Page 1
FLAT BAGGER KLR.5050 INNOVATIVE WAY TO PUT FLAT BREAD PRODUCT INTO A BAG THE BAG IS OPENED BY A VACCUM SYSTEM, AVOIDING POTENTIAL CONTAMINATION OF THE BAG BY COMPRESSED AIR HEAD OFFICE 944 des Herons, Tel. : (450) 388-0404 order@klrsystems.com St-Pie, Quebec Canada Tel.
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 .................. 526 CHECK LIST .............................. 627 Maintenance and repairs by specialized technicians from KLR Systems Inc. .......... 829 Contact information .......................... 829 LISTS OF SPARE PARTS AND FURNITURE (ANNEXE) ................. 829 DECOMMISSIONING OF THE MACHINE .................... 829 ...
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 1 ...
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. Touch Screen Infeed Conveyor Right Hand Left Hand 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) 2 ...
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: 3 ...
Location of instructions Inside the control panel OPERATION System Status Main screen (Operational mode): Unlock the Lock the following following pages. pages Start/Stop Change the wicket bag Counter Bag State zero Counter Bags/minute Parameters Recipe Send Selection 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; ...
Page 7
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 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). 5 ...
Page 8
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 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). 6 ...
Page 9
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). 5 1 2 7 ...
Page 10
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; 8 ...
Page 11
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; 9 ...
Page 12
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. 10 ...
Page 13
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 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; 11 ...
Page 14
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 12 ...
Page 15
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: Top crank Plates Front Rear 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). 13 ...
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. 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. 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. KLR is not responsible for any abuse, mishandling, misuse, improper maintenance and repair by owners and users Equipment must be supervised when operating. 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. 14 ...
Leave doors with this label closed while the machine is running. NEVER bypass the systems put in place for the safety of the user This machine has automatic controls, as soon as all the conditions are reached, the machine is will start a movement. ALWAYS lockout the machine for any kind of maintenance or cleaning. Keep hands away from these areas 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. 15 ...
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. Verify if the protection cap is still there. Motor retract 1 greasing port 3 months Change greasing ports when leaking. Bearing up and 2 greasing ports 3 months Change greasing down retract ports when leaking. Bearing forward and 2 greasing ports 3 months Change greasing reverse of retract ports when leaking. plates Up/down shaft Grease lightly with a brush Every cleaning None ...
Maintenance steps Greasing Grease the blue bearing, one push each maintenance is enough; Grease the motor of the retract; 17 ...
Page 20
Grease both top bearings; Grease both linear bearings; 18 ...
Page 21
Grease the up/down shaft with food grade grease. To do so, use a brush or a nitryl 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. Trouble shooting Make sure the movement is easy and without restriction: 19 ...
Page 22
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 shaft. In normal case, when you raise the plates, the shaft shouldn’t bind side to side by the rod end. It should move freely. Part number (refer to the spare part list): PR‐03142‐A 20 ...
Page 23
Verify by hand if you can manipulate the plates forward and reverse easily. Remember that you force against couple of mechanism like belt tension and gearbox. Try to notice any change each time you are performing the maintenance. Make sure the both rails are clean and not damage by tool 21 ...
Page 24
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; 22 ...
Page 25
A well installed belt should not go over each side; If you do use a lot of the up and down adjustment (mostly for first setup, then not used at all), check if it is easy to raise. The piece that is most likely to wear is the brass part. If needed, see the part list; 23 ...
Cleaning Cleaning is an important part of a maintenance program. We recommend cleaning the following areas every working day. Cleaning interior Open the doors to get access; Use air blowers to remove dust; Sanitize the retract belts, both the upper and lower belts; Clean the retract scoop guards; Clean and grease the up/down shaft. Cleaning the infeed conveyor Blow with air guns on top and under; Spray sanitizer directly on the belt; Cleaning the outfeed conveyor Blow with air guns on top and under; Spray sanitizer directly on the belt; Note: Cleaning is a good time to do a visual inspection of the belts. Any cracks or wear can easily be seen during cleaning. Worn belts should be replaced before they can fail. See spare parts list in this document. 24 ...
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 above. Suggested spare part list per machine for KLR.5050‐16 Numbers Part numbers Quantity Descriptions 1 PB‐00152‐7 2 BAGGER PITA RETRACTABLE BELT 7'' WIDTH 2 P02‐00133 4 BEARING 3 PM‐01418 1 MOTOR COUPLING 4 PR‐02301‐.625 1 HUB FOR SERVO MOTOR 5 PM‐01419 1 CROSS COUPLING FOR SERVO MOTOR 6 PM‐00114 1 LINEAR BEARING 7 PP‐00535 1 VALVE PURGE 8 PP‐00521 1 ...
