Kemper EVOLUTION LINE User manual

OPERATING MANUAL
(Translation of the original operating manual)
EVOLUTION LINE roll machine
Emil Kemper GmbH
Neuenkirchener Maschinenfabrik
Lange Straße 8 – 10
D - 33397 Rietberg
Tel.: [phone] / 402-0
Fax: [phone] / 40 22 20
www.emil-kemper.de
[e-mail]
Keep for future use!

Machine type: Evolution Line
Machine number:
Edition: April 2011
© GmbH
This operating manual and all images contained herein are copyright protected. Any use outside the
limitations of the copyright without prior written approval is forbidden and liable to prosecution. This
applies especially for reproduction, translation, microfilming, saving and editing in electronic systems.

Contents
Emil Kemper GmbH EVOLUTION LINE roll machine I
Contents
1 Introduction..........................................................................................................................................1
1.1 Notational conventions.......................................................................................................................1
1.2 Symbols used on the line...................................................................................................................2
1.3 Safety information ..............................................................................................................................2
1.3.1 General safety information......................................................................................................3
1.3.2 Personal protective equipment ...............................................................................................3
1.3.3 Safety devices and guards......................................................................................................3
1.3.4 Electric power hazards............................................................................................................4
1.3.5 Pneumatic power hazards.......................................................................................................4
1.3.6 Flour dust and sugar hazards .................................................................................................5
1.3.7 Information for emergencies ...................................................................................................5
1.3.8 Training level of personnel......................................................................................................5
1.4 Residual risks.....................................................................................................................................6
1.5 Intended use.......................................................................................................................................6
1.6 Structural alterations to the line..........................................................................................................7
1.7 Cleaning and waste disposal..............................................................................................................7
1.8 Obligations of the plant operator........................................................................................................7
1.9 Obligations of personnel.....................................................................................................................8
1.10 Warranty and liability........................................................................................................................8
2 Transport and storage ........................................................................................................................9
2.1 Inspection by the recipient on handover ............................................................................................9
2.2 Packaging...........................................................................................................................................9
2.3 Transport information .......................................................................................................................10
2.4 Temporary storage...........................................................................................................................11
3 Installation..........................................................................................................................................13
3.1 Erecting the line................................................................................................................................13
3.2 Choice of installation site..................................................................................................................14
3.2.1 Necessary operating and maintenance space......................................................................14
3.2.2 Floor requirements................................................................................................................15
3.3 Erecting the line................................................................................................................................15
3.4 Electrical characteristics of the supply network................................................................................15
3.4.1 Preparations..........................................................................................................................16
3.4.2 Rating plate...........................................................................................................................17
3.4.2.1 Line 17
3.4.2.2 Roll-out station........................................................................................................18
3.4.2.3 Reciprocating belt...................................................................................................19
3.4.2.4 Reciprocating belt AB60.1......................................................................................20
4 Commissioning .................................................................................................................................21
5 Overview of the line ..........................................................................................................................23
5.1.1 Overview of the basic module assembly...............................................................................23
5.1.2 Overview of the roll-out station assembly.............................................................................24
5.2 Overview of the lines modules' function elements...........................................................................25
5.2.1 Function elements of the basic module ................................................................................25

