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Instruction manual
(Instruction manual MC4_2_14030_DB_GMT)
1
Content
1. Before you start… ...............................................................................................................3
1.1 This instruction manual ...............................................................................................3
1.2 Precaution ...................................................................................................................3
1.3 Recycling ....................................................................................................................3
2. Description of the machine ..................................................................................................4
2.1 Intended use ...............................................................................................................4
2.2 Type ............................................................................................................................4
2.3 Properties ...................................................................................................................4
2.4 The environment .........................................................................................................9
3. Installing the machine ....................................................................................................... 10
3.1 Component description ............................................................................................ 10
3.2 Set up the machine .................................................................................................. 13
4. Operating the machine ..................................................................................................... 14
4.1 Control devices ........................................................................................................ 14
4.2 Daily checkup .......................................................................................................... 15
5. Cleaning ........................................................................................................................... 17
5.1 Washing ................................................................................................................... 17
5.2 Opening and closing belts ....................................................................................... 18
6. Maintenance schedule ..................................................................................................... 19
6.1 Every day ................................................................................................................. 19
6.2 Every month ............................................................................................................. 19
6.3 Every half year ......................................................................................................... 20
7. Service and support ......................................................................................................... 21
7.1 Wearstrips ................................................................................................................ 21
7.2 Adjusting the weighing unit - Precision .................................................................... 21
7.3 Flippers .................................................................................................................... 22
7.4 Belt ........................................................................................................................... 26
8. Spare parts ....................................................................................................................... 29
8.1 Infeed conveyor in frame: (A38939) ........................................................................ 29
8.2 MC4: (A38852) ........................................................................................................ 42
8.3 Grader: (A38765) ..................................................................................................... 54
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1. Before you start…
This documentation is the original instruction manual and contains important information
about the purchased machine and instructions to operate it. MARELEC Food Technologies is
not responsible for damage caused by ignoring these instructions.
1.2 Precaution
Read this manual before installing or using the machine. Improper use
DANGER!
can cause serious damage to the user and the functions of the machine.
1.3 Recycling
Disposal of the machine at end of life must be carried out in accordance with local
environmental recycling regulations. Please verify if the protective packing crate for
transport can be recycled.
The MARELEC MC4/2 weighing, grading and infeed unit is designed for automatically sorting
products with the properties and characteristics as described in chapter ‘Description of the
machine’ . Any other use as described is considered to be improper.
Way to work:
One or two operators can feed the machine.
The elevation belt brings the products to the acceleration belt 1.
The acceleration belts bring the products to the right speed.
The products are weighed on the weighing belt.
The grader grades the products to 2 batching exits.
2.2 Type
Type: MC4/2-14030-DB
2.3 Properties
The MC4/2 is a machine that sorts out product based on the weight of the product into
maximum 2 classes. The machine is controlled by the Marelec Z2 computer.
Outside dimensions
The A-weighted emission sound pressure level at the work place (refer Fout!
Verwijzingsbron niet gevonden.) amounts not more than 70 dB(A).
It’s recommended to use ear protection when exposed a long time to dull
NOTE
noise of the machine
Infeed conveyor
1. Infeed belt
2. Acceleration belt
Weighing unit
1. Acceleration belt
2. Weighing belt
3. Marelec Z2 computer
4. Electrical cabinet
This acceleration belt was preceded by another acceleration belt to increase the distance
between two products. The last belt on the MC4 is the weighing belt.
The entire installation is controlled by the Marelec Z2 computer that is located on the MC4 –
unit.
Grading belt
1. Grading belt
2. Flipper assembly
3. Batching bin
4. Pneumatic cabinet
The grader consists of a conveyor with on each side 1 pull arm and 1 batching bin.
4. To prevent noise emission, it’s important that the belts on all machines run properly
and smooth. Therefore check every passage of the belt between wearstrips and side-
guidance and check the contact with the guidance-wheels. Check also the contact
with the sprockets.
5. The weighing platform is dismantled from the loadcell to prevent damage during
transport. Reassemble the weighing platform. Tighten the bolts in the loadcell using a
torque wrench (8Nm).
