KLR 5051 User manual

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
0
TABLE OF CONTENTS
0.0: REVISIONS NOTICES ............................................................................................................................... 4
1.0: SAFETY PRECAUTIONS ............................................................................................................................ 5
2.0: IDENTIFICATION ..................................................................................................................................... 7
2.1: Product brand and type designation: ................................................................................................ 7
2.2: Name and manufacturer contact: ..................................................................................................... 7
3.0: PRODUCT SPECIFICATION ...................................................................................................................... 8
3.1: Right or left version ............................................................................................................................ 8
3.2: General functions intended use:........................................................................................................ 9
3.3: Dimensions for transport ................................................................................................................... 9
3.4: Power data – Electricity and Pneumatic ............................................................................................ 9
3.4.1: Electricity data ............................................................................................................................ 9
3.4.2: Pneumatic data ........................................................................................................................... 9
3.5: Safety specification ............................................................................................................................ 9
3.5.1: Emergency button....................................................................................................................... 9
3.5.2: Sliding door ............................................................................................................................... 10
3.5.3: Safety light curtain .................................................................................................................... 10
.................................................................................................................................................................... 11
4.0: OPERATION KLR.5051 .......................................................................................................................... 11
4.1: Main screen (Operational mode) ..................................................................................................... 11
4.2: Procedure for start up...................................................................................................................... 11
4.2.1: Choosing recipes ....................................................................................................................... 11
4.2.2: Bag table adjustment ................................................................................................................ 12
4.2.3: Plate height adjustment ............................................................................................................ 12
4.2.4: Infeed guides adjustment ......................................................................................................... 13
4.2.5: Outfeed guides adjustment ...................................................................................................... 13
4.2.6: filling bag ................................................................................................................................... 14
5.0: OPERATION KLR.5051-AB ..................................................................................................................... 15
5.1: Main screen (Operational mode) ..................................................................................................... 15
5.2: Procedure for start up...................................................................................................................... 15
5.2.1: Choosing recipes ....................................................................................................................... 15
5.2.2: Bag table adjustment ................................................................................................................ 16

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
1
5.2.3: Plate height adjustment ............................................................................................................ 16
5.2.4: Infeed guides adjustment ......................................................................................................... 17
5.2.5: Outfeed guides adjustment ...................................................................................................... 17
5.2.6: filling bag ................................................................................................................................... 18
6.0: RECIPE SETTING PAGE KLR.5051 .......................................................................................................... 19
6.1: Definitions of functions and acronyms ............................................................................................ 19
6.1.2: Acronyms .................................................................................................................................. 19
6.1.3: Two step motions ..................................................................................................................... 20
6.2: Definitions of parameters ................................................................................................................ 20
7.0: RECIPE SETTING PAGE KLR.5051-AB .................................................................................................... 31
7.1: Unlock advance parameters ............................................................................................................ 31
7.2: Definitions of functions and acronyms ............................................................................................ 31
7.2.2: Acronyms .................................................................................................................................. 32
7.2.3: Two step motions ..................................................................................................................... 32
7.3: Bag management ............................................................................................................................. 32
7.4: Bagger stroke ................................................................................................................................... 34
7.5: Infeed management ......................................................................................................................... 38
7.6: Motor speed .................................................................................................................................... 40
7.7: Bag table .......................................................................................................................................... 41
7.8: Scoop ................................................................................................................................................ 43
7.9: Outfeed management ...................................................................................................................... 46
7.10: Manual adjustment ........................................................................................................................ 46
8.0: RECIPE MANAGER KLR.5051 ................................................................................................................ 49
9.0: MAINTENANCE ..................................................................................................................................... 50
9.1: Preventive maintenance schedules ................................................................................................. 50
9.2: Maintenance steps ........................................................................................................................... 52
9.2.1: Greasing ports ........................................................................................................................... 52
9.2.2: Retract plates ............................................................................................................................ 53
9.2.3: Scoop rails ................................................................................................................................. 54
9.2.4: Bag inputs module .................................................................................................................... 55
9.2.5: Bag sensor programming .......................................................................................................... 59
9.2.5: Servo belt .................................................................................................................................. 61
9.4: Stepper motor assembly for KLR.5051 ............................................................................................ 63