Contents
II EVOLUTION LINE roll machine Emil Kemper GmbH
5.2.2 Function elements of the discharge belt 1 ........................................................................... 26
5.2.3 Function elements of the pressure roller.............................................................................. 27
5.2.4 Function elements of the roll-out roller................................................................................. 28
5.2.5 Function elements of the centering unit ............................................................................... 29
5.2.6 Function elements of the cutting station............................................................................... 30
5.2.7 Function elements of the pre-pressing station..................................................................... 31
5.2.8 Function elements of the conveyor belt ............................................................................... 32
5.2.9 Function elements of the flour duster with flour break-up shaft........................................... 33
5.2.10 Function elements of the long-moulding belt ..................................................................... 34
5.2.11 Function elements of the folding mats ............................................................................... 35
5.2.12 Function elements of the alignment and pressure roller (timing roller).............................. 37
5.2.13 Function elements of the reciprocating belt ....................................................................... 38
5.2.14 Function elements of reciprocating belt AB60.1................................................................. 39
5.3 Overview of the operator controls.................................................................................................... 40
5.3.1 Operator controls of the basic module ................................................................................. 40
5.3.2 Operator controls of the discharge belt 1............................................................................. 42
5.3.3 Operator controls of the pressure roller................................................................................ 43
5.3.4 Operator controls of the roll-out roller................................................................................... 44
5.3.5 Operator controls of the centering unit................................................................................. 45
5.3.6 Operator controls of the cutting station ................................................................................ 46
5.3.7 Operator controls of the pre-pressing station....................................................................... 47
5.3.8 Operator controls of the flour duster with flour break-up shaft............................................. 48
5.3.9 Operator controls of the long-moulding station top belt ....................................................... 49
5.3.10 Operator controls of the folding mats................................................................................. 50
5.3.11 Operator controls of the alignment and pressure roller (timing roller)................................ 51
5.3.12 Operator controls of the reciprocating belt......................................................................... 52
5.3.13 Reciprocating belt AB60.1.................................................................................................. 53
5.4 Overview of safety devices.............................................................................................................. 54
6 Description of the line...................................................................................................................... 55
6.1 Basic module................................................................................................................................... 55
6.2 Discharge belt 1............................................................................................................................... 56
6.3 Pressure roller ................................................................................................................................. 56
6.4 Roll-out roller ................................................................................................................................... 56
6.5 Centring unit .................................................................................................................................... 56
6.6 Cutting station.................................................................................................................................. 57
6.7 Pre-pressing station......................................................................................................................... 57
6.8 Conveyor belt................................................................................................................................... 57
6.9 Flour duster with flour break-up shaft.............................................................................................. 57
6.10 Long-moulding belt........................................................................................................................ 58
6.11 Folding mats.................................................................................................................................. 58
6.12 Alignment and pressure roller (timing roller) ................................................................................. 58
6.13 Reciprocating belt.......................................................................................................................... 59
6.14 Reciprocating belt AB60.1............................................................................................................. 59
6.15 Electrical equipment ...................................................................................................................... 59
6.16 Switchbox ...................................................................................................................................... 60
6.17 Touch panel................................................................................................................................... 61
6.17.1 Password levels.................................................................................................................. 62
6.17.2 Structure of the main and sub-menus................................................................................ 63
6.17.3 Start screen........................................................................................................................ 64

