KLR 5050 User manual

INNOTIVE Y TO PUT AT BREAD PRODUCT INTO A BAG
THE BAG IS OPENED BY A VACCUM SYSTEM, AVOIDING
POL CONTAMITION OF THE G BY COMPRESSED AIR

944 des Herons,
St-Pie, Quebec Canada
J0H1W0





FLAT BAGGER KLR.5050

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TABLEOFCONTENTS
Identification.................................................................................................................................................1
Productbrandandtypedesignation:........................................................................................................1
Nameandmanufacturercontact:.............................................................................................................1
Declarationofconformitytoproductstandards:......................................................................................1
ProductSpecification.....................................................................................................................................2
Generalfunctionsintendeduse:...............................................................................................................2
Dimensionsandweight:............................................................................................................................2
Powerdata–ElectricityandPneumatic....................................................................................................2
Installation.....................................................................................................................................................3
Locationofinstructions.............................................................................................................................4
OPERATION...................................................................................................................................................4
SAFETYPRECAUTIONS.................................................................................................................................14
Security....................................................................................................................................................14
Personalprotection.................................................................................................................................14
SecurityLabels........................................................................................................................................14
Safetycomponents.................................................................................................................................15
MAINTENANCE............................................................................................................................................16
Preventivemaintenanceschedule..........................................................................................................16
Maintenancesteps..................................................................................................................................17
Cleaning...................................................................................................................................................24
LISTSOFSPAREPARTSANDCONSUMABLES..........................................................................................2526
CHECKLIST..............................................................................................................................................2627
MaintenanceandrepairsbyspecializedtechniciansfromKLRSystemsInc...........................................2829
Contactinformation............................................................................................................................2829
LISTSOFSPAREPARTSANDFURNITURE(ANNEXE).................................................................................2829
DECOMMISSIONINGOFTHEMACHINE...................................................................................................2829
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1


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DesHérons,
ST‐PIE,QUEBEC,CANADA
J0H1W0
Declarationofconformitytoproductstandards:
Norms:CE






2

ProductSpecification
Howtoknowthedifferencebetweenarighthandandalefthandlayout:
Thinkyourselfinfrontoftheinfeedconveyorandlookingtowardsthemovementoftheproducts,the
handonthesideofthetouchscreenistobethesideofthemachines.

Generalfunctionsintendeduse:
Equipmentdesignedtobagflatbread.
Dimensionsandweight:
High:55"
Long:130"
Depth:45"
Powerdata–ElectricityandPneumatic
Electricity:220volts–10A–3phases–60Hertz
Pneumatic:8CFM@80PSI(lb/po²)
RightHand
LeftHand
TouchScreen
InfeedConveyor
Product

3

Installation
Procedureforunpacking:
 Ifmachineisdeliveredin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.

Floorplansrequesttoinstallthemachine:
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4

Locationofinstructions
Insidethecontrolpanel

OPERATION
Mainscreen(Operationalmode):
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

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Oncethepoweris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bagsonthebagtable.TheBagStateshouldbegreen;
 SelecttheappropriaterecipefortheproductwiththeRecipeSelectionandpress"Send"; 
 Makesurethedoorisclosedsecurely.PulltheemergencystopbuttonandpresstheResetbutton.
TheSystemsStatusindicatorwillturngreen;
 PressStartonthetouchscreenandthestatusindicatorwillchangetogreenwith“SystemOn”.




Start/Stop
BagState
Bags/minute
Send
Unlockthe
following
pages.
Lockthe
following
pages
SystemStatus
Changethe
wicketbag
Counter
zero
Counter
Parameters
Recipe
Selection

5

RecipeSettingpage:

AdvancedSettingsmustbeunlockedontheMainScreentochangerecipeparameters.
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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currentrecipeandbeableto
keeptrackofyourchanges.



Definitionsofparameters:

SpeedplateFwd:Speedatwhichtheplatesmovetoforward(RPM);
SpeedplateRev:Speedatwhichtheplatesmovewhilereturning(RPM);
Twostepmotion:Optionallowingtheplatestowaitfortheproductwhentheyareinthebag.0=not
activated,1=activated;
Halfdistance:Wherethe"two‐stepmotion"occurs(DEGREES);
Fulldistance:Placewheretheplatesfinishtheircourse(DEGREES);
Infeedconveyorspeed:Conveyorspeedofentry(RPM);
Retractbeltspeed:Speedofthebeltsoftheplates(RPM);
Outfeedspeed:Speedoftheoutputconveyor(RPM)(ifapplicable);
Stopvacuum(fwd):wherethevacuumstopswhentheplatesaremovingforward(DEGREES);
Startbaglifter(ms):Timebeforestartingthesequencebag(MILLISECONDS);
Stopbaglifter(rev):Locationwherethebagsequencestopswhentheplatesarereturning(DEGREES);
Stopvacuumlifter(rev):Placewheretheactuatorofthevacuumgoesdownwhentheplatesare
comingback(DEGREES);
Restartinfeed(ms):Waitingtimebeforetheinfeedconveyorstartingaftertheseplatescomingback
(MILLISECONDS);
Changebagauto:optionchangeautomaticallythebagtablewhenit’sempty.0=non‐activate,1=
activate;
Timeplatestayhalf(ms):Timewhentheplatesstayinhalf‐motion(MILLISECONDS).



