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Cleaning and maintenance

188

EVOLUTION LINE roll machine

Emil Kemper GmbH

8.6 Maintenance contracts

Kemper is pleased to assist you with maintenance and servicing of the line. For this
purpose we offer maintenance contracts which the plant operator can negotiate and sign
with Kemper according to different operating hours.

We would like to point out, however, that maintenance and servicing of the line is always
the responsibility of the plant operator and the maintenance contract can only serve to
increase the service life and operational reliability of the line.

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Summary of Contents for EVOLUTION LINE

Page 1: ...inal operating manual EVOLUTION LINE roll machine Emil Kemper GmbH Neuenkirchener Maschinenfabrik Lange Stra e 8 10 D 33397 Rietberg Tel 49 0 52 44 402 0 Fax 49 0 52 44 40 22 20 www emil kemper de ger...

Page 2: ...ual and all images contained herein are copyright protected Any use outside the limitations of the copyright without prior written approval is forbidden and liable to prosecution This applies especial...

Page 3: ...ersonnel 8 1 10 Warranty and liability 8 2 Transport and storage 9 2 1 Inspection by the recipient on handover 9 2 2 Packaging 9 2 3 Transport information 10 2 4 Temporary storage 11 3 Installation 13...

Page 4: ...Operator controls of the roll out roller 44 5 3 5 Operator controls of the centering unit 45 5 3 6 Operator controls of the cutting station 46 5 3 7 Operator controls of the pre pressing station 47 5...

Page 5: ...1 Setting a recipe at the roll out station 103 7 4 Setting the line modules 106 7 4 1 Setting the discharge belt 106 7 4 1 1 Adjusting the height of the pressure roller 106 7 4 2 Setting the discharge...

Page 6: ...142 7 6 1 Touch panel 142 7 6 2 Operator panel 142 7 7 Behaviour after triggering safety devices 143 7 7 1 EMERGENCY STOP button 143 7 7 2 Limit switches 144 8 Cleaning and maintenance 145 8 1 Safety...

Page 7: ...ides 163 8 3 8 2 Inspecting and replacing the triangular knife 164 8 3 8 3 Checking the pneumatic equipment 165 8 3 9 Belt stamp 166 8 3 9 1 Cleaning the belt stamp 166 8 3 10 Conveyor belt 167 8 3 10...

Page 8: ...ts 185 8 4 1 Lubricant recommendations 185 8 4 2 Greases 186 8 4 3 Storage of lubricants 186 8 5 Stocking spare parts Customer Service 187 8 5 1 Stocking spare parts 187 8 5 2 Accessories 187 8 5 3 Cu...

Page 9: ...ating manual e g machine operators supervisors mechanics electricians This applies in particular to the safety information given in this chapter It is also necessary to obey the accident prevention ru...

Page 10: ...following this mark describes actions to be performed in the specified order Text in single quotation marks indicates screens on the touch panel Text in double quotation marks refers to other chapter...

Page 11: ...Wear the necessary personal protective equipment e g safety shoes whenever working at the line These must be provided by the plant operator and must satisfy the requirements It is also necessary to o...

Page 12: ...device cabling with plugs and sockets tested by an electrical specialist or by a trained person using suitable inspection facilities every 6 months at least Equipment is non fixed if by its nature and...

Page 13: ...a clean towel helps prevent baker s eczema 1 3 7 Information for emergencies In emergencies always press the EMERGENCY STOP button red mushroom button on a yellow background Extinguish any burning oil...

Page 14: ...se which is deemed to be common practice due to design configuration and function of the technical product To keep the line functional it is only allowed to be used as intended according to DIN 31000...

Page 15: ...ication systems and devices and cleaning with solvents All parts of the electrical installations must be protected from moisture humidity and dust Before all cleaning work on the line shut off electri...

Page 16: ...uded if they are attributable to one or more of the following causes Unintended or inappropriate use of the line Inappropriate installation commissioning operating or maintenance of the line Operation...

Page 17: ...ediately report any transport damage to the transporting organisation 2 2 Packaging The method of transport partly determines the type of packaging Unless a special contractual agreement exists the pa...

Page 18: ...st be taken when transporting this line in order to avoid damage from extraneous elements or from careless loading and unloading The line may be delivered on a pallet depending on the type and duratio...

Page 19: ...ry storage If the line is not installed immediately after delivery it must be carefully stored in a protected place The line must be temporarily stored so that no dust and no moisture can enter Note N...

Page 20: ...Transport and storage 12 EVOLUTION LINE roll machine Emil Kemper GmbH...

Page 21: ...e line is erected by Emil Kemper GmbH according to the line documentation that is delivered in advance The dimensions space requirements and weights can be seen there Note To ensure correct installati...

Page 22: ...hoice of installation site 3 2 1 Necessary operating and maintenance space Note When choosing the installation site make sure there is enough operating and maintenance space The space at the line shou...

Page 23: ...ecting the line The line may have been transported on a pallet In this case the line modules are secured on the pallet with belts Note Please refer to the layout provided by Emil Kemper GmbH to see mo...