Never change the amount of links in the modular belt of the weighing belt.
NOTE The amount of links is important for a correct weighing. Refer to software
users guide.
MARELEC Z2
1. function keys
2. numeric keyboard
3. screen
After the computer has started up, all flippers and batching slides will open
DANGER! and close several times. Danger for injury and damage to machine if
flippers are blocked.
For all software applications, setup and programs, look in the software manual.
1. If the inductive sensors are blinking when the belt are running.
2. All detection eyes detect a product or a flight when it is passing by.
3. Weight indication with empty running belt on Z2 computer is between -1 g and +1 g.
5.1 Washing
Clean the grader after every use. Conventional cleaning products can be used. However, it is
absolutely necessary to rinse the machine with sweet water afterwards to avoid damage
caused by chemical products.
Cleaning the machine is extremely important for the final quality of your product. This
deserves attention and the cleaning staff should be well educated to perform the job correctly.
The least IP grade is IP65, however many components may have a higher protection degree.
This means that high pressure cleaning on belts is permitted, but fragile components like
sensors, buttons and motors should be cleaned with low pressure (less than 3 bar).
Even more important than the right cleaning product, is the correct cleaning time (in case of
foam cleaning for instance) and sufficient rinsing afterwards.
When using hot cleaning, the water in your cleaning solution will evaporate quicker than on
cold cleaning. Concentration of cleaning agent will rise as the water disappears, and will
finally attack materials even if they are listed as compatible! Therefore instruct your staff
correctly on these issues. Typical example is changes in color of stainless steel, this is
caused by overconcentration, itself caused by poor rinsing or cleaning overtime.
Cleaning shall be performed carefully in the food contact area. Any part of the machine that
comes into contact with the machine, either directly or indirectly, needs proper attention
during cleaning. MARELEC Food Technologies cannot take any responsibility if this is not
respected.
In general, the machine has been made in an open design in favour of easy accessibility and
hygienic demands. Cleaning of most conveyors will not require any specific remarks, and can
be done while having the belts running.
In case of doubt about the employed cleaning product do not use any
product that damages the following materials used in the grader:
1. Stainless steel AISI 304 / AISI 316
2. Polyacetal (POM)
3. Polyethylene (PE)
! CAUTION! 4. Polycarbonate (PC)
5. Polyamide (PA)
Do not use cleaning products with a higher temperature than 80°C
Although everything has been done to make the machine waterproof, be
careful with the water jet especially in the environment of electrical
cabinet, junction boxes, Z2 computer and the local pneumatic cabinets.
Fout! Verwijzingsbron niet gevonden. shows how to open belts of the machine. Therefore
take a hammer and a screwdriver to punch out the rod. This handling is the same for all used
types of belts.
NOTE
For detailed instructions for all actions about maintenance, refer to
Chapter Service and support
Cleaning
Clean the entire machine after every use. See chapter Cleaning and Daily checkup for
details.
Compressed air
The compressed air used for the pockets has to be dry (dew point 3°C). Install a
compressed air dryer to prevent that water comes into cylinders.
It’s not necessary to use lubrication for the cylinders as they are lubricated
for life when manufactured. But once they are lubricate external, it’s
NOTE
necessary to keep on lubricating because the original grease has flown
away
NOTE Vertical clearance is a problem if the product tends to go under the flippers.
Speed of cylinders
Check the speed of the cylinders. It has to be equal for all cylinders. The speed can
easily be adjusted with the flow-control couplings on the cylinder itself.
Signal functions
Check the function of the buttons and lamps, the power switch and the emergency stop.
While servicing on the machine, it’s important to secure all bolt – nut
connections with a thread locking compound (e.g. Loctite 243).
DANGER!
Risk for injury and damage to the machine because of loosened bolts
caused by vibrations
7.1 Wearstrips
Wearstrips at the weighing belt have an original thickness of 25mm. If they have worn out to
less than 20mm, replace them. To replace them, take off the belt and take the wearstrips out.
