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KLR 5050-16 Manual

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Summary of Contents for KLR 5050-16

  • Page 2: Table Of Contents

    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...

  • Page 3: Safety Precautions

     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;...
  • Page 4  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;...

  • Page 5: Identification

    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...

  • Page 6: Product Specification

    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.

  • Page 7: Power Data - Electricity And Pneumatic

    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; ...

  • Page 8: Location Of Instructions

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

  • Page 9: Operation

    OPERATION System Status Main screen (Operational mode) Lock the Unlock the following following pages pages. Change the Start/Stop wicket bag table Bag State Counter zero Bags/minute Counter Parameters Send Recipe Selection 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"...

  • Page 10: Definitions Of Parameters

    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.
  • Page 11 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.
  • Page 12 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.
  • Page 13 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.
  • Page 14 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. Infeed conveyor Plates Change bag auto Option change automatically the bag table when it’s empty.
  • Page 15 Infeed sensor Infeed conveyor 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.
  • Page 16 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).
  • Page 17 Recipe manager Here is where to copy, rename and create new recipes. This also helps to track changes. Change pages Change pages 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; ...
  • Page 18 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;...
  • Page 19 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;...
  • Page 20  Remove the rubber under the wicket bags pack;  Remove the cardboard backer, if necessary, as it may block the bag sensor;...
  • Page 21  Insert the wicket bag rod as shown in the picture, evenly spaced on both sides of the bag table;  Some bag wicket comes with cardboard on top as well. If it is the case, remove it;  Take care to place the bags on the bag table to be sure that the products packed correctly. Ensure corners not folded and bottom of bag is free.
  • Page 22  If the top bag is damaged, discard it;...
  • Page 23  Make sure the rod (wicket) is well inserted; 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"...
  • Page 24 Load wicket bags without the enhanced safety guard:  Take the wicket bags with both your hands to ensure the pack is tight together;  Remove the rubber under the wicket bags pack;...
  • Page 25  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;  Some bag wicket comes with cardboard on top as well. If it is the case, remove it;...
  • Page 26  Take care to place the bags on the bag table to be sure that the products packed correctly. Ensure corners not folded and bottom of bag is free.
  • Page 27  If the top bag is damaged, discard it;  Make sure the rod (wicket) is well inserted;  Note: If you notice that the wicket does not stay in place during the 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;...
  • Page 28 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;...

  • Page 29: Trouble Shooting/Jam

    Trouble shooting/Jam Here are some troubles that may happen during the normal operation of the machine: Situations Causes Solutions The plates have moved forward,   Stacks of products Press the emergency but the product remain stuck in are spread out and button;...
  • Page 30 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 adjusted to the thickest product if there is many. There is an exception when the customer has really thin and thick stack of products and he is still using the same bagger (this covered in the training session).

  • Page 31: Safety Precautions

    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 done by a qualified technician or by KLR Systems.

  • Page 32: Safety Components

    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.

  • Page 33: Maintenance

    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: PREVENTIVE MAINTENANCE SCHEDULE Location Procedure Time interval Remarks Infeed conveyor 1 greasing port 3 months Change greasing ports when leaking.

  • Page 34: Maintenance Notice

    Maintenance notice READ the Careful: Here is what NOT to do to avoid damage the machine 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.
  • Page 35 Grease both top bearings; Grease both linear bearings;...
  • Page 36 Grease the up/down the shaft with food grade grease. To do so, use a brush or a nitrile glove. Raise the plate by hand and grease underneath. In use, this part is likely to be covered by dust. Please, keep it clean and lubricated. It will help greatly the machine in overall.
  • Page 37  If it is not the case, you might want to check the end bearings if they need to be changed: Part number (refer to spare part list): PM-01520  If the previous step was not concluding, you might want to check ''the up/down the shaft''. In normal case, when you raise the plates, the shaft should not bind side to side by the rod end.
  • Page 38  Verify by hand, if you can manipulate the plates forward and reverse easily. Remember that you force against a couple of mechanism like belt tension and gearbox. Try to notice any change each time you are performing the maintenance. ...
  • Page 39  Check the forward/reverse belt is always in the middle of the aluminum roller. If not, both axis (aluminum roller and the sprocket) are not parallel.  The belt must be in the middle of the sprocket;...
  • Page 40  A well-installed belt should not go over each side;  If you do that use the up and down adjustment (mostly for the first set up, then not used at all), check if it is easy to raise. The piece that is most likely to wear is the brass parts. If needed, see the part list;...

  • Page 41: Cleaning

    Cleaning Cleaning is an important part of a maintenance program. We recommend cleaning the following areas every working day. The machine must be stopped when cleaning. Cleaning interior  Open the doors to get access;  Use air blowers to remove dust; ...

  • Page 42: Lists Of Spare Parts And Consumables

    There are multiple options available for your machine. If you need to order a piece, make sure to look in the correct list. If you need assistance, see contact information. Suggested spare part list per machine for KLR.5050-16 Numbers Part numbers...

  • Page 43: Check List

    CHECK LIST START UP CHECK LIST FOR FLAT BREAD BAGGER KLR.5050-16 SERIAL NUMBER: _______________ CUSTOMER: _________________________________________ Mechanical Where Tasks Check Bag table Ensure the scoop plate has ¼ inch clearance to the Nylatron ☐N/A ☐ roller The bag table stopper is centred with the retract plates ☐N/A ☐...
  • Page 44 Pneumatic Where Tasks Check Air shut off Set air pressure up to 80 psi ☐N/A ☐ valve Machine Verify every line for leaks ☐N/A ☐ Manifold Check each output to ensure the manifold is working correctly and ☐N/A ☐ there are no leaks in every single valve state Vacuum Check the speed of the vacuum lifter ☐N/A ☐...

  • Page 45: Maintenance And Repairs By Specialized Technicians From Klr Systems Inc

    SAINT-PIE, QUEBEC, CANADA J0H 1W0 Info@klrsystems.com www.klrsystems.com LISTS OF SPARE PARTS AND FURNITURE (ANNEXE) DECOMMISSIONING OF THE MACHINE It is advisable to schedule a visit from KLR to reinstall the equipment after an extended decommissioning or relocation. Destruction, recycling, scrapping...

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