KLR 5050-16 User manual

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TABLE OF CONTENTS
SAFETY PRECAUTIONS ................................................................................................................................... 2
Identification ................................................................................................................................................. 4
Product brand and type designation: ........................................................................................................ 4
Name and manufacturer contact: ............................................................................................................. 4
Declaration of conformity to produce standards: ..................................................................................... 4
Product Specification..................................................................................................................................... 5
General functions intended use: ............................................................................................................... 5
Dimensions and weight: ............................................................................................................................ 5
Power data – Electricity and Pneumatic .................................................................................................... 6
Installation ..................................................................................................................................................... 6
Location of instructions ............................................................................................................................. 7
OPERATION ................................................................................................................................................... 8
Main screen (Operational mode) .............................................................................................................. 8
Recipe setting page ................................................................................................................................... 8
Definitions of parameters ......................................................................................................................... 9
Trouble shooting/Jam ......................................................................................................................... 28
SAFETY PRECAUTIONS ................................................................................................................................. 30
Security .................................................................................................................................................... 30
Personal protection ................................................................................................................................ 30
Security Labels ........................................................................................................................................ 30
Safety components ................................................................................................................................. 31
MAINTENANCE ............................................................................................................................................ 32
Preventive maintenance schedule .......................................................................................................... 32
Maintenance notice ................................................................................................................................ 33
Maintenance steps .................................................................................................................................. 33
Cleaning................................................................................................................................................... 40
LISTS OF SPARE PARTS AND CONSUMABLES .............................................................................................. 41
CHECK LIST .................................................................................................................................................. 42
Maintenance and repairs by specialized technicians from KLR Systems Inc. .............................................. 44
Contact information ................................................................................................................................ 44
LISTS OF SPARE PARTS AND FURNITURE (ANNEXE) ..................................................................................... 44
DECOMMISSIONING OF THE MACHINE ....................................................................................................... 44

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SAFETY PRECAUTIONS
CAUTION
 The Flat bread bagger is covered with a safety door. For any interventions during functioning
of the machine regarding to product jam, material disfunction, cleaning, etc: operator must
open the door to stop the machine assuring maximum safety and minimizing risk;
 The equipment described in this manual designed and manufactured to the highest KLR
standards. Special attention made to ensure that the operation of the machine is safe and
convenient;
 Even with the safety cover opened or closed, keep hands away from the working machine. Go
against this notice can result in a severe injury or death;
 Always use two (2) lockout devices, one on the supply and one on the air supply when
performing any maintenance or cleaning;
 If the system is linked to another machine or install onto another machine. Lock the electrical
box of the other machines before performing any maintenance on this equipment. Please
refer to the local regulations and laws on locking out machinery;
 When working in the electrical box. Disconnect the equipment at the source and use a
lockout device to avoid any risk of danger. Make sure you also have the space required to
complete the work to avoid any risk of danger.
 Any modifications with any aspect of the mechanical, safety, electrical design, design, or any
parts connected with the equipment will void the warranty and liability of KLR Systems. If a
change is required, you should contact KLR Systems for approval. All technical handling must
be done by a qualified technician or by KLR Systems;
 KLR is not responsible for any abuse, mishandling, misuse, improper maintenance and repair
by owners and users;
 Equipment must be supervised when operating;

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CAUTION
 This machine designed to be as safe as possible. Danger areas have been enclosed with
guards and doors for better protection;
 Safety switches: DO NOT bypass any safety components for any reason. Violation will void all
guaranties and responsibility from KLR Systems. If a safety switch is broken, the machine will
not start, but the safety switch must be replaced before starting the machine;
 Safety panel (fix panel) or safety doors: As a safety, component does not try to remove or
unscrew them unless it is necessary for a maintenance operation. If it is the only option, use a
lockout device during this procedure and reassemble every single piece as it was when
finished.
 When closing the safety door, careful about the pinch points. Make sure nobody’s hands or
fingers are in the way;
 When the air supply is OFF and it is required in a maintenance to move manually the bag
table in order to access something. When the maintenance is over, DO NOT put the pressure
back if the machine is in ready state. ALWAYS push the emergency button before putting the
pressure on the machine. Go against this notice can result in equipment damage;
 When the air pressure is turned ON, the bag table may move promptly depending of what
position is the bag table valve is. To avoid this problem, unscrew the air regulator until it
reaches 0 pressure before shutting off the main air pressure. Go against this notice can result
in a severe injury or death.