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
2
9.4.1: Wiring ........................................................................................................................................ 63
9.4.2: DIP switch resolution setting .................................................................................................... 65
9.5: Stepper motor for KLR.5051-X-AB ................................................................................................... 66
9.5.1: Local IP address ......................................................................................................................... 66
9.5.2: Wire stepper motor .................................................................................................................. 66
9.5.3: LED indicators description ........................................................................................................ 67
9.5.4: Set IPv4 address of the computer ............................................................................................. 68
9.5.5: Lexium Software Suite .............................................................................................................. 70
9.6: Error messages on KLR.5051-X-AB ................................................................................................... 70
9.7: Cleaning............................................................................................................................................ 70
10.0: LISTS OF SPARE PARTS AND CONSUMABLES ..................................................................................... 72
10.1: KLR.5051 ........................................................................................................................................ 72
10.2: KLR.5051-AB ................................................................................................................................... 73
11.0: Maintenance and repairs by specialized technicians from KLR Systems Inc. .................................... 74
11.1: Contact information ....................................................................................................................... 74
12.0: DECOMMISSIONING OF THE MACHINE ............................................................................................. 74
13.0: KLR.5051-L AND KLR.5051-L-AB EXPLOSED VIEWS ............................................................................ 75
13.1: Main body ...................................................................................................................................... 76
13.2: Covers ............................................................................................................................................ 77
13.3: Infeed tunnel .................................................................................................................................. 78
13.4: Infeed conveyor ............................................................................................................................. 79
13.4.1: Prefeed stepper motor for KLR.5051-X-AB ............................................................................. 80
13.5: Bottom scoop frame ...................................................................................................................... 81
13.6: Bottom scoop motor drive ............................................................................................................. 82
13.7: Bottom scoop ................................................................................................................................. 83
13.8: Upper scoop ................................................................................................................................... 84
13.9: Retract lifter ................................................................................................................................... 85
13.10: Retract motors ............................................................................................................................. 86
13.11: Slanted guard ............................................................................................................................... 87
13.12: Pneumatic .................................................................................................................................... 88
13.13: Servo motor ................................................................................................................................. 89
13.14: Bag table frame ............................................................................................................................ 90
13.15: Bag table lifter .............................................................................................................................. 91

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
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13.15.1: Retract lifter stepper motor for KLR.5051-X-AB ................................................................... 92
13.16: Bag table feeder ........................................................................................................................... 93
13.17: Bag table back side ...................................................................................................................... 94
13.18: Bag holder .................................................................................................................................... 95
13.19: Sliding door .................................................................................................................................. 96
13.20: Control panel ............................................................................................................................... 97

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
4
0.0: REVISIONS NOTICES
Coming soon:
- Recipe manager for KLR.5051-AB to be done.
- Download program for stepper motor for KLR.5051-AB.
2022-11-25: Exploded views added. Spare parts list updated.
2022-08-24: Deep switches resolution setting for KLR.5051 (9.4.2) is now explained in more details.
2022-08-23: Clarified the wiring part of integrated stepper motor 9.4 and 9.5.
2022-07-05: Added normal wiring and on bench test for Lexium Mdrive stepper motor (9.3.2 and
9.3.2.1). Added LED indicators description (9.3.3)
2022-06-16: Mdrive motor download procedure for KLR.5051-AB (in progress)
2022-04-22: Parameters for the KLR.5051-AB
2022-04-21: New 6.2 maintenance step version. Completion of the 7.0 KLR.5051-SPARE-AB. KLR.5051-
SPARE still need to be address.
2022-03-21: Initial version of the 6.0 maintenance.
2022-02-22: Initial version of the 2.0 identification, 3.0 product specification, 4.0 operation and 5.0
recipe setting page.

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
5
1.0: 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;

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
6
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 parts 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. To avoid this problem, unscrew the air regulator until it reaches
0 pressure before Turning ON the main air pressure, Then crank slowly the air supply regulator
back to 80 PSI . Go against this notice can result in a severe injury or death.

