ø20/ø10 L=6 AISI 304
8.6 740-0985-08 12 Self-locking nut M8
8.7 740-0603-08025 6 Mushroom head bolt M8 x 25
8.9 740-0933-08016 4 Hexagon head screw M8 x 16
9. Support for reject box
9.1 004-0200-A033 1 Left support
9.2 004-0201-2276 4 Axle
9.3 004-0201-2277 1 End plate for support beam
9.4 004-0200-A034 1 Right support beam

Figure 52 Take-away conveyor.

Idle end
1.1 008-0045-20030356 1 Roller Ø90 W (belt) 356 L=413
1.2 004-0201-a084 1 Bracket for idle end
1.3 740-0931-10030 2 Hexagon head bolt M10 x 30, stainless steel
1.4 740-125a-10 2 Medium washer M10, stainless steel
Beam
2.1 004-0201-23400002 1 Proline beam for take-away
2.2 730-0000-00000100 4 Side support for belt
2.3 004-0200-21880002 2 Belt return support with side guard 20 x 140 mm
2.4 004-0200-21880001 1 Belt return support 20 x 140 mm
Motor end
3.1 727-e135-35010016ta2 1 Drum motor
3.2 004-0201-A083 1 Bracket for 350 mm drum motor
3.3 004-0201-2353 1 Guide, left
3.4 004-0201-2354 1 Guide, right
3.5 004-0201-2346 2 Bracket for drum motor (20 mm)

Other parts
4 730-1600-ftpp0356 1 Belt
5 744-0ngi-m10635330 6 Foot
6 704-psl5-sl2025 4 Wear strip 20 x 25 [mm]

Electrical Parts and Diagrams – Weighing Unit

Electrical Parts and Diagrams – Discharge Unit

74 • ProLine Grader
Glossary of Terms
Adjustment bolt
A bolt under the weighing plates, used to adjust the height level of the
weighing plates.
Controller
See M3000 Controller.
Emergency stop button

When activated, the button immediately stops the ProLine Grader.
Located on the side of the electrical cabinet and on the operator panel.
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.
Hardware Manual Glossary of Terms • 75

76 • Glossary of Terms ProLine Grader
Index
electrical cabinet 37, 39
M3000 display 39
A water temperature 32
A520 7 Controls, description 19
Accessibility See Site requirements Conveyor ends 20
Acidity 33 Customer support 3
Adjusting
belt sensor 15 D
cylinder speed 28
encoder bearing 14 Damaged equipment 9
gate arm 16 Detergents
legs 10, 14 choosing 33
light beam 25 use of 31
product sensor 25 Dimensions 7
weighing plates 15 Discharge unit belt, maintenance 25
Air See Site requirements Disinfectants 34
consumption 7 Division 7
cylinders 12
pressure, local 9, 12
pressure, operating 26 E
quality 12 Electrical cabinet 19
Aligning equipment 11 Electrical cabinet, cleaning 37, 39
Arms 20, 28 Electrical hazard, warning sign 20
Electrical installations 12
B Electricity See Site requirements
Emergency stops 19, 30
Belt Encoder bearing 14
quality 24 Equipment, verification 9
sensor 15
width 7
Belt speed 7 F
Belts Floor See Site requirements
cleaning 36
discharge unit, maintenance 25
weighing unit, maintenance 24 G
Bins 20, 29
Gate arms 16, 20, 28
cleaning 37
Bushings 30
H
C Height 7
Height difference 11
Capacity 7
Changing oil, motor 30
Chlorine 31 I
Chutes 29
Cleaning 7 Idle end 20
belts 36 Idle shaft 30
bins and chutes 37 Indicator lamps 19
Infeed conveyor 11
Hardware Manual Index • 77