Page 24: ...ies and line modules see section 3 4 2 Rating plate Note The line can be connected to a 300 mA residual current operated circuit breaker We recommend a residual current operated circuit breaker that i...

Page 25: ...ion of rating plates on the assemblies and line modules 3 4 2 1 Line Note The illustration below contains optional assemblies and line modules which may not be included in the line s scope of delivery...

Page 26: ...GmbH 3 4 2 2 Roll out station Configuration of the assembly Roll out station in the line is displayed in chapter 5 Overview of the line Make sure that existing electrical equipment corresponds to the...

Page 27: ...allation Emil Kemper GmbH EVOLUTION LINE roll machine 19 3 4 2 3 Reciprocating belt Make sure that existing electrical equipment corresponds to the values shown on the rating plate see illustration be...

Page 28: ...ation 20 EVOLUTION LINE roll machine Emil Kemper GmbH 3 4 2 4 Reciprocating belt AB60 1 Make sure that existing electrical equipment corresponds to the values shown on the rating plate see illustratio...

Page 29: ...ntended use determine optimum handling instruct operating personnel and pass on additional advice for maintenance and servicing Note When the line is commissioned by Emil Kemper GmbH the demonstrator...

Page 30: ...Commissioning 22 EVOLUTION LINE roll machine Emil Kemper GmbH...

Page 31: ...rator controls Note For the head machine details about this chapter can be found in the separate user manual of the head machine 5 1 1 Overview of the basic module assembly The following illustration...

Page 32: ...ed in the line s scope of delivery The following illustration displays configuration of the line modules and components of the roll out station assembly on the left in running direction 1 Long mouldin...

Page 33: ...low give an overview of the line modules function elements 5 2 1 Function elements of the basic module Note The illustration below contains optional line modules which may not be included in the line...

Page 34: ...ssure roller line module Note The illustration of the pressure roller line module resembles the version that is delivered The version that is delivered may include a hand guard and a flexible shaft to...

Page 35: ...he illustration of the pressure roller line module resembles the version that is delivered The version that is delivered may include a hand guard and a flexible shaft to move the adjusting wheel to op...

Page 36: ...Overview of the line 28 EVOLUTION LINE roll machine Emil Kemper GmbH 5 2 4 Function elements of the roll out roller 1 Roll out roller 3 Adjusting wheel for the roll out roller 2 Scraper...

Page 37: ...roll machine 29 5 2 5 Function elements of the centering unit Note The schematic diagram below describes the centering unit The version that is delivered may differ from the version shown here 1 Hold...

Page 38: ...Overview of the line 30 EVOLUTION LINE roll machine Emil Kemper GmbH 5 2 6 Function elements of the cutting station 1 Triangular knife 3 Centering unit 2 Hold down...

Page 39: ...5 2 7 Function elements of the pre pressing station Note The schematic diagram below describes the pre pressing station line module The version that is delivered may differ from the version shown her...

Page 40: ...LINE roll machine Emil Kemper GmbH 5 2 8 Function elements of the conveyor belt Note The schematic diagram below describes the conveyor belt The version that is delivered may differ from the version s...

Page 41: ...ion elements of the flour duster with flour break up shaft Note The schematic diagram below describes the flour duster with break up shaft The version that is delivered may differ from the version sho...

Page 42: ...Overview of the line 34 EVOLUTION LINE roll machine Emil Kemper GmbH 5 2 10 Function elements of the long moulding belt 1 Linear drive adjustment 3 Conveyor belt drive 2 Top belt...

Page 43: ...LINE roll machine 35 5 2 11 Function elements of the folding mats Illustration on the left in running direction 1 Top receiver x2 4 Handle x2 2 Receiver side rail 5 Wire mesh belt x4 3 Receiving shaf...

Page 44: ...Overview of the line 36 EVOLUTION LINE roll machine Emil Kemper GmbH Illustration on the right in running direction 1 Folding flap x4...

Page 45: ...the line Emil Kemper GmbH EVOLUTION LINE roll machine 37 5 2 12 Function elements of the alignment and pressure roller timing roller 1 Holder 3 Pressure roller adjustment mechanism 2 Pressure roller...

Page 46: ...Overview of the line 38 EVOLUTION LINE roll machine Emil Kemper GmbH 5 2 13 Function elements of the reciprocating belt 1 Belt 3 Baking tray discharge table 2 Baking tray side stop...

Page 47: ...Overview of the line Emil Kemper GmbH EVOLUTION LINE roll machine 39 5 2 14 Function elements of reciprocating belt AB60 1 1 Belt...

Page 48: ...ollowing sections provide an overview of the operator controls of the individual line modules 5 3 1 Operator controls of the basic module On the left in running direction The following illustration di...

Page 49: ...ne Emil Kemper GmbH EVOLUTION LINE roll machine 41 On the right in running direction The following illustration displays the basic module on the right in running direction 1 Operator panel of the stea...

