Suncrest Line # 7 Maintenance and Operations Manual PDF

_______________________________________________________________________________
AUTO-BAKE SERPENTINE™
218-PAN CONVECTION HEATED OVEN
FREE-TRAY LTS BAKING LINE
OPERATIONS & MAINTENANCE

MANUAL
SUNCREST LINE # 7
Philippines
J/N 5128
SERIAL NO: 793 LTS218 02 13
LTS OPERATIONS & MAINTENANCE MANUAL - SUNCREST LINE #7 - W/O 5128 - JULY 2013 1
_______________________________________________________________________________
TABLE OF CONTENTS
SECTION 1 ...................................................................................................................................... 5
1.1 Definition of Symbols ..................................................................................................... 6
1.2 General Safety Checks ................................................................................................. 7
1.3 Lock-Out Procedure ...................................................................................................... 8
SECTION 2 GENERAL DESCRIPTION OVERVIEW .................................................................. 10
2.1 System Process .......................................................................................................... 11
2.2 Oven Infeed Module – 4m (including Free-Tray Loading System) .............................. 14
2.3 Serpentine™ Gas-Fired Convection Heated Oven - 218 Pans ................................... 14
2.4 Product Inspection Station – 2.5m............................................................................... 17
2.5 Oven Drive Unit c/w Vertical Pan Transfer System (VPTS) ........................................ 17
2.5.1 Mechanical Overload System ..................................................................................... 17
2.5.2 Chain Tensioning System ........................................................................................... 18
2.6 Serpentine™ MK 126-8/9 Ambient Coolers – 207/232 Pans ...................................... 18
2.7 Cooler-Mounted Drive & Chain Take-Up System ........................................................ 19
2.8 Outfeed Module – 3m c/w Drive Unit & Main Chain Take-Up ..................................... 20
2.9 Automatic Lubrication System (Chain & Carrier Bearings).......................................... 20
2.10 Robotic Product Depanning System – Dual Head....................................................... 21
2.11 Conveyor Circuit System (CCS) .................................................................................. 21
2.12 Pan Washer & Dryer - Colussi .................................................................................... 21
2.13 Pan Greaser - Dubor ................................................................................................... 21
2.14 Steam Generator – Simons Boilers ............................................................................. 22
2.15 Electrical Control Cabinet (MCC) & HMI (Touch Screen Control) ............................... 22
2.16 ATTACHMENTS ......................................................................................................... 22
 Production Line Drawing ............................................................................................. 22
 Services Information ................................................................................................... 22
 Tray/Product Drawings ............................................................................................... 22
 Line and Factory Layout ............................................................................................. 22
 Colussi Pan Washer & Dyer Operating Instructions Manual ...................................... 22
 Dubor Pan Greaser Operating Instructions Manual .................................................... 22
 Simons Steam Generator (Boiler) Operating Instructions Manual .............................. 22
SECTION 3 OVEN INFEED MODULE ........................................................................................ 23
3.1 Oven Infeed Module .................................................................................................... 24
SECTION 4 GAS-FIRED CONVECTION-218 PAN BAKING OVEN ........................................... 27
4.1 Description of Heating System .................................................................................... 29
4.2 Gas Train ..................................................................................................................... 30
4.3 Detailed Purge Process ............................................................................................... 31
4.3.1 PLC-Automated Purge Sequence ............................................................................... 31
4.4 Burner Start-Up Sequencing ....................................................................................... 32
4.5 Temperature Control ................................................................................................... 32
4.6 Oven Exhaust System ................................................................................................. 34
4.7 Pan Too-High Sensor .................................................................................................. 35
4.8 Oven Cleaning – Annual Schedule ............................................................................. 35
4.9 ATTACHMENTS ......................................................................................................... 37
 AeroVent Fan Operation & Maintenance Instructions................................................. 37
 Eclipse Burner Manuals (Design and Installation) ...................................................... 37
 Eclipse Air Heat Burners – Model AH ......................................................................... 37
 Eclipse Butterfly Valves and Belimo Servo Motors ..................................................... 37
 Burner Fan Manual – Moro ......................................................................................... 37
 Krom Schroder Pressure Switches ............................................................................. 37
 Siemens LFL Series – Burner Flame Safeguard Control............................................ 37
_______________________________________________________________________________
 Schematic of Gas Supply Chain ................................................................................. 37

 MSDS Superwool 607 Triple T ................................................................................... 37
SECTION 5 DRIVE SYSTEMS ..................................................................................................... 38
5.1 Description of Drive Units ............................................................................................ 39
5.2 Drive Modules ............................................................................................................. 40
5.3 Power Transmission Motor/Gearbox Unit.................................................................... 41
5.4 Drive Speed Synchronisation ...................................................................................... 41
5.5 Mechanical Overload System ...................................................................................... 42
5.6 Main Chain Take-Up System....................................................................................... 45
5.7 Drive System Maintenance ......................................................................................... 47
5.8 Air Supply .................................................................................................................... 47
5.9 Air Pressure Switch ..................................................................................................... 47
5.10 ATTACHMENTS ......................................................................................................... 48
 Motor Gearbox Catalogues ......................................................................................... 48
 Drawing of Main/Master Drive..................................................................................... 48
 Schematic of Chain Tension and Overload Pneumatic Circuit ................................... 48
 Procedure for the Removal of a Pitch of Chain........................................................... 48
SECTION 6 CONVEYOR SPROCKET SYSTEM ........................................................................ 49
6.1 Chain Idler & Levelling Sprocket Assemblies .............................................................. 50
6.2 Chain Idler & Levelling Sprocket Assembly & Removal .............................................. 51
6.3 Procedure for Setting/Checking Timing on LTS Sprocket Sets ................................... 53
6.4 Cross-Shaft System .................................................................................................... 54
6.5 Procedure for Checking Cross-Shaft Alignment .......................................................... 56
6.6 Conditions for Re-Setting Alignment of Cross-Shafts.................................................. 56
6.7 Procedure for Re-Setting Cross-Shaft Assembly Alignment – Condition #1 ............... 57
6.10 Transmission and Gear Train Lubrication ................................................................... 64
6.11 ATTACHMENTS ......................................................................................................... 64
 Position of bearing housings and sprocket assemblies .............................................. 64
 Identification of guide types ........................................................................................