Contents
Emil Kemper GmbH EVOLUTION LINE roll machine III
6.17.3.1 Displays ................................................................................................................65
6.17.3.2 Buttons and illustrations........................................................................................66
6.17.4 Illustration of the assemblies and line modules ..................................................................67
6.17.4.1 'Proofer menu'.......................................................................................................68
6.17.4.2 Roll-out station menu............................................................................................72
6.17.4.3 'Cutting station menu' ...........................................................................................77
6.17.4.4 'Reciprocating belt menu'......................................................................................81
6.17.5 RECIPE button......................................................................................................................87
6.17.6 INFO button ..........................................................................................................................89
6.17.7 ACK BUTTON .........................................................................................................................90
6.17.8 MENU button ........................................................................................................................91
6.18 Safety devices and guards.............................................................................................................92
6.18.1 EMERGENCY STOP button......................................................................................................92
6.18.2 EMERGENCY STOP button on the operator panel..................................................................93
6.18.3 Limit switches......................................................................................................................93
7 Operation............................................................................................................................................95
7.1 Switching the line on and off ............................................................................................................95
7.2 Switching the control voltage on ......................................................................................................96
7.3 Setting assemblies...........................................................................................................................96
7.3.1 Basic module.........................................................................................................................96
7.3.1.1 Switching on the steam generator system..............................................................96
7.3.1.2 Setting the heating, convection, sterilization and drying.........................................97
7.3.1.3 Setting a recipe at the basic module ......................................................................97
7.3.2 Roll-out station ....................................................................................................................103
7.3.2.1 Setting a recipe at the roll-out station...................................................................103
7.4 Setting the line modules.................................................................................................................106
7.4.1 Setting the discharge belt....................................................................................................106
7.4.1.1 Adjusting the height of the pressure roller............................................................106
7.4.2 Setting the discharge belt 1 ................................................................................................107
7.4.2.1 Setting the pressure roller height on the pressure roller line module...................107
7.4.3 Setting the pressure roller...................................................................................................108
7.4.3.1 Adjusting the height of the pressure roller............................................................108
7.4.4 Setting the roll-out roller......................................................................................................109
7.4.4.1 Adjusting the height of the roll-out roller...............................................................109
7.4.5 Setting the centering unit ....................................................................................................109
7.4.5.1 Replacing the centering flap.................................................................................109
7.4.5.2 Setting a recipe at the centering unit....................................................................110
7.4.6 Setting the cutting station....................................................................................................112
7.4.6.1 Setting the cutting depth.......................................................................................112
7.4.6.2 Setting the hold-down...........................................................................................112
7.4.6.3 Setting the centering unit......................................................................................113
7.4.6.4 Setting the timing adjustment ...............................................................................114
7.4.6.5 Setting a recipe at the cutting station ...................................................................114
7.4.7 Setting the pre-pressing station ..........................................................................................117
7.4.7.1 Setting the pre-pressing depth..............................................................................117
7.4.7.2 Replacing the pre-pressing tool............................................................................118
7.4.7.3 Setting a recipe at the pre-pressing station..........................................................119
7.4.8 Setting the conveyor belt.....................................................................................................120

Contents
IV EVOLUTION LINE roll machine Emil Kemper GmbH
7.4.8.1 Setting a recipe at the conveyor belt.................................................................... 120
7.4.9 Setting the flour duster with flour break-up shaft................................................................ 121
7.4.9.1 Filling the flour duster with flour break-up shaft................................................... 121
7.4.9.2 Setting a recipe at the flour duster with break-up shaft ....................................... 122
7.4.10 Long-moulding belt........................................................................................................... 123
7.4.11 Setting the folding mats.................................................................................................... 126
7.4.11.1 Lifting folding mats out of the transport area ..................................................... 126
7.4.11.2 Setting the folding flaps...................................................................................... 126
7.4.12 Setting the alignment and pressure roller (timing roller) .................................................. 127
7.4.12.1 Setting the height of the alignment and pressure roller..................................... 127
7.4.12.2 Setting a recipe at the alignment and pressure roller........................................ 127
7.4.13 Setting the reciprocating belt............................................................................................ 129
7.4.13.1 Setting the wooden tray stop ............................................................................. 129
7.4.13.2 Setting a recipe at the reciprocating belt............................................................ 129
7.4.14 Reciprocating belt AB60.1................................................................................................ 134
7.5 Selecting a recipe via the touch panel........................................................................................... 140
7.6 Starting/Stopping the line .............................................................................................................. 142
7.6.1 Touch panel........................................................................................................................ 142
7.6.2 Operator panel.................................................................................................................... 142
7.7 Behaviour after triggering safety devices ...................................................................................... 143
7.7.1 EMERGENCY STOP button..................................................................................................... 143
7.7.2 Limit switches..................................................................................................................... 144
8 Cleaning and maintenance............................................................................................................ 145
8.1 Safety information for cleaning and maintenance......................................................................... 145
8.2 Cleaning and maintenance intervals ............................................................................................. 146
8.2.1 Every 10 operating hours or daily....................................................................................... 146
8.2.1.1 Basic module........................................................................................................ 146
8.2.1.2 Roll-out station..................................................................................................... 146
8.2.1.3 Centring unit......................................................................................................... 146
8.2.1.4 Conveyor belt....................................................................................................... 147
8.2.1.5 Flour duster with flour break-up shaft .................................................................. 147
8.2.1.6 Long-moulding belt............................................................................................... 147
8.2.1.7 Folding mats......................................................................................................... 147
8.2.1.8 Alignment and pressure roller (timing roller)........................................................ 148
8.2.1.9 Reciprocating belt ................................................................................................ 148
8.2.1.10 Reciprocating belt AB60.1 ................................................................................. 148
8.2.2 Every 50 operating hours or weekly................................................................................... 148
8.2.2.1 Basic module........................................................................................................ 148
8.2.2.2 Discharge belt 1................................................................................................... 149
8.2.2.3 Conveyor belt....................................................................................................... 149
8.2.2.4 Reciprocating belt ................................................................................................ 149
8.2.2.5 Reciprocating belt AB60.1.................................................................................... 150
8.2.3 Every 200 operating hours or monthly ............................................................................... 150
8.2.3.1 Basic module........................................................................................................ 150
8.2.3.2 Discharge belt 1................................................................................................... 150
8.2.3.3 Long-moulding belt............................................................................................... 151
8.2.3.4 Reciprocating belt ................................................................................................ 151
8.2.3.5 Reciprocating belt AB60.1.................................................................................... 151
8.2.4 Every 700 operating hours or every three months............................................................. 152