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Identification
Product brand and type designation:
Automatic Flat Bread Bagger
Model: KLR.5050-16
Serial number location:
On the side of the infeed conveyor near the control panel.
Name and manufacturer contact:
KLR SYSTEMS INC.
944 rue Herons Street
SAINT-PIE, QUEBEC, CANADA
J0H 1W0
Declaration of conformity to produce standards:
Norms : CE

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Product Specification
How to know the difference between a right hand and a left-hand layout:
Standing on the operator side of the machine (able to work with the touch screen) and look toward
direction of products. In the example, the machine is a left version because it happen to be to the left of
the operator.
General functions intended use:
Equipment designed to bag flat bread.
Dimensions and weight:
High: 55"
Long: 130"
Depth: 45"
Right Hand
Left Hand
Touch Screen
Infeed Conveyor
Product
Operator

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Power data – Electricity and Pneumatic
Electricity: 220 volts – 10A – 3 phases – 60 Hertz
Pneumatic: 8 CFM @ 80 PSI (lb/po²)
Installation
Procedure for unpacking:
 If machine is arriving in a crate, unscrew all the screws circled in red from the wooden box;
 Remove all screws connecting the machine's legs to the bottom of the box or palette;
 With a forklift, gently lift the underside of the machine structure;
 Move back with the machine making sure it is stable and go down as soon as possible.
To verify before the installation:
 Check the voltage before turning on the machine;
 Check that all the legs are adjusted to keep the machine stable and level;
 Make sure there is nothing on the belts or mechanisms that could damage the machine such as
a part or tool;
 Check the adjustment of the belts (see maintenance).
Required to anchor the machine on the ground
 Once the machine is in position, set working height and level the machine by adjusting the feet.
 Drill at least one anchor hole per foot and fix securely.

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Floor plans request to install the machine:
Location of instructions
Inside the control panel

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OPERATION
Main screen (Operational mode)
Once the power turned ON, the machine and the main page appears, follow these steps to start the
bagger (refer to the "Product size change" section for more information):
 Install the wicket bags on the bag table. The Bag status should be green;
 Select the appropriate product recipe with the Recipe Selection and press "Send";
 Make sure the door closed securely. Pull the emergency stop button and press the Reset button.
The Systems Status indicator turn green;
 Press Start on the touch screen and the status indicator will change to green with “System on”.
Recipe setting page
Advanced Settings must be unlocked on the Main Screen to change recipe parameters.
Caution: It is possible to adjust parameters to the point of a malfunction of the packaging
machine. Exercise caution when making parameter changes and make changes in small
increments. See recipe manager (next page) to save your recipe and be able to keep
track of your changes.
Start/Stop
Bags/minute
Send
Change the
wicket bag
table
System Status
Unlock the
following
pages.
Lock the
following
pages
Bag State Counter zero
Counter
Parameters
Recipe
Selection