CHECK LIST Our internal check list for machine startup, included in the manual for reference. Note that the list is not comprehensive to all checks performed during assembly, only those of machine function on startup. START UP CHECK LIST FOR FLAT BREAD BAGGER KLR.5050‐16 SERIAL NUMBER: _______________ CUSTOMER: _________________________________________ Mechanical Where Tasks Check ☐N/A ☐ Bag table Ensure the scoop plate has ¼ inch clearance to the Nylatron roller ☐N/A ☐ The bag table stopper is centered with the retract plates The bag stopper is parallel to the bag tables. Pull test on each ☐N/A ☐ bag table to ensure correct grip tension on the bag stack. ☐N/A ☐ Ensure correct bag stopper for fitted retract plate width. (for ...
Page 29
Pneumatic Where Tasks Check ☐N/A ☐ Air shut off Set air pressure up to 80 psi 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 ☐ system When the machine is ready, check that the vacuum lifter is in down ☐N/A ☐ position. Press the E‐Stop, the vacuum lifter should not move. Bag table Check the speed of the bag table cylinder ☐N/A ☐ mechanism ☐N/A ☐ Check that the bag table cylinder is in up position at the start ...
Maintenance and repairs by specialized technicians from KLR Systems Inc. Contact information KLR SYSTEMS INC. 944 rue Des Hérons 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 28 ...
Page 34
SYSTEMES SYSTEMS Inc KLR.5050-16-L PNEUMATICS # Document Title F01-250S FLAT WASHER # 14 STAINLESS F10-250C08S SOCKET CAP 1/4-20 X 1/2" STAINLESS PP-00166 90 ELBOW 1/4 NPT F / 1/4 NPT M PP-00168 UNION CONNECTOR 3/8 TUB - 3/8 NPT FRAME...
Page 35
REDUCTOR 3/8"-1/2" BRASS FE/MA PP-00523 PLATE TO BLOCK MANIFOLD STATION PP-00531 MANIFOLD 6 STATIONS PP-00654 FILTER IN LINE 3/8 NPT VENTURY SIMPLE 3,00 mm BUSE PP-00655 AIR TUBE FLEXIBLE PR-00767 SOLENOID VALVE KLR ABS 7-12 1 SOLENOID VALVE KLR ABS 7-12 Page: 5...
Page 36
SYSTEMES SYSTEMS Inc INFEED KLR.5050-16-L # Document Title F01-375S FLAT WASHER 3/8" STAINLESS STEEL F01-500S FLAT WASHER 1/2'' STAINLESS F02-250S LOCK WASHER 1/4 STAINLESS F02-375S LOCK WASHER 3/8" STAINLESS F02-500S LOCK WASHER 1/2'' STAINLESS STEEL F06-250C20 SET SCREW 1/4-20 x 1 1/4" ZINC F10-250C48S SOCKET CAP 1/4-20 X 3"...
Page 37
SYSTEMES SYSTEMS Inc SPLIT INFEED ( OPTION ) SPLIT INFEED LEFT SIDE PAGE 8 KLR.5050-16-L # Document Title F06-250C20 SET SCREW 1/4-20 x 1 1/4" ZINC F12-190F08S FLAT HEAD 10-32 X 3/8" STAINLESS PB-00501 INFEED BELT 13" X 88 1/4"...
Page 38
SYSTEMES SYSTEMS Inc SPLIT INFEED LEFT SIDE ( OPTION ) SPLIT INFEED PAGE 7 KLR.5050-16-L # Document Title F01-500S FLAT WASHER 1/2'' STAINLESS F02-250S LOCK WASHER 1/4 STAINLESS F02-500S LOCK WASHER 1/2'' STAINLESS STEEL F10-250C48S SOCKET CAP 1/4-20 X 3" STAINLESS F11-190F04S BUTTON HEAD 10-32 x 1/4"...
Page 39
SYSTEMES SYSTEMS Inc SPLIT INFEED RIGHT SIDE ( OPTION ) SPLIT INFEED PAGE 7 KLR.5050-16-L # Document Title F01-375S FLAT WASHER 3/8" STAINLESS STEEL FRAME F01-500S FLAT WASHER 1/2'' STAINLESS PAGE 3 F02-375S LOCK WASHER 3/8" STAINLESS F02-500S LOCK WASHER 1/2'' STAINLESS STEEL F10-250C48S SOCKET CAP 1/4-20 X 3"...
Page 42
SPRING (OPTION) PAGE 16 SERVO MOTOR (OPTION) PAGE 15 MOTOR 1 PAGE 13 FRAME MOTOR 2 PAGE 3 PAGE 14 LOWER SCOOP PAGE 17 KLR.5050-16-L # Document Title F13-500C40 HEX HEAD 1/2-13 X 2 1/2" ZINC PR-04525 SUPPORT PLATE Page: 12...