Contents
Emil Kemper GmbH EVOLUTION LINE roll machine V
8.2.5 Inspection every 1400 operating hours or every half-year..................................................152
8.3 Cleaning and maintenance tasks...................................................................................................152
8.3.1 Preparations........................................................................................................................152
8.3.2 Basic module.......................................................................................................................153
8.3.2.1 Cleaning the collecting trays.................................................................................153
8.3.2.2 Tensioning the cup chains....................................................................................154
8.3.2.3 Lubricating the cup chains....................................................................................155
8.3.3 Roll-out station ....................................................................................................................156
8.3.3.1 Cleaning collecting trays.......................................................................................156
8.3.4 Discharge belt 1 ..................................................................................................................157
8.3.4.1 Cleaning the belt...................................................................................................157
8.3.4.2 Tensioning the belt ...............................................................................................157
8.3.4.3 Cleaning the chain wheels....................................................................................158
8.3.5 Pressure roller.....................................................................................................................158
8.3.5.1 Cleaning the pressure roller..................................................................................158
8.3.6 Roll-out roller.......................................................................................................................159
8.3.6.1 Cleaning the roll-out roller.....................................................................................159
8.3.6.2 Cleaning the scraper.............................................................................................159
8.3.7 Centering unit......................................................................................................................160
8.3.7.1 Cleaning the centering flap...................................................................................160
8.3.7.2 Checking the pneumatic equipment .....................................................................162
8.3.8 Cutting station .....................................................................................................................163
8.3.8.1 Lubricating the triangular knife and knife guides..................................................163
8.3.8.2 Inspecting and replacing the triangular knife........................................................164
8.3.8.3 Checking the pneumatic equipment .....................................................................165
8.3.9 Belt stamp ...........................................................................................................................166
8.3.9.1 Cleaning the belt stamp........................................................................................166
8.3.10 Conveyor belt....................................................................................................................167
8.3.10.1 Cleaning the conveyor belt.................................................................................167
8.3.10.2 Tensioning the conveyor belt..............................................................................168
8.3.11 Flour duster with flour break-up shaft ...............................................................................168
8.3.11.1 Cleaning the flour container................................................................................168
8.3.11.2 Cleaning the flour cloth.......................................................................................169
8.3.12 Long-moulding belt............................................................................................................171
8.3.12.1 Cleaning the top belt...........................................................................................171
8.3.12.2 Tensioning the top belt .......................................................................................171
8.3.13 Folding mats......................................................................................................................172
8.3.13.1 Cleaning the wire mesh belts..............................................................................172
8.3.13.2 Cleaning the folding flaps ...................................................................................173
8.3.14 Alignment and pressure roller...........................................................................................174
8.3.14.1 Cleaning the alignment and pressure roller........................................................174
8.3.15 Reciprocating belt .............................................................................................................174
8.3.15.1 Cleaning the belt.................................................................................................174
8.3.15.2 Tensioning and lubricating the drive chain of the conveyor belt stroke..............175
8.3.15.3 Tensioning and lubricating the drive chain conveyor belt drive..........................176
8.3.15.4 Tensioning the conveyor belt..............................................................................177
8.3.15.5 Tensioning and lubricating the conveyor belt chains..........................................178
8.3.16 Reciprocating belt AB60.1 ................................................................................................179