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
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2.0: IDENTIFICATION
2.1: Product brand and type designation:
Automatic Flat Bread Bagger
Models:
- KLR.5051 (Schneider)
- KLR.5051-AB (Allen Bradley)
Serial number and specification location:
On the support of the touch screen.
2.2: Name and manufacturer contact:
KLR SYSTEMS INC. Packaging systems manufacturer
Address: 944 rue des Hérons,
City, province, Country: Saint-Pie, Québec, Canada
Zip code: J0H 1W0
Phone: [phone]
Web site: http://klrsystems.com/
Technical support Email: [e-mail]
For other information: [email protected]om
KLR.5051-L (Left version) picture 2A

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
8
3.0: PRODUCT SPECIFICATION
3.1: Right or left version
Standing on the operator side of the machine (able to work with the touch screen) and looking toward
the direction of products. The hand closer to the machine tells what version (right or left).
KLR.5051 (Basic)
Left Hand
Right Hand
Touch Screen
Infeed Conveyor
Products
Products
Right outfeed
Left
outfeed
Right outfeed
Left outfeed
Bag input
picture 3A

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
9
3.2: General functions intended use:
Equipment designed to bag flat bread.
3.3: Dimensions for transport
Stand alone (without outfeed conveyor)
Height: 55"
Length: 132"
Width: 57"
3.4: Power data – Electricity and Pneumatic
3.4.1: Electricity data
See serial number specification for specific voltage since KLR offer different voltage options.
3.4.2: Pneumatic data
Flow: 5 CFM
Pressure: 80 PSI
3.5: Safety specification
3.5.1: Emergency button
Pressing the emergency stop everything in the machine instantly. It requires a second action to reset the
machine when pulled off.
Emergency button
KLR.5051-L (left version) picture 3B

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
10
3.5.2: Sliding door
Open the sliding door during operation stop instantly all moving mechanisms including conveyors. A
latch clamp prevents the door from opening unintentionally.
3.5.3: Safety light curtain
Since the bag input module is adjustable from front to rear, it creates a gap. If operator passing his hand
thought the gap, the light curtain stops instantly the moving parts inside the machine. However, the
conveyors do not stop because it does not represent a danger in that case.
Sliding door
Latch
clamp
Sa
f
ety
switch
Invisible light curtain
Adjustable bag
input
module
KLR.5051-L (left version) picture 3C
KLR.5051-L (left version) picture 3D

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
11
4.0: OPERATION KLR.5051
4.1: 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 "Procedure for startup" section for more information):
4.2: Procedure for start up
4.2.1: Choosing recipes
Press the recipe selector (1). Select the desired product to bag (2), then press SEND (3).
Unlock
the
advanced
parameters
Start/Stop
Main safety
status
Bag/minute
Send
recipe
Bag table s
afety
status
Manual load
and unload bag
button
Counter zero
Counter
Recipe
selection
Bag status
H
eight
setting
indicator
bag
table
setting
indicator
1
2
3
KLR.5051 screen picture 4A
KLR.5051 screen picture 4B KLR.5051 screen picture 4C

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
12
4.2.2: Bag table adjustment
It is important to select the recipe first. See "Choosing recipe". Look at the value for BAG TABLE
measurement on the display (1), Pull up the bag table latch (2) and adjust according to the measure (3).
Secure with the bag table latch.
4.2.3: Plate height adjustment
It is important to select the recipe first. See "Choosing recipe". Look at the PLATE setting (1) and adjust
the top crank according to the value on the display (2).
1
2
3
1
2
KLR.5051 screen picture 4D KLR.5051-L (left version) picture 4E
KLR.5051-L (left version) picture 4F
KLR.5051 screen picture 4G KLR.5051-L (left version) picture 4H

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
13
4.2.4: Infeed guides adjustment
The numbers on the scale are in inches. Adjust a little bit bigger to the product size.
4.2.5: Outfeed guides adjustment
Adjust the back gauge on the outfeed conveyor so the products sit on the belt as close as possible to the
bag closing machine without shifting on the side. If needed, fine tune on production.
Scale indicator
Adjustment crank
KLR.5051-L (left version) picture 4I
KLR.5051-L (left version) picture 4J