Page 50: ...includes the pressure roller line module Note The illustration of the pressure roller resembles the version that is delivered The version that is delivered may include a hand guard and a flexible shaf...

Page 51: ...The illustration of the pressure roller line module resembles the version that is delivered The version that is delivered may include a hand guard and a flexible shaft to move the adjusting wheel to o...

Page 52: ...Overview of the line 44 EVOLUTION LINE roll machine Emil Kemper GmbH 5 3 4 Operator controls of the roll out roller 1 Adjusting wheel for the pressure roller...

Page 53: ...l machine 45 5 3 5 Operator controls of the centering unit Note The schematic diagram below describes the centering unit The version that is delivered may differ from the version shown here 1 Handle o...

Page 54: ...LINE roll machine Emil Kemper GmbH 5 3 6 Operator controls of the cutting station 1 Triangular knife adjusting wheel 4 Centering unit arrester lever 2 Timing adjusting wheel 5 Centering unit adjusting...

Page 55: ...roll machine 47 5 3 7 Operator controls of the pre pressing station Note The schematic diagram below describes the pre pressing station line module The version that is delivered may differ from the ve...

Page 56: ...bH 5 3 8 Operator controls of the flour duster with flour break up shaft Note The schematic diagram below describes the flour duster with break up shaft The version that is delivered may differ from t...

Page 57: ...49 5 3 9 Operator controls of the long moulding station top belt Note The schematic diagram below describes the long moulding station top belt The version that is delivered may differ from the versio...

Page 58: ...the line 50 EVOLUTION LINE roll machine Emil Kemper GmbH 5 3 10 Operator controls of the folding mats 1 Adjusting lever for the folding flaps 3 Star shaped handle lock 2 Receiving shaft for the wire...

Page 59: ...Overview of the line Emil Kemper GmbH EVOLUTION LINE roll machine 51 5 3 11 Operator controls of the alignment and pressure roller timing roller 1 Adjusting wheel for the pressure roller...

Page 60: ...Overview of the line 52 EVOLUTION LINE roll machine Emil Kemper GmbH 5 3 12 Operator controls of the reciprocating belt 1 Adjusting wheel for baking tray side stop 2 Baking tray discharge table...

Page 61: ...Overview of the line Emil Kemper GmbH EVOLUTION LINE roll machine 53 5 3 13 Reciprocating belt AB60 1 1 Operator panel EMERGENCY STOP 2 Row of buttons optional...

Page 62: ...54 EVOLUTION LINE roll machine Emil Kemper GmbH 5 4 Overview of safety devices 1 EMERGENCY STOP button on the operator panel 2 EMERGENCY STOP button on the touch panel Note All the doors are secured...

Page 63: ...he respective pieces of dough The intermediate proofer is used to hold and for intermediate proofing of the pieces of dough They are transported through the intermediate proofer via the proofing frame...

Page 64: ...ia the head machine s control system 6 4 Roll out roller The roll out roller uses a chrome roller to roll out the pieces of dough into an adjustable flat shape The stainless steel roller is adjusted m...

Page 65: ...an adjusting wheel A hold down fixes the dough pieces during pre pressing on the timing belt Control is via the line s or head machine s touch panel 6 8 Conveyor belt The conveyor belt transports the...

Page 66: ...ng edge to raise the flattened pieces of dough thus creating a fold in them The pieces of dough are subsequently moved underneath the wire mesh belts The wire mesh belts wind the pieces of dough at th...

Page 67: ...hwise in the programmed sequence This ensures that the edges of the baking trays and the wooden boards can be considered during programming Programming occurs via the line s control unit If desired by...

Page 68: ...d Live parts Danger of electric shock Always disconnect the line before carrying out work in the switchbox Work at the switchbox should only be carried out by a qualified electrical specialist It is n...

Page 69: ...OP button Stops the line immediately 3 CONTROL VOLTAGE ON button Switches the line control voltage on 4 Control lamp control voltage doors Extinguishes when opening a door 5 Control lamp control volta...

Page 70: ...hould only be accessed by experienced persons or after consultation with competent employees at Emil Kemper GmbH The menus are protected by different passwords depending on the users level of knowledg...

Page 71: ...Description of the line Emil Kemper GmbH EVOLUTION LINE roll machine 63 6 17 2 Structure of the main and sub menus...

Page 72: ...stration below contains optional assemblies and line modules which may not be included in the line s scope of delivery The start screen appears after switching on the control voltage The line is then...

Page 73: ...d in the red box There are respective status displays for the operating status green On red Off underneath the illustrations of the line and the head machine The time is shown at the top left on each...

Page 74: ...llustration 2 Open the menu of the head machine by touching the illustration optional Recipe button 3 Display and select the recipe Input of new recipe names for example 5 Cut rolls START button Start...

Page 75: ...4 5 The corresponding assembly menus open after touching the illustration of a desired assembly on the start screen Illustration of the head machine 1 Multimatic menu Illustration of the basic module...