Contents
VI EVOLUTION LINE roll machine Emil Kemper GmbH
8.3.16.1 Cleaning the belt................................................................................................ 179
8.3.16.2 Tensioning the drive chain of the conveyor belt pull-off..................................... 180
8.3.16.3 Tensioning the drive chain of the conveyor belt drive........................................ 181
8.3.16.4 Tensioning the conveyor belt............................................................................. 182
8.3.16.5 Tensioning the conveyor belt chains.................................................................. 183
8.3.16.6 Checking the pneumatic equipment................................................................... 184
8.4 Operating materials, lubricants and cleaning agents .................................................................... 185
8.4.1 Lubricant recommendations............................................................................................... 185
8.4.2 Greases.............................................................................................................................. 186
8.4.3 Storage of lubricants .......................................................................................................... 186
8.5 Stocking spare parts / Customer Service...................................................................................... 187
8.5.1 Stocking spare parts........................................................................................................... 187
8.5.2 Accessories........................................................................................................................ 187
8.5.3 Customer Service............................................................................................................... 187
8.6 Maintenance contracts................................................................................................................... 188
9 Faults ............................................................................................................................................... 189
9.1 Behaviour in case of faults ............................................................................................................ 189
9.2 Safety shutdown............................................................................................................................ 189
9.3 Start-up after a fault....................................................................................................................... 190
9.4 Troubleshooting............................................................................................................................. 191
10 Decommissioning, dismantling and disposal ........................................................................... 193
10.1 Decommissioning the line............................................................................................................ 193
10.2 Dismantling the line ..................................................................................................................... 193
10.3 Disposing of the line .................................................................................................................... 193
11 Appendix ....................................................................................................................................... 195
11.1 Technical data ............................................................................................................................. 195
11.2 Compliance with laws, standards and directives......................................................................... 195

Introduction
Emil Kemper GmbH EVOLUTION LINE roll machine 1
1 Introduction
This operating manual provides all the information you need to run the EVOLUTION LINE
roll machine (called line from now on).
After reading the operating manual you will be able to:
–operate the line safely,
–carry out maintenance according to the rules and
–take the necessary action in the event of a fault.
All persons working with the line must follow this operating manual (e.g. machine
operators, supervisors, mechanics, electricians). This applies in particular to the safety
information given in this chapter.
It is also necessary to obey the accident prevention rules in force at the point of use.
This operating manual must always be kept at the line's point of use.
1.1 Notational conventions
Passages of this user manual that require special attention or are a direct danger warning
are shown as follows:
Note!
This symbol indicates information about a function or setting or that care is
required.
Attention!
This symbol indicates potential damage to line components and how to
behave at the line.

Introduction
2EVOLUTION LINE roll machine Emil Kemper GmbH
Hazard!
This symbol indicates a particular hazard to health from the line and ways
of averting it.
Warning – electrical hazard!
This symbol indicates an electrical hazard.
Work on electrical equipment should only be carried out by qualified and
authorized electrical specialists.
The following conventions are also used:
–Text following this mark represents an item in a list.
Text following this mark describes actions to be performed in the specified order.
' ' Text in single quotation marks indicates screens on the touch panel.
" " Text in double quotation marks refers to other chapters or sections in this document.
ONText in small capitals indicates an operator control pushbutton/switch or a button /
input box on the touch panel.
1.2 Symbols used on the line
Warning – electrical hazard!
This symbol indicates an electrical hazard.
1.3 Safety information
Before working with the line you must carefully read the safety information below and
then follow it. It is intended to protect you, averting hazards and/or injuries.