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Definitions of parameters
This figure below will be used to describe couple next parameters. Keep in mind that picture features a
full options machine. General parts remain the same concept through all the machines. With
parameters that only available with certain options will not be visible from the display. In this document,
all parameters are explained in the same order of the touch screen.
Speed plate Fwd (see picture above)
Speed in hertz multiplied by 10 (hz x10) of the plates when moving forward in the bag sequence. Raise
the number to raise the speed. Most of the recipe will be between 2000 and 6000. Finetuning this
parameter is necessary when the product arrives first in front, in this case it need to be lowered down.
The goal is: when the plate has reached the destination, the product should arrive just after.
Changing this parameter may required to revisit other parameters. Check: retract belt speed and delay
plates (ms).
Speed plate Rev (see picture above)
Speed in hertz multiplied by 10 (hz x10) of the plates when moving reverse (back) in the bag sequence.
Used specially to retract quick enough from the bag, to avoid the infeed conveyor stopping too often
and loosing efficiency. Value should be rather high but can be lowered down to save on the mechanic
side when the package per minute is low.
Plates (top
and bottom)
Bottom scoop
s (2)
Antennas
(2)
Up scoops
(2)
In
feed
conveyor

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Two step motions
Option allowing the plates to split his motion in two steps to wait a certain amount of time at a
predetermine position inside the bag. 0 = not activated, 1 = activated. Used when the bags are small,
and the plate need to travel further to deposit the bagged product on a conveyor. In other words, step 1
(in blue) would be required to bag properly and step 2 (in green) would be required for the product to
reach the conveyor.
Half distance (see picture above)
This parameter is only relevant if "two step motions" is activated (1). Value at which the plates stop to
step 1. Value is between 10 and 380. Most of the machines are set between 200 and 250.
Full distance (see picture above)
Place where the plates are set to stop to step 2. Value is between 10 and 390. 390 is the maximal
distance allowed.
Infeed conveyor speed
Setting in hertz multiplied by 10 (hz x10). Raise the number to raise the speed. The speed allowed is
between 10 and 2700. If the speed needs to be changed, consider checking "Stop infeed delay (ms)".
Infeed conveyor
Bag
Step 1
Step
2
Tw
o step
motion OFF
B
ottom
plate
Conveyor edge
Half distance
Full distance
0 position

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Retract belt speed
Setting in hertz multiplied by 10 (hz x10). Raise the number to raise the speed. The speed allowed is
between 10 and 3000. A speed too high would make the product arrives before the moment the scoops
open. On the other hand, a speed too low would not let the product enough momentum to reach the
bottom of the bag leaving a gap.
Outfeed speed
Only if the bagger is equipped with a outfeed conveyor from KLR. The setting is in hertz multiplied by 10
(hz x10). Raise the number to raise the speed. The speed allowed is between 10 and 2700. To be set so
the products have at least a little space in between when travelling onto it.
Stop bag opener (fwd)
This parameter is the combination of either blower or vacuum system that open the bag. Vacuum
system is an option while blower is on every machine. When the plates can move, it travel from 0
position to full distance (from 0 to 390 max). When the plates are moving forward and reach the "stop
bag opener (fwd)" value, then either the blower or the vacuum stop. Bag opener start when the infeed
sensor sees a product. Do not put higher value than "full distance"
Retract
belt
Blower
Vacuum system

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Start bag lifters (ms)
Delay in milliseconds the machine waits before the bag table go down. The delay starts when the plates
start their motion. The bag table should go down approximately when the product reaches the end of
the plates. A too long delay may either roll the product at the bottom of the bag or the bag never get
detached. A too short delay may do the same.
Stop bag lifters (rev) (see figure above)
When the plates travel back from full distance to 0 position (from 390 max to 0) and reach the "stop bag
lifter (rev)" value, the bag table lift back up. The plates must get out the way before the bag table can lift
because the bottom plate could bring some bags with it when it travels back.
Stop vacuum lifter (rev)
The normal position of the vacuum lifter is down. When the plates travel back from full distance to 0
position (from 390 max to 0) and reach the "stop vacuum lifter (rev)" value, the vacuum lifter back
down.
Front view
Bag table
Vacuum lifter