Page 76: ...ttons CAPACITY button Capacity menu PARAMETER button Proofer menu SERVICE button Service proofer menu PROGRAM button Display and select recipes START button Start the line STOP button Stop the line AC...

Page 77: ...menu HOURLY CAPACITY Input of the hourly capacity of pieces of dough The control then calculates the cycle in rpm for the proofing frames The calculated value is displayed SPEED RPM Display of the cal...

Page 78: ...screen PARAMETER button The Proofer menu appears after pressing the PARAMETER button In the sub menu Proofer menu you can change the operating mode of the proofer INLET POSITION Selection of Lower or...

Page 79: ...between 5 and 12 pulses DOWN The interval period under Down of the centring unit can be set between 1 and 17 pulses START button Start the line STOP button Stop the line Finally the buttons for saving...

Page 80: ...ons CAPACITY button Capacity menu PARAMETER button Roll out station menu SERVICE button Roll out station service PROGRAM button Display and select recipes START button Start the line STOP button Stop...

Page 81: ...the capacity values of the line by touching the respective input boxes in the Capacity menu Note The Capacity menu is also used in other menus It is always identical see section 6 17 4 1 Proofer menu...

Page 82: ...u item Top belt option long moulding belt to select between four settings OFF The top belt drive is switched off SYNCHRONOUS The top belt and the bottom belt run in the same direction but the speed is...

Page 83: ...pulses DUSTING QUANTITY Input of the speed of the round brushes in the flour duster in Hertz In the optional menu item Timing roller use the drop down menu to select between the following four alignm...

Page 84: ...he line SAVE button to save the inputs Password level 7 is required for saving BACK button to return to the Moulding station menu BACK button to return to the start screen SERVICE button This button i...

Page 85: ...g station menu TIMING BELT button multistation Conveyor belt Centering unit Belt stamp menu SERVICE button Not assigned Recipe number button Display and select recipes START button Start the line STOP...

Page 86: ...put boxes in the Capacity menu Note The Capacity menu is also used in other menus It is always identical see section Fehler Verweisquelle konnte nicht gefunden werden Fehler Verweisquelle konnte nicht...

Page 87: ...can be entered in the Centering unit box to set the timing In the Knife running time submenu you can compensate for the triangular knife s different running times during the outward and return strokes...

Page 88: ...dentical see section Fehler Verweisquelle konnte nicht gefunden werden Fehler Verweisquelle konnte nicht gefunden werden Finally the buttons for operation saving and navigation START button Start the...

Page 89: ...nu CAPACITY button Capacity menu PARAMETER button Reciprocating belt menu BELT POSITION button option Reciprocating belt menu SERVICE button Service reciprocating belt Program button Display and selec...

Page 90: ...the capacity values of the line by touching the respective input boxes in the Capacity menu Note The Capacity menu is also used in other menus It is always identical see section 6 17 4 1 Proofer menu...

Page 91: ...sizes located on the extending table ROWS LONGITUDINAL Input of the number of rows of pieces of dough located on the wooden board baking tray CORRECTION STEP Input of a correction value for the step...

Page 92: ...and 50 Hertz BASIC POSITION Input of the return speed to the basic position between 15 and 30 Hertz In the menu item Location touch the drop down menu to select the following three settings TABLE ACCE...

Page 93: ...t Release is issued automatically after each stroke Finally the buttons for operation saving and navigation START button Start the line STOP button Stop the line SAVE button to save inputs Password le...

Page 94: ...nicht gefunden werden Fehler Verweisquelle konnte nicht gefunden werden Finally the buttons for operation saving and navigation START button Start the line STOP button Stop the line SAVE button to sa...

Page 95: ...NE roll machine 87 6 17 5 RECIPE button The following display appears after pressing the button with the current recipe name Enable recipe Start Stop 11 27 35 14000 pcs h Head machine Line 1 0 01 02 0...

Page 96: ...ame a window and a keypad appear for password input After entering this data the Enable recipe button switches to Text input The Text input button then flashes red Touch a name box to assign a new rec...

Page 97: ...rection appears on the start screen after pressing the flashing Info button The error source is marked red in the line fault image START button Start the line STOP button Stop the line ACK button Ackn...

Page 98: ...een eliminated within a line module See the following section 6 17 7 ACK BUTTON Note Not all error sources have to be acknowledged If the fault in the line module has been eliminated press the ACK but...

Page 99: ...Emil Kemper GmbH PASSWORD LIST button List of users and passwords administrator OPERATING HOURS button Display of operating hours with value DISPLAY button Display of service parameters cleaning image...

Page 100: ...button to return to the start screen 6 18 Safety devices and guards The line is equipped with the following safety devices also see chapter 5 Line overview EMERGENCY STOP button on the touch panel EME...

Page 101: ...t de energized after pressing the EMERGENCY STOP button The line is still under power See section 7 7 Behaviour after triggering safety devices 6 18 3 Limit switches If an access door is opened while...

Page 102: ...Description of the line 94 EVOLUTION LINE roll machine Emil Kemper GmbH...

