Contents IDENTIFICATION... 1 Name and address of the manufacturer... 1 Declaration of conformity with standards of products... 1 Range of applications, intended use and general functions... 1 Dimensions and weight (for transport)... 2 Power for electricity and air data... 2 Installation... 2 Location of the instructions... 3 OPERATION... 4 TROUBLE SHOOTING... 4 MAINTENANCE AND CLEANING... 5 Safety and logo (Localization)... 19 Relay... 21 DANGER ZONE... 22 Safety precautions... 22 DEFINITION:... 23 Maintenance and cleaning by users.... 23 Maintenance and cleaning by qualified personnel... 24 MAINTENANCE AND REPERATIONS BY TECHNICIANS FROM KLR SYSTEMS INC.... 24 Addresses and contact information for service technicians... 24 LISTS OF SPARE PARTS AND CONSUMABLES... 25 DECOMMISSIONING OF THE PRODUCT... 25 0
IDENTIFICATION KLR.5100 Bagels bagger Left/right: right SERIAL NUM: 201616 Name and address of the manufacturer KLR SYSTEMS INC. 565 DESRANLEAU EST, SAINT-HYACINTHE, QUEBEC, CANADA J2T 2L 9 Declaration of conformity with standards of products CE Range of applications, intended use and general functions The equipment is design to pack bagel automatically, included all servo motor technology, chute could be quickly changed for different bagel size you can add bags while the machine is running. SPEED: pack 40 to 50 bags per minute. Can pack four, five or six bagels per bag. Made of stainless steel and anodize aluminium. 1
The control is assured by a state of the hart CIP motion controller. Equipped with ETHERNET communication. You can choose between two different set ups (left hand or right hand). The conveyor is equipped with a start and stop option to get tighter bags. The KWIK LOK machine can be adapted to this system. Dimensions and weight (for transport) Height: 72,2 inches Length: 91 inches Width: 93.5 inches Power for electricity and air data ELECTRICAL 220 VOLTS 15 AMPS 3 PH 60 HZ PNEUMATIC 10 CFM @ 90 PSI Installation To be check before installation Check proper voltage before turn on the power on the machine Check if all legs are level and stable on the floor Make sure nothing else than bread product sitting on the belt Check for proper belt tracking Procedure for unpacking Remove all red marked screws from the wood box. Remove all lag bolt from the legs. With a fork lift gently lift the machine from underneath the frame. Move back with the fork lift drop the machine as low as possible as soon you are out from the wood box. Requirements for fixing/anchoring and vibration damping When proper location is find, proceed with levelling the legs Drill at least one ancrage per legs Minimum space required for use (men on the layout drawing) 2
Location of the instructions Inside the control panel 3
OPERATION Training users, training courses are highly recommended given the complexity of the product, the indications to observe, the protection of persons and the instructions for the detection of faults. TROUBLE SHOOTING PROBLEM SYMPTOMS SOLUTIONS Machine won t Start 1- Emergency button depressed 2- One of the cover is still open 3- Drive Error 1. Pull off the emergency button, press reset and press start 2. When the sensor start flashing green, look at all the door sensor light. If one of them is red close the door related to the sensor. Press the reset button and press start 3. Open the electrical box. Look at error code on the drive and refer to page 112 of the Allen Bradley Kenetix 350 Manual for solution. Visit Allen Bradley Web site for PDF version : http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2097- um002_-en-p.pdf 4
MAINTENANCE AND CLEANING Pusher Motor Replacement Instruction 1. Turn off the equipment and put a padlock on the electrical box 2. Unscrew the side outfeed cover (6 screws) 3. Unscrew the set cap s screw on the head of the gear box 4. Inside the gear box, loose the socket head cap screw 5. Disconnect the electricity on the motor (2 connections) 6. Unscrew the bolts of the motor s support (4) 7. Take off the motor 8. Fix the new motor on the support (4 bolts) 9. Reconnect the electricity 10. Inside the gear box, tight the socket head cap screw 5
11. Screw the set cap s screw on the head of the gear box 12. Put back the outfeed cover Rotary Motor Replacement Instruction 1. Turn off the equipment and put a padlock on the electrical box 2. Unscrew the front outfeed cover (6 screws) 3. Open the hood of the bagger 4. Unscrew the set cap s screw on the head of the gear box 5. Inside the gear box, loose the socket head cap screw 6. Disconnect the electricity on the motor (2 connections) + the cable s clamp (2 clamps) 7. Unscrew the bolts of the motor s support (1) 8. Take off the motor 9. Fix the new motor on the support (1 bolt) 6
10. Reconnect the electricity + and fix the cable with the cable s clamp. 11. Inside the gear box, tight the socket head cap screw 12. Screw the set cap s screw on the head of the gear box 13. Put back the outfeed cover Outfeed Motor 1. Turn off the equipment and put a padlock on electrical box 2. Disconnect the electricity on the motor (2 connections) + the cable s clamp (2 clamps) 3. Unscrew the bolts of the motor s support (4) 7
4. Take off the motor 5. Unscrew the Love Joy s junction on the shaft of the motor 6. Put the Love Joy s junction on the new motor 7. Fix the new motor on the support (4 bolts) 8. Reconnect the electricity + and fix the cable with the cable s clamp. 8