Page 43
SYSTEMES SYSTEMS Inc MOTOR 1 KLR.5050-16-L # Document Title F01-500S FLAT WASHER 1/2'' STAINLESS F02-312S LOCK WASHER 5/16" STAINLESS F02-375S LOCK WASHER 3/8" STAINLESS F02-500S LOCK WASHER 1/2'' STAINLESS STEEL F03-500C NUT HEX 1/2-13 ZINC F03-500CS HEX NUT 1/2-13 STAINLESS F10-312C08S SOCKET CAP 5/16-18 X 1/2"...
Page 44
SYSTEMES SYSTEMS Inc KLR.5050-16-L # Document Title F02-312S LOCK WASHER 5/16" STAINLESS MOTOR 2 F02-375S LOCK WASHER 3/8" STAINLESS F10-190F10S SOCKET CAP 10-32 X 5/8" STAINLESS F10-312C16S SOCKET CAP 5/16-18 X 1" STAINLESS F10-375C12S SOCKET CAP 3/8-16 X3/4" STAINLESS F10-M6-1X16s...
Page 45
SYSTEMES SYSTEMS Inc SERVO MOTOR (OPTION) KLR.5050-16-L # Document Title F10-210C12S SOCKET CAP 12-24 X 0.75" STAINLESS KR-02032 Chain assembly #40 PE-00555 SERVO MOTOR PM-04003 IDLER SPROCKET PR-08040 PR-08041 SERVO MOTOR PLATE PR-08042 MOTOR PLATE PR-08051 WEIGHT PR-08052 SQUARE TUBING...
Page 46
SYSTEMES SYSTEMS Inc SPRING (OPTION) FRAME PAGE 3 UPPER SCOOP PAGE 16 KLR.5050-16-L # Document Title B375-625-075C STEEL SPACER F01-375S FLAT WASHER 3/8" STAINLESS STEEL F02-375S LOCK WASHER 3/8" STAINLESS LOWER SCOOP F13-375C16S HEX HEAD 3/8-16 X 1" STAINLESS PAGE 17 F13-375C20S HEX.
Page 47
SYSTEMES SYSTEMS Inc LOW SCOOP SCOOP OPTION PAGE 19 OPTION KLR.5050-16-L KLR.5050-16-L # Document Title # Document Title F01-250S FLAT WASHER # 14 STAINLESS PB-00152-7 RETRACTABLE BELT F02-375S LOCK WASHER 3/8" STAINLESS PB-00159 RETRACTABLE BELT 5" X 114 5/8" F02-438S LOCK WASHER 7/16"...
Page 48
SYSTEMES SYSTEMS Inc UPPER SCOOP KLR.5050-16-L # Document Title F12-375C16 FLAT HEAD 3/8-16 x 1" ZINC F13-375C12 HEX HEAD 3/8-16 x 3/4 ZINC F13-438C12S HEX. HEAD 7-16-14 X 3/4" STAINLESS F20-156i SPRING PIN 5/32'' X 1/2" P02-00133 BEARING PB-00152-4 RETRACTABLE BELT...
Page 50
SYSTEMS Inc OPTION SCOOP GUIDE OPTION SPRING GUIDE LOWER SCOOP PAGE 17 LOWER SCOOP PAGE 17 OPTION SPRING GUIDE OPTION PNEUMATIC GUIDE OPTION KLR.5050-16-L PNEUMATIC GUIDE # Document Categorie Title PR-08698 Machinage SPRING STEEL PR-08697-R Machinage/alu RIGHT SPRING BLOCK PR-08697-L Machinage/alu...
Page 51
SYSTEMES SYSTEMS Inc DOOR KLR.5050-16-L # Document Title F01-190S FLAT WASHER #10 STAINLESS F02-164S LOCK WASHER #8 STAINLESS F10-138C06S SOCKET CAP 6-32 X 3/8 STAINLESS F10-164C04S SOCKET CAP 8-32 X 1/4 STAINLESS F10-250C08S SOCKET CAP 1/4-20 X 1/2" STAINLESS F11-164C06S BUTTON HEAD 8-32 X 3/8"...
Page 52
SYSTEMES SYSTEMS Inc ADJUSTABLE GUIDE KLR.5050-16-L # Document Title B375-625-1000 COUPLING F01-312S FLAT WASHER 5/16 STAINLESS F02-312S LOCK WASHER 5/16" STAINLESS F02-375S LOCK WASHER 3/8" STAINLESS F03-375C HEX NUT 3/8-16 ZINC F10-312C48S Stainl e ss Steel Socket Head Cap Screw 5/16"-18 Thread, 3" Length F10-375C32S SOCKET CAP 3/8-16 X 1 1/4"...
Need help?
Do you have a question about the 5050 and is the answer not in the manual?
Questions and answers