Page 103: ...ribed in the following sections Note For the head machine details about this chapter can be found in the separate user manual of the head machine 7 1 Switching the line on and off Switching on Turn th...

Page 104: ...the CONTROL VOLTAGE ON button 1 7 3 Setting assemblies The following sections describe operation of the assemblies 7 3 1 Basic module 7 3 1 1 Switching on the steam generator system The operator pane...

Page 105: ...GmbH 7 3 1 3 Setting a recipe at the basic module Note The touch control contains recipes which have been set by Emil Kemper GmbH according to your wishes This section describes all the necessary wor...

Page 106: ...er GmbH Touch the illustration of the basic module on the start screen The Proofer menu opens after touching the illustration of the basic module on the start screen Start Stop 10 59 59 00000 pcs h He...

Page 107: ...enu to change the proofer settings The Capacity menu opens after pressing the CAPACITY button Note The Capacity menu can be opened from the menu of all the assemblies It is always identical Start Stop...

Page 108: ...ces of dough in pcs h Attention The rows in the Capacity menu should only be changed after retooling the assemblies to the corresponding rows Otherwise components may be damaged Touch the input box RO...

Page 109: ...e button to save your settings in the displayed recipe Password level 7 is required for saving Press the button Pressing the button opens the Proofer menu In the Proofer menu press the PARAMETER butto...

Page 110: ...splay to toggle between Lower green dough and Upper intermediate proofer Note Operation of the menu item Centring is described in secSetting the centering unittion 7 4 5 Setting the centering unit Pre...

Page 111: ...cipes at the roll out station assembly Switch the line on see section 7 1 Switching the line on and off Switch the control voltage on see section 7 2 Switching the control voltage on Open the desired...

Page 112: ...e CAPACITY button is available in the menus of all the assemblies see section 7 3 1 Basic module In the Roll out station menu press the PARAMETER button to change the settings of the roll out station...

Page 113: ...ration when touched Note Operation of the menu item Top belt option is described in section Fehler Verweisquelle konnte nicht gefunden werden Fehler Verweisquelle konnte nicht gefunden werden Note Ope...

Page 114: ...press the button to open the start screen 7 4 Setting the line modules The following sections describe operation of the line modules of the assemblies 7 4 1 Setting the discharge belt Configuration o...

Page 115: ...ing the pressure roller height on the pressure roller line module Note The illustration of the discharge belt includes the pressure roller line module Note The illustration of the pressure roller line...

Page 116: ...ine is displayed in section 5 Overview of the line 7 4 3 1 Adjusting the height of the pressure roller Note The illustration of the pressure roller line module resembles the version that is delivered...

Page 117: ...clockwise 2 to increase the height of the roll out roller anti clockwise 3 to decrease the height of the roll out roller The setting can be read on the scale 4 7 4 5 Setting the centering unit Configu...

Page 118: ...older Ensure that the index pin 3 engages in the holder 7 4 5 2 Setting a recipe at the centering unit Note The menu item Centering unit can be accessed in the main menu of the respective assembly aft...

Page 119: ...input box LOWER 1 Enter the number of pulses time span during which the centering unit is to be lowered Touch the input box Lift 1 Enter the number of pulses time span during which the centering unit...

Page 120: ...n be read on a scale Turn the adjusting wheel 1 in the direction of the arrow 2 to increase the cutting depth Turn the adjusting wheel 1 in the direction of the arrow 3 to reduce the cutting depth 7 4...

Page 121: ...ed button 4 with your thumb to be able to use the ratchet function of the arrester lever 1 if necessary Turn the knob 1 in the direction of the arrow 2 to increase the gap between the centering unit a...

Page 122: ...ing station to the right Turn the adjusting wheel 1 in the direction of the arrow 3 to move the cutting station to the left 7 4 6 5 Setting a recipe at the cutting station Note The menu item Cutting s...

Page 123: ...ch the cutting station on or off Touch the CENTERING UNIT input box 3 A keypad appears for entering numbers Enter the number of pulses between 5 and 200 to adjust the centering unit to the timing In t...

Page 124: ...rs for entering numbers Enter a time between 100 and 200 milliseconds to correct the anti clockwise drive speed Confirm your entry via the keypad Touch the CLOCKWISE DRIVE input box 5 A keypad appears...

Page 125: ...re pressing station line module The version that is delivered may differ from the version shown here 7 4 7 1 Setting the pre pressing depth The pre pressing depth can be adjusted directly via an adjus...

Page 126: ...be inserted to produce different stamped rolls Removal Turn the arresting pin 1 90 degrees in the direction of the arrow 2 Pull the pre pressing tool 3 out of the holder in the direction of the arrow...

Page 127: ...bly with the menu item Pre pressing unit Press the OPTION button 1 When touched the display toggles between On and Off You can switch the pre pressing station on or off Touch the input box SPEED 1 A k...