Dispatch Motor Instruction 1. Turn off the equipment and put a padlock on electrical box 2. Disconnect the electricity on the motor (2 connections) + the cable s clamp (6 clamps) 3. Unscrew the bolts of the motor s support (4) 4. Take off the motor 5. loose the set screw on the pinion gear 6. Take off the pinion gear 7. Put the pinion on the new motor 8. Tight the pinion gear 9. Fix the new motor on the support (4 bolts) 9
10. Reconnect the electricity + and fix the cable with the cable s clamp. Conveyor Stopper Motor Replacement Instruction 1. Turn off the equipment and put a padlock on electrical box 2. Unscrew the cover of the motor s electrical box 3. Unscrew the electricity ground 4. Untwist the twist-on wire connection (3) 5. Unscrew the 90 degrees electric connector (PE-00106) 6. Loose the bolt of the motor s support (2) and push the motor forward to loose the belt. 10
7. Unscrew the bolts of the motor s support (4) 8. Take off the motor 9. Unscrew the timing pulley 10. Fix the Timing pulley on the new motor 11. Fix the new motor on the motor s support (4 bolts) 12. Tight the belt by pushing backward the motor support and tight the bolt (2) to fix the position 13. Put back the 90 degrees electric connector 14. Twist all the twist-on wire (Each wire s color have to be matched) 15. Put back the electric ground 16. Put back the cover of the motor electrical box N.B.: If the motor start turning in wrong direction, Untwist the blue and red wire in the electrical box and match the blue color and red color by twisting them together. 11
Conveyor Infeed Motor replacement Instruction 1. Turn off the equipment and put a padlock on the electrical box 2. Unscrew the belt cover guard (3 screws) 3. Unscrew the cover of the motor s electrical box 4. Unscrew the electricity ground 5. Untwist the twist-on wire connection (3) 6. Unscrew the 90 degrees electric connector (PE-00106) 7. Loose the bolt of the motor s support (5) and push the motor forward to loose the belt. 8. Unscrew the timing pulley 9. Unscrew the bolts of the motor s support (4) 10. Take off the motor 11. Fix the new motor on the motor s support (4 bolts) 12. Fix the Timing pulley on the new motor 13. Tight the belt by pushing backward the motor support and tight the bolt (3) to fix the position 14. Put back the 90 degrees electric connector 15. Twist all the twist-on wire (Each wire s color have to be matched) 16. Put back the electric ground 17. Put back the cover of the motor electrical box 18. Put back the belt guard N.B.: If the motor start turning in wrong direction, Untwist the blue and red wire in the electrical box and match the blue color and red color by twisting them together. 12
BELTS Drive s Belt Infeed Instruction 1. Turn off the equipment and put a padlock on the electrical box 2. Unscrew the belt cover guard (3 screws) 3. Loose the bolt of the motor s support (5) and push the motor forward to loose the belt. 4. Put the new belt 5. Tight the belt by pushing backward the motor support and tight the bolt (3) to fix the position 6. Put back the belt guard Infeed belt Instruction 1. Turn off the equipment and put a padlock on electrical box 2. Take off the yellow junction 13
Top pusher drive belt Instruction 1. Turn off the equipment and put a padlock on electrical box 2. Loose the bearing bolt (2) 3. Push the bearing to loose the belt 4. Take off the belt 5. Put the new belt 6. Tight the belt by pushing the bearing in the opposite way. 7. Tight the bearing bolt (2) Bottom Pusher Drive Belt Instruction 1. Turn off the equipment and put a padlock on the electrical box 14
2. Unscrew the side outfeed cover (6 screws) 3. Disconnect the electricity on the motor (2 connections) 4. Unscrew the bolts of the motor s support (4) 5. Take off the motor support 6. Loose the bolt (2) of the drive s shaft support 7. Push the belt drive support forward to loose the belt tension 8. Take off the belt 9. Put a new belt and pull the belt drive support backward to tight the belt 10. Tight the bolt (2) of the drive shaft support to fix the position 11. Fix the motor s support (4) 12. Connect the electricity to the motor (2 connections) 13. Fix the side outfeed cover Pusher Homing Sequence 1- On the screen, below the PUSHER title, press HOME to position the pusher. 2- Verify if the indication is in the right position with the linear bearing. If not, you ll need to move the home sensor position. 3- Verify if the top pusher position match with the indication. If not, loose the bearing support and loose the tension of the belt. Make the belt jump a few teeth until you have a perfect match with the position. (see next page) 15
Rotary Homing Sequence 1- On the screen, below the Rotary title, press HOME. To position the Rotary 2- On the screen, change the value of the home position until the position match 3- To Align the Rotary bucket, loose the bolt of the timing pulley to align each bucket. See picture for right and wrong position Right Position Wrong position 16
The Chute assemblage 1. Unscrew the set cap s screw on the head of the gear box 2. Pull off the gear box 3. Unlock the slider s Chute (Yellow Lock) 17
4. Pull the chute out of the machine 5. To pull the Chute out of his support, lift the chute s frame to pull it out Product Corridor Adjustment 1- Turn off the equipment and put a padlock on the electrical box 2- Turn the black handle to adjust the width for the product size Stopper position adjustment 1- Turn off the equipment and put a padlock on the electrical box 2- Use the black handle to adjust the positon of the stopper, the top palm has to stop the second product to go in the chute 18