The wearstrips of the acceleration belts can be replaced by following the same steps.
The wearstrips on the grading conveyor have a thickness of 25mm. They should be replaced
when they have worn out to less than 20mm or when it happens that the product get stuck
between belt and underside of the flipper when the flipper is already in its lowest position.
The wearstrips on the infeed conveyor have a thickness of 30mm. They should be replaced
when they have worn out to less than 25mm.
Weighing indication should be within -1 g en +1 g when running empty. When this is not the
case it is possible that the machine doesn’t run smoothly. It is also possible that the belt has
lengthened to much (due to wear,…) Repositioning the friction rod at the underside will help
to get a better weighing.
1. Release 4x M8 until the whole flipper assembly can be moved. Replace the
assembly with a new one.
3. Open the flipper. The top of the flipper must be parallel with the belt at approximately
0.5 mm . If not, release the nut M8 after the frame and adjust M8 nut before
the frame until the top of the flipper is completely parallel at 0.5mm with the belt.
After all, tighten nut M8 again.
7.4 Belt
NOTE 2. When there is too much wear on the top surface of the belt.
3. The belt is too stiff after cleaning the belt thoroughly.
It’s recommended to replace also the sprockets on drum motor when
replacing the belt.
For cleaning the infeed belt, use the handle Ⓐ to retract the belt, so that you can clean
thoroughly. After cleaning, place the lever in its original position.
When the infeed belt is extended, there is a possibility to lengthen the rod Ⓑ by screwing or
unscrewing its nuts. If this extension is not enough remove some links from the belt. There
would likely be a smaller pocket, we recommend that you remove these links from this pocket.
The belt will lengthen due to wear on the connection rods. A lot of wear will be compensated
automatically due to the free space on the return side of the belt.
The belt will lengthen due to wear on the connection rods. This wear must be compensated
by repositioning the wearstrips on the underside of the belt.
Weighing belt
Never change the amount of links in the modular belt of the weighing belt.
NOTE The amount of links is important for a correct weighing. Refer to software
users guide.
The belt will lengthen due to wear on the connection rods. A lot of wear will be compensated
automatically due to the free space on the end of the grading belt.
7 Turnover A38872 1
1 Speedsensor G23685 1
6 Key G27127 7
3 Axel A38814 1
1 Washer A9044 1
2 Wheel A1407 1
1 Washer A6794 4
2 Axle A38805 1
6 T-bushing A38920 2
7 L-profile G38915 2
8 L-profile G38914 2
9 T-bushing A38919 2
10 A2762 +
Bushing with lever 2+2
G38913
2 Sprocket G588 3
3 Driveshaft A38942 1
1 Axle A41757 1
2 Axle A37778 1
1 Axle A37778 1
5 Driveshaft A38641 1
9 Sprocket G588 3
1 Axle A42201 1
2 Axle A37778 1
1 Axle A37778 1
1 Spacer A42278 2
5 Spacer A42279 2
6 Spacer A8696 8
1 Shaftend A44350 1
2 Seal G36007 2
3 Endfllange A39897 1
6 Sprocket A37357 3
8 Spacer A10942 1
9 Transmissionflange A39899 1
10 Endflange A39900 1
11 Shaftend A39901 1
12 O-ring 4 x 68 G32397 2
14 Motorflange A10940 1
16 Key A1496 3
1 Axle A38821 2
1 Spacer A11437 4
2 Bracket G43228 2
4 Washer G30475 4
5 Axle A38817 2
A A38654 /
Batching right / Batching left 1/1
A38663
B A38650 /
Flipper assembly pull right / left 300mm 1/1
A38644
E A39895 /
Side guard carryway / returnway 4/4
A40093
8 Large bearing
G38099 G38099 1
housing
13 Small bearing
G38098 G38098 1
housing
5 Driveshaft A38641 1
8 Sprocket G588 3
1 Axle A42201 1
1 Seal G33342 1
2 Cover A42184 1
5 Washer G32262 4
9 Elbow-coupling G33186 2
11 Elbow-coupling G1455 1
12 Elbow-coupling G33326 1