Page 128: ...ection 7 3 Setting assemblies In the input box BOTTOM BELT you can change the speed of the conveyor belt in the respective assembly The following illustration displays a menu excerpt of an assembly wi...

Page 129: ...ematic diagrams below describe the flour duster with break up shaft The version that is delivered may differ from the version shown here 7 4 9 1 Filling the flour duster with flour break up shaft Pull...

Page 130: ...the assembly Operation of the flour duster can also be switched on and off via the menu item Flour duster Note After touching the input boxes a keypad appears for entering numbers Confirm your entry v...

Page 131: ...cipe Password level 7 is required for saving Press the button to open the start screen 7 4 10 Long moulding belt Setting the top belt via the row of buttons Note The height of the top belt can be set...

Page 132: ...bly with the long moulding belt as an example 1 2 Under Top belt option you can change the settings of the respective long moulding belt in the assembly Touch the triangle 1 in the drop down menu The...

Page 133: ...p down menu closes your selection is entered Touch the TOP BELT input box 2 A keypad appears for entering numbers Enter the speed rotary frequency Press the button to save your settings in the display...

Page 134: ...lts can be deactivated by lifting them out of the transport area The folding flaps remain functional Take hold of the supporting shaft 1 for the wire mesh belts with both hands at the ball handles 2 P...

Page 135: ...e alignment and pressure roller Note The menu item Timing roller can be accessed in the main menu of the respective assembly after pressing the PARAMETER button see section 7 3 Setting assemblies In t...

Page 136: ...FOLLOWING 1 Enter the starting point in pulses time span during which the alignment and pressure roller should be switched to following 1 Touch the input box RUNTIME 1 Enter the runtime for following...

Page 137: ...ing belt Note The touch control contains recipes which have been set by Emil Kemper GmbH according to your wishes This section describes all the necessary working steps to carry out changes to your re...

Page 138: ...tion on the start screen Note The CAPACITY button is available in the menus of all the assemblies see section Fehler Verweisquelle konnte nicht gefunden werden Fehler Verweisquelle konnte nicht gefund...

Page 139: ...ROCATING BELT input box 1 and enter the distance in millimeters from the photoelectric sensor to the required position of the first row of dough pieces on the first baking tray Touch the PULL OFF LENG...

Page 140: ...r piece if the calculated placement control speed needs to be adjusted Under STEP LENGTH MM 8 touch an input box of your choice The respective step length is listed for each tray wooden trays baking t...

Page 141: ...e drop down menu opens You can select between three settings Table acceptance Mould transport and Manual acceptance Touch the desired setting The drop down menu closes your selection is entered Press...

Page 142: ...orking steps to carry out changes to your recipes at the reciprocating belt Switch the line on see section 7 1 Switching the line on and off Switch the control voltage on see section 7 2 Switching the...

Page 143: ...pens after touching the illustration on the start screen Note The CAPACITY button is available in the menus of all the assemblies In the Reciprocating belt menu press the PARAMETER button to change th...

Page 144: ...the end of the reciprocating belt Touch the PULL OFF LENGTH input box 2 A keypad appears for entering numbers Enter the distance in millimetres that the reciprocating belt pulls off Touch the TRAY SI...

Page 145: ...start time in pulses for the reciprocating belt s step between depositing patterns Touch the DEPOSITING CORRECTION input box 7 A keypad appears for entering numbers Enter a correction value in millim...

Page 146: ...ypad appears for entering numbers Enter the reciprocating belt speed in hertz Touch the BASIC POSITION input box 2 A keypad appears for entering numbers Enter the reciprocating belt s speed of return...

Page 147: ...wn menu The drop down menu opens You can choose between three settings Table removal Tray conveyor and Manual removal Touch the desired setting The drop down menu closes your selection is entered Pres...

Page 148: ...ired settings are saved in your recipes Switch the line on see section 7 1 Switching the line on and off Switch the control voltage on see section 7 2 Switching the control voltage on After a few seco...

Page 149: ...See the following excerpt of the start screen 1 The recipe number and name are entered in the RECIPE NUMBER 1 button on the start screen The line is ready for operation See the following section Start...

Page 150: ...and hoods are closed 7 6 1 Touch panel The following illustration displays the row of buttons at the bottom of the start screen 1 2 Starting Press the START button 1 Stopping Press the STOP button 2 7...

Page 151: ...e main switch on the switchbox A padlock can be used to lock the main switch to prevent accidental reconnection After pressing the EMERGENCY STOP button you must carry out the following steps to put t...

Page 152: ...gh moving parts in the line If an access door is opened while the line is running the respective limit switch immediately stops the line After waiting 20 seconds the following steps must be carried ou...

Page 153: ...otect electrical and electronic components from water splashes Only use a pH neutral food grade cleaning agent Do not use a steam cleaner or water hose to clean the line After cleaning check that all...

Page 154: ...e Cleaning point Cleaning agent Comment Collecting trays Vacuum cleaner clean cloth Remove residual dough and flour Further explanations can be found in section 8 3 2 Basic module 8 2 1 2 Roll out sta...