6

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recipe(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

7


Productsizechange(orbeginningofproductionshift):

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).
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

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1
5
2

8


Loadwicketbags:
 Takethewicketbagswithbothyourhandstoensurethepackistighttogether;



 Removetherubberunderthewicketbagspack;
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



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

9
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
 Removethecardboardbacker,ifnecessary,asitmayblockthebagsensor;



 Insertthewicketbagrodasshowninthepicture,evenlyspacedonbothsidesofthebagtable;













10

 Takecaretoplacethebagsonthebagtabletobesurethattheproductsarepackedcorrectly.
Ensurecornersarenotfoldedandbottomofbagisfree.
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

11

 Ifthetopbagisdamaged,discardit;
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 Makesuretherod(wicket)iswellinserted;
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 Note:Ifyounoticethatthewicketdoesnotstayinplaceduringoperation,addinyourroutine:
bendthewicketopenoneachsidetopreventseveralproblems.Donotoverbenditsoitistoo
hardtopulloutbyhand;







12
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Ifthemachineisalreadyinoperation,andtherearestillbagsontheothertable,thebagtablewill
automaticallychangeoverwhenthefirstsiderunsoutofbags.

Ifstartinguporthebagneedstobechangedimmediately,press"ChangeBag"onthetouchscreento
initiateamanualchange;




Push

13

Topcrankadjustment



Mostofthetime,whentheKLRtechnicianhasadjustedthetopcrankaccordingtothecustomer
products.ThereisNOneedtotouchitanymore,sinceitshouldbeadjustedtothethickestproductif
thereismany.Thereisanexceptionwhenthecustomerhasreallythinandthickstackofproductandhe
stillusingthesamebagger(thismustbecoveredinthetrainingsession).

Incasetheuserwantstoaddathickerproductthathealreadyhas.Itisimportanttoknowthisfollowing
fact:

Asalever,themorethetopcrankisusedtoraisetherearpart,themorethefrontplatesgetcloseeach
other:



Theimportantis:atHOMEposition(coverclosedandresetbuttonpressed),thefrontplatesmusthave
1/16ofaninchclearancefromeachotherattheminimum.

PleasecontactKLRsystemsforfurtherassistancewiththisfeature(seenameandmanufacturer
contact).
Rear
Front
Plates
Topcrank

14

SAFETYPRECAUTIONS
Security
Alwaysbesuretolocktheelectricalboxbeforeperforminganymaintenanceontheequipment.Please
refertothelocalregulationsandlawsonlockingoutmachinery.
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Itisstronglyrecommendedtodisconnecttheequipmentwhenperformingmaintenancetoavoidanyrisk
ofdanger.Makesureyoualsohavethespacerequiredtocompletetheworktoavoidanyriskofdanger.
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Anymodificationsinconnection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.
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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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Personalprotection
Airblower:wearsafetyglasseswhenusinganairblowerforcleaning.
Clothing:longhairandlooseclothesshouldbeavoidedaroundworkingconveyorsandmovingbelts.
SecurityLabels
Securitylabelsarethereforyoursafety,keepthemcleanandlegible.Donotremovelabels,evenifitis
blockinglineofsight.Ifyoumustreplaceapiecethathasasafetylabelonit,pleaseorderalabelto
replaceitaswell.
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15
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Leavedoorswiththislabelclosedwhilethemachineisrunning.
NEVERbypassthesystemsputinplaceforthesafetyofthe
user .
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Thismachinehasautomaticcontrols,assoonasallthe
conditionsarereached,themachineiswillstartamovement.
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ALWAYSlockoutthemachineforanykindofmaintenanceor
cleaning.
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Keephandsawayfromtheseareas .
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Safetycomponents
Thismachineis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won’tstartandmustbe
replacedbeforestartingthemachine
Safetypanelorsafetydoors:Asasafetycomponent,donottrytoremoveorunscrewthemunlessitis
necessaryforamaintenanceoperation.Usealockoutdeviceduringthisprocedureandtoreassemble
everysinglepieceasitwaswhenfinished.
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16
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MAINTENANCE
Preventivemaintenanceschedule
Duetothecomplexityofourmachine,theseproceduresaresubjecttochangeandshouldbe
adequatelyadjustedinextremeconditions:
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PREVENTIVEMAINTENANCE
SCHEDULE
LocationProcedureTimeintervalRemarks
Infeedconveyor1greasingport3monthsChangegreasing
portswhenleaking.
Verifyifthe
protectioncapisstill
there.
Motorretract1greasingport3monthsChangegreasing
portswhenleaking.
Bearingupand
downretract
2greasingports3monthsChangegreasing
portswhenleaking.
Bearingforwardand
reverseofretract
plates
2greasingports3monthsChangegreasing
portswhenleaking.
Up/downshaftGreaselightlywithabrushEverycleaningNone
PREVENTIVE
TROUBLEFINDING
RetractplatesTesttheup/downarm.Raiseit
byhandupandletitgo.Checkif
thereisrestriction.
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3monthsIfthereis
restriction,thenit
mightbethe
up/downshaftthat
hasbeendryfortoo
longandisworn
out.
Movebyhandtheplateforward.
Checkifthereisrestriction.
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Don’tforgetthatit
willalwaysbealittle
difficultbyhand,
noteanychanges
overthetime.
Verifyiftheservobelt(forward
andreverse)remaininthe
centerofthealuminumroller
andthesprocket
Bothaxesmustbe
parallel.
Cleaning
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Cleanthedustwithanairblower
andsanitiseallthesurfacesthat
isincontactwithfoods.
DailyNone

17
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Maintenancesteps
Greasing
Greasethebluebearing,onepusheachmaintenanceisenough;
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Greasethemotoroftheretract;
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18
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Greasebothtopbearings;
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Greasebothlinearbearings;
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