Safety and logo (Localization) Safety (7) Emergency button (1) Notice : The bag door table works in parallel with bag table. If the bag table is pulled out of position the equipment won t work. You can open the table s door during operation to reload the bag magazine without stopping the operation. 19
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Relay To work in junction with another equipment (ex: Rotary Slicer). Make sure to plug the relay cable to the relay input. If it s not plugged correctly the bagger won t work. 21
DANGER ZONE Make sure there s not space between the two equipment when system work in relay. Safety precautions Always put a padlock on the electrical box before processing to any operation of maintenance with the equipment We highly recommend to turn off and disconnect the equipment for all maintenance and cleaning. Pleased check that you have enough space to work and to open the equipment for maintenance. Any modification made on the equipment regarding, mechanical aspect, safety sensor, electricity, design or any part that are closely related to the equipment will avoid all guaranty and responsibility from KLR Systems. If a modification is required, please contact KLR Systems for approval. All technical manipulation has to be made by a qualified technician or a technician from KLR Systems. We re not responsible for any abuse, wrong manipulation, wrong utilization, wrong maintenance and reparation made by the owner, qualified technician and users. 22
DEFINITION: Danger : eventual source of injury or risk for the health. Danger Zone : All zone in or out of the equipment or in contact with the equipment. Person Exposed : All people that is in danger zone. Users : Person responsible to only operate the equipment with required training. Qualified personnel : Person who have received a training from KLR Systems for maintenance and possible issue related to the equipment. risk : possibility of potential event that can put in danger any person who are in the danger zone. Physical Safety : Physical part of the equipment made to reduce a risk of danger Safety device : Device (other than physical safety) made to reduce a risk of danger related or not with a physical safety. Normal use : operation of the equipment regarding the instruction Abuse, wrong utilization, wrong maintenance, wrong manipulation : operation of the equipment that are in contradiction with the instruction that can be related to a predicable human comportment Maintenance and cleaning by users. Recommendation: Safety: We recommend to blow air on each belt to avoid obstruction of the machine after each day of operation We recommended to call a qualified technician for any mechanical and electric issues All operation have to be made in a safe environment and proper condition to avoid any risk of damage on the equipment and for the safety of the users The Equipment have to be turned off to perform any maintenance and cleaning operation Regular Checks Before each utilization, please check if all belt are rolling in the proper direction and if there s no noise that come from the bearing. Contact a qualified technician for any maintenance regarding the bearing or the belt. If you see any suspicious problem that could damage the equipment or the safety of the user, please contact a qualified technical 23
Maintenance and cleaning by qualified personnel Recommendation: Safety: We recommend to blow air on each belt to avoid obstruction of the machine after each day of operation We recommended to refer to the manual or to a technician from KLR System for any mechanical and electric issues All operation have to be made in a safe environment and proper condition to avoid any risk of damage on the equipment and for the safety of the user The Equipment have to be turned off to perform any maintenance and cleaning operation Regular Checks Before each utilization, please check if all belt are rolling in the proper direction and if there s no noise that come from the bearing. Contact a qualified technician for any maintenance regarding the bearing or the belt. Each 3 month check all the bearing to make sure there s no noise and they can safely turn. Put some grease on it each 3 months. Use the proper grease (food grade grease). If you see any suspicious problem that could damage the equipment or could put in danger the safety of the user, please contact a technical from KLR Systems For any adjustment refer to the manual. For trouble shooting, refer to the drive manual (link in the trouble shooting section of the manual) or contact a technical from KLR Systems. MAINTENANCE AND REPERATIONS BY TECHNICIANS FROM KLR SYSTEMS INC. We recommend to contact a technician from KLR for any trouble shooting that can t be solve by qualified personnel. For all drive, programming and software issues, please call 1-800-918-8777. Addresses and contact information for service technicians Please call: 1-800-918-8777. Or email at: info@klrsystems.com KLR SYSTEMS INC. 565 DESRANLEAU IS, SAINT-HYACINTHE, QC, CANADA J2T 2L 9 (450)774-8338 24
Info@klrsystems.com www.klrsystems.com LISTS OF SPARE PARTS AND CONSUMABLES Annexed document DECOMMISSIONING OF THE PRODUCT It is advisable to plan a tour of KLR to reinstall the equipment after a prolonged deactivation or a move. 25