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Restart infeed (ms)
When the plates have traveled back to their 0 position, the machine waits this time in milliseconds
before starting back the infeed conveyor. If there is no product waiting, the infeed conveyor would still
run.
Change bag auto
Option change automatically the bag table when it’s empty. 0 = not activated, 1 = activated
Time plate stay half (ms) (see "two step motions" figure)
Time in milliseconds the plates stay in the half distance position. This parameter is only relevant if "two
step motions" is activated.
Time plate stay full (ms) (see "two step motions" figure)
Time in milliseconds the plates stay in the full distance position before running back.
Stop infeed delay (ms) (see next figure)
This parameter is only relevant when the products arrive really close each other. This delay will start
only if a product is already inside the plates and another product arrive. It is the time the infeed takes to
stop when a product triggers the sensor located on the infeed conveyor. From the time the sensor sees
a product (red line) until it reaches the end of the infeed belt (infeed must stop when the product
reaches green line). The position of that sensor is subject to change from a machine to another.
Infeed conveyor
Plates
Bag table
2
Bag table
1

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Belt tension
Torque that the servo can give to the mechanics. Used to make the tension of the retract belts in the
procedures. Value must be in relation to the width of the belt currently installed on the machine.
Vacuum 1/blower 0
The machine must have the vacuum option to get this parameter. Machine use the vacuum when the
machine is set to 1, and it uses the blower as the bag opener when the machine is set to 0.
Bypass
When set to 1, the machine is in mod bypass.
Height
This parameter is only available with "up/down servo" option. Value given to ''the up/down servo'' to
raise the top plate at the height value during the bagging sequence. The value is associated to the
thickness of the product stacks; it does not correspond to a measure.
Home position
Value is between 0 and 20. It is the normal position, where the machine is waiting for product.
Infeed conveyor
Infeed sensor

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Speed up
This parameter is only available with up/down servo option. It reacts in relation of the parameter
"Height". The value tells the machine how fast the top plate has to raise to the height value during one
cycle. Raise the value will increase the speed. That speed is constant (except the acceleration and
deceleration of the drive itself). A too slow value will either jam the product inside or make the retract
belt slip.
Speed down
This parameter is only available with up/down servo option. It tells the machine how fast the plate
comes back to the homing position after the bagging sequence
Bag flattener (option)
Only available with the bag flattener option (Installed on the outfeed conveyor)
1= ON; 2= OFF
Delay plates (ms)
Time the machine waits starting the plates cycle from the moment the infeed sensor is triggered.
Product must be sitting onto the plates before launching the plates. Will change according to the size of
the product. Value is in milliseconds (1000ms = 1 sec)
Infeed
sensor
Plates
DELAY
PLA
TES

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Recipe manager
Here is where to copy, rename and create new recipes. This also helps to track changes.
Create a new recipe:
 Select a current recipe (1);
 Create new recipes (2), it will automatically copy the current recipe and ask to rename it;
 Press in the text box (3) and type a different name;
 Enter (4);
 Rename (5);
 Save (6).
To delete a recipe:
Select the recipe to be deleted (1) and press delete (7).
Change pages
Change pages

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Product size change (or beginning of production shifts):
To begin a new production or a production transition to a new product, please refer to the following
steps:
 Adjust the guides with the crank handle, for the space between the guides to be slightly wider
than the product;
 Select the appropriate recipe on the touch screen (1);
 Touch "Send" to register the selected recipe (2);
 Ensure that the emergency button is pulled out;
 Push the blue "reset" button;
 Touch "System on" to start the machine (5).
1
5
2

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Load wicket bags with the enhanced safety guard:
Enhanced safety guard is an option, see "Load wicket bags without the enhanced safety guard"
 Open the empty bag table cover. In case the bag table is in motion, wait until it stops
completely before opening the cover, then the open cover will prevent any movement;
 If the table is empty, remove the brooch;
 Take the wicket bags with both your hands to ensure the pack is tight together;

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 Remove the rubber under the wicket bags pack;
 Remove the cardboard backer, if necessary, as it may block the bag sensor;