Installing the ProLine Grader 10 S
Schedule, maintenance 23
L Sensors
Labels, warning 20 belt 15
Light beam 25 encoder bearing 14
Load cell 7 product 25
Local air pressure 9, 12 Shock absorber 27
Site requirements 9
Software type 7
M Speed adjustment, cylinders 28
Start button 19, 22
M3000 Controller 22
Starting the ProLine Grader 22
M3000 display, cleaning 39
Steel frame 20
Main modules 4
Stop button 19
Mains breaker 20, 39
Maintenance procedures 24
air cylinders 27 T
bins 29
chutes 29 Temperature 9
discharge unit belt 25 range 7
gate arms 28 Temperature, water 32
motors 30 Throughput 7
pneumatic system 26
product sensor 25 V
weighing unit belt 24
Maintenance schedule 23 Verification of equipment 9
Modular belt 24 Vibrations 10
Motor unit, safety 20
Motors 30
type 7 W
Motors, switch 35 Warning labels 20
Warranty 4
Washing mode 36
O Water
Oil change 30 temperature 32, 35, 36
Operating air pressure 26 trap 26
Overload indicator 20 ventilator 26
Weighing plates 15
Weighing platform 37
P Weighing unit belt, maintenance 24
Plates 15 Welding 10
Platforms
number of 7
sizes 7
Pneumatic installations 11, 12, 26
Pneumatic system 26
Power voltage 7
Power-on
indicator 20
procedure 22
Pressure control 26
Product chutes 20
Product sensor 25, 38
ProLine Grader, main modules 4
ProWeigher 43
R
Replacing air cylinders 27
78 • Index ProLine Grader

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Hardware Manual

Technical File Responsible: Director of Product Development

Manufacturer: Marel ehf

 2006/42/EC Machinery. Safety of Machinery

STANDARD SAFETY AND WARNING NOTICE FOR ALL MAREL

Additional Safety Information

ABOUT THIS MANUAL ........................................................................................... 3

SITE REQUIREMENTS ............................................................................................ 9

CONTROLS AND INDICATOR LAMPS ................................................................... 19

MAINTENANCE SCHEDULE ................................................................................. 23

Hardware Manual Contents • i

CLEANING IN GENERAL ...................................................................................... 31

MECHANICAL PARTS LISTS ................................................................................ 41

ii • Contents ProLine Grader

About This Manual

This manual is divided into the following chapters:

Improvements and Customer

Hardware Manual Introduction • 3

About the ProLine Grader

Figure 1 ProLine Grader, main modules.

4 • Introduction ProLine Grader

Figure 2 Weighing unit, main parts.

Non-stick 400 bin, optional

Take-away conveyor, optional

Figure 3 Discharge unit, main parts.

This is how the ProLine Grader works:

1 The material to be weighed and graded is transported to the

2 The weighing unit’s product sensor detects individual pieces of the

Hardware Manual Introduction • 5

4 The pieces of material are then transported on to the discharge unit.

5 The M3000 software determines through which gate a specific

6 The pneumatically operated gate arms direct the material flow on

6 • Introduction ProLine Grader

Hardware Manual Introduction  7

Verifying the Equipment

Hardware Manual Installation  9

To install the ProLine Grader:

1 Position the ProLine Grader on the location of your choice,

2 The grader must be kept free of vibrations. Therefore, make

3 During installation, be careful not to twist or force the grader

5 Tighten the adjustment bolts on the legs of every module.

10 • Installation ProLine Grader

9 It is important for correct operation that the main modules of

• If an infeed conveyor is used with the grader, the speed

• The conveyor belt or the distance between a conveyor’s

• Position the belts end to end, with center lines aligned,

• A slight drop in height between modules will ensure a

Figure 5 Height difference between weighing unit and discharge unit.

Hardware Manual Installation • 11

Warning! Electrical installations are to be performed by a licensed

Pressure dew point is the temperature to

Note: Recommended local air pressure is minimum 7 bars. Pressure

12 • Installation ProLine Grader

Hardware Manual Installation • 13

• Gate arms and pneumatic cylinders, if necessary

To adjust the legs:

• Use a spirit-level to check that the conveyor belts are level,

• Use the adjustable legs to make any necessary adjustments.