Page 155: ...n be found in section 8 3 11 Flour duster with flour break up shaft 8 2 1 6 Long moulding belt Cleaning point Cleaning agent Comment Top belt Plastic scraper clean cloth Remove residual dough and flou...

Page 156: ...in section 8 3 15 Reciprocating belt 8 2 1 10 Reciprocating belt AB60 1 Cleaning point Cleaning agent Comment Belt Plastic scraper clean cloth Remove residual dough and flour Pneumatic equipment Check...

Page 157: ...essary retension the belt Further explanations can be found in section 8 3 10 Conveyor belt 8 2 2 4 Reciprocating belt Cleaning point Cleaning agent Comment All chain drives Brush clean cloth Remove r...

Page 158: ...ain drives OKS 371 Check the chain tension If necessary retension the chains Lubricate the chains Further explanations can be found in section 8 3 16 Reciprocating belt AB60 1 8 2 3 Every 200 operatin...

Page 159: ...g of the brake If necessary readjust the brake Bearing of the deflection carriages Check the bearing If necessary replace the bearing Chain drive for belt advance motor OKS 371 Check the chain tension...

Page 160: ...is of ten hours of operation a day Have the entire line inspected by Kemper Service every 1400 hours 8 3 Cleaning and maintenance tasks Configuration of the assemblies and line modules in the line is...

Page 161: ...odules which may not be included in the line s scope of delivery 8 3 2 1 Cleaning the collecting trays Carry out the preparations see section 8 3 1 Preparations The extractable cleaning trays 1 are lo...

Page 162: ...appears on the touch panel and the line registers a fault Carry out the preparations see section 8 3 1 Preparations Note Make sure the cup chain is tensioned equally on both sides If this is not the...

Page 163: ...er GmbH EVOLUTION LINE roll machine 155 8 3 2 3 Lubricating the cup chains Carry out the preparations see section 8 3 1 Preparations Lubricate the cup chain 1 on both sides of the line with the specif...

Page 164: ...l line modules which may not be included in the line s scope of delivery 8 3 3 1 Cleaning collecting trays Carry out the preparations see section 8 3 1 Preparations The extractable collecting trays 1...

Page 165: ...verview of the line 8 3 4 1 Cleaning the belt Carry out the preparations see section 8 3 1 Preparations Use a plastic scraper and a clean cloth to clean the belt 1 8 3 4 2 Tensioning the belt Carry ou...

Page 166: ...rations Use a brush to clean the chain wheel 1 Clean the chain wheels on both sides 8 3 5 Pressure roller Configuration of the line module Pressure roller in the line is displayed in section 5 Overvie...

Page 167: ...roller in the line is displayed in section 5 Overview of the line 8 3 6 1 Cleaning the roll out roller Carry out the preparations see section 8 3 1 Preparations Use a clean cloth to clean the roll out...

Page 168: ...figuration of the line module Centering unit in the line is displayed in section 5 Overview of the line 8 3 7 1 Cleaning the centering flap Carry out the preparations see section 8 3 1 Preparations Pu...

Page 169: ...achine 161 Use a clean cloth to clean the centering flap 1 Fit the cleaned centering flap 1 in the holder in the direction of the arrow 2 ensuring that the slots in the centering flap engage in the ho...

Page 170: ...nit of the centering unit in the basic module is located on the right in running direction in the basic module Check the pressure setting 5 bar at the compressed air maintenance unit 1 Inspect all the...

Page 171: ...of the line 8 3 8 1 Lubricating the triangular knife and knife guides Carry out the preparations see section 8 3 1 Preparations Cutting hazard Pay attention to the triangular knife during maintenance...

Page 172: ...k of hand injuries Inspect the triangular knife for damage Replace it if applicable Loosen the setscrew 1 Loosen the locking screw 2 Turn the adjusting screw 3 in the direction of the arrow until the...

Page 173: ...r GmbH EVOLUTION LINE roll machine 165 8 3 8 3 Checking the pneumatic equipment Carry out the preparations see section 8 3 1 Preparations Check the pressure setting 5 bar Inspect all the pneumatic hos...

Page 174: ...displayed in section 5 Overview of the line 8 3 9 1 Cleaning the belt stamp Carry out the preparations see section 8 3 1 Preparations Turn the arresting pin 1 90 degrees in the direction of the arrow...

Page 175: ...row 2 Ensure that the arresting pin 3 engages in the holder 8 3 10 Conveyor belt Configuration of the line module conveyor belt in the line is displayed in chapter 5 Overview of the line 8 3 10 1 Clea...

Page 176: ...tion of the line module flour duster with flour break up shaft in the line is displayed in section 5 Overview of the line Note The schematic diagrams below describe the flour duster with break up shaf...

Page 177: ...tion of the arrow 2 Turn the adjusting handle until the drive engages 8 3 11 2 Cleaning the flour cloth Carry out the preparations see section 8 3 1 Preparations Open the quick fixtures 1 to 3 Remove...

Page 178: ...Clean the flour cloth 1 with a soft brush Fit the flour cloth into the flour duster with the hooks 1 to 3 Guide the flour cloth under the flour duster Open the quick fixtures 4 to 6 if applicable Fit...

Page 179: ...view of the line 8 3 12 1 Cleaning the top belt Carry out the preparations see section 8 3 1 Preparations Use a plastic scraper and a clean cloth to clean the belt 1 8 3 12 2 Tensioning the top belt C...

Page 180: ...the line is displayed in section 5 Overview of the line 8 3 13 1 Cleaning the wire mesh belts Carry out the preparations see section 8 3 1 Preparations Use the handles see arrows to remove the folding...

Page 181: ...3 2 Cleaning the folding flaps Carry out the preparations see section 8 3 1 Preparations Use the handles see arrows to remove the folding mats 1 from the holder Use a clean cloth to remove residual do...

Page 182: ...eaning the alignment and pressure roller Carry out the preparations see section 8 3 1 Preparations Use a clean cloth to clean the alignment and pressure roller 1 8 3 15 Reciprocating belt Configuratio...

Page 183: ...8 3 1 Preparations The chain tension is retained for a period of time by a coil spring The chain must be retensioned after this period Remove the panel 1 by unscrewing the fastening screw Check the co...

Page 184: ...1 Preparations The chain tension is retained for a period of time by a coil spring The chain must be retensioned after this period Remove the panel 1 by unscrewing the fastening screw Check the correc...

Page 185: ...tting influences the tension of the conveyor belt chains If necessary also tension the conveyor belt chains see next page Remove the panel 1 by unscrewing the fastening screw Check the correct tension...

Page 186: ...nfluences the tension of the conveyor belt If necessary also tension the conveyor belt see previous page Remove the panel 1 by unscrewing the fastening screw Check the correct tension of the chain 1 I...

Page 187: ...mil Kemper GmbH EVOLUTION LINE roll machine 179 8 3 16 Reciprocating belt AB60 1 8 3 16 1 Cleaning the belt Carry out the preparations see section 8 3 1 Preparations Use a plastic scraper and a clean...

Page 188: ...ction 8 3 1 Preparations The chain tension is retained for a period of time by a coil spring The chain must be retensioned after this period Remove the panel 1 by unscrewing the fastening screw Check...

Page 189: ...ion 8 3 1 Preparations The chain tension is retained for a period of time by a coil spring The chain must be retensioned after this period Remove the panel 1 by unscrewing the fastening screw Check th...

Page 190: ...tting influences the tension of the conveyor belt chains If necessary also tension the conveyor belt chains see next page Remove the panel 1 by unscrewing the fastening screw Check the correct tension...

Page 191: ...ing influences the tension of the conveyor belt If necessary also tension the conveyor belt see previous page Remove the panel 1 by unscrewing the fastening screw Check the correct tension of the chai...

Page 192: ...mbH 8 3 16 6 Checking the pneumatic equipment Carry out the preparations see section 8 3 1 Preparations Remove the panel 1 by unscrewing the fastening screw Check the pressure setting 5 bar Check the...

Page 193: ...ation as a food grade lubricant is proof that it only contains substances that satisfy the high purity requirements of the Guidelines of Security 21 CFR 178 3570 of the FDA Food and Drug Administratio...

Page 194: ...nder number 124384 Product form Spray 500ml Characteristics Appearance Transparent Temperature range for use 10 C to 180 C Base oil viscosity 40 C 14 mm s Applications Lubrication of valve seals sleev...

Page 195: ...re parts and wear parts lists Always specify the line number when ordering parts The line number is specified on the rear of the title page of this user manual Only use original spare parts as only th...

Page 196: ...s purpose we offer maintenance contracts which the plant operator can negotiate and sign with Kemper according to different operating hours We would like to point out however that maintenance and serv...

Page 197: ...mation given below local safety regulations apply in all cases when it comes to rectifying faults Switch the line off before starting to rectify any faults see chapter 7 Operation Prevent the line fro...

Page 198: ...epairs are required after a fault make sure that all the safety devices are reinstalled according to the delivery condition If the fault was caused by a safety device triggering eliminate the fault an...

Page 199: ...s defective always replace the motor and the motor protection relay Press the black knob on the motor protection circuit breaker This reactivates the motor protection circuit breaker Emergency stop ha...

Page 200: ...Faults 192 EVOLUTION LINE roll machine Emil Kemper GmbH...

Page 201: ...electrical hazard Work on the electric system should only be carried out by an electrical specialist 10 2 Dismantling the line Please contact our Service department if you wish to dismantle the line...

Page 202: ...Decommissioning dismantling and disposal 194 EVOLUTION LINE roll machine Emil Kemper GmbH...

Page 203: ...o see more information about this section 11 2 Compliance with laws standards and directives The line complies with the respective version of the following directives and standards Machinery Directive...

Page 204: ...Appendix 196 EVOLUTION LINE roll machine Emil Kemper GmbH...

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