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
14
4.2.6: filling bag
When there is no bag, the bag status will show NO BAG.
1. Remove any cardboard and rubber retainer from the bag stack.
2. Insert wicket tips into intended holes of the bag input belt. Flatten the bags and verify under the
stack for good placement. The following drawing is for a left version, A right version is a mirror of
this.
3. Press LOAD BAGS.
Theoretical
center
KLR.5051-L bag input module picture 4N
X
X
X
Never used
KLR.5051 screen picture 4K
Bag picture 4L Bag picture 4M
KLR.5051 screen picture 4O KLR.5051 screen picture 4P

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
15
5.0: OPERATION KLR.5051-AB
5.1: 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 "Procedure for startup" section for more information):
5.2: Procedure for start up
5.2.1: Choosing recipes
Press next page to get to the recipe selector (1). Select the desired product to bag (2). Press SEND (3).
Press left arrow (4) to get back to main screen.
L
ock
the
advanced
parameters
Start/Stop
Sliding door
safety
status
Bag/minute
Manual unload
bag button
Counter zero
Counter
Next page
Height setting
reference KLR.5051-X-AB screen picture 5A
Manual load
bag button
Safety curtain
status
Infeed guide
adjustment ref.
Unl
ock
the
advanced
parameters
1
2
3
4
KLR.5051-X-AB screen picture 5B KLR.5051-X-AB screen picture 5C
Bag table position
adjustment ref.

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
16
5.2.2: Bag table adjustment
It is important to select the recipe first. See "Choosing recipe". Look at the value for BAG TABLE
measurement on the display (1), Pull up the bag table latch (2) and adjust according to the measure (3).
Secure with the bag table latch.
5.2.3: Plate height adjustment
It is important to select the recipe first. See "Choosing recipe". Look at the PLATE setting (1) and adjust
the top crank according to the value on the display (2).
1
2
3
1
2
KLR.5051-X-AB screen picture 5D KLR.5051-L-AB (left version) picture 5E
KLR.5051-L-AB (left version) picture 5F
KLR.5051-L-AB (left version) picture 5G KLR.5051-L-AB (left version) picture 5H

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
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5.2.4: Infeed guides adjustment
The numbers on the scale are in inches. Adjust according to the reference (1) with the adjustment crank
(2).
5.2.5: Outfeed guides adjustment
Adjust the back gauge on the outfeed conveyor so the products sit on the belt as close as possible to the
bag closing machine without shifting on the side. If needed, fine tune on production.
Scale indicator
Adjustment crank
1
KLR.5051-X-AB screen picture 5I KLR.5051-L-AB (left version) picture 5J
KLR.5051-L-AB (left version) picture 5K

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
18
5.2.6: filling bag
When there is no bag, the bag status will show NO BAG.
1. Remove any cardboard and rubber retainer from the bag stack.
2. Insert wicket tips into intended holes of the bag input belt. Flatten the bags and verify under the
stack for good placement. The following drawing is for a left version, A right version is a mirror of
this.
3. Press LOAD BAGS.
Theoretical center
KLR.5051-L-AB bag input module picture 5Q
X
X
X
Never used
Bag picture 5O Bag picture 5P
KLR.5051-X-AB screen picture 5M
KLR.5051-X-AB screen picture 5R KLR.5051-X-AB screen picture 5S

KLR.5051 Revision: 2022-11-25
Serial numbers: 2415 – beyond
19
6.0: RECIPE SETTING PAGE KLR.5051
 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.
Advanced Settings must be unlocked on the Main Screen to change recipe parameters.
6.1: Definitions of functions and acronyms
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.
6.1.2: Acronyms
Fwd: The bagging cycle can be split into two different actions, forward and reverse. "Fwd” Stand for
forward movement. See picture above.
Rev: The bagging cycle can be split into two different actions, forward and reverse. "Rev" Stand for
reverse movement. See picture above.
Plates (top
and bottom)
Bottom scoops (2)
Top
scoops (2)
Infeed
conveyor
KLR.5051-L (Left version) picture 6B
Bag input
KLR.5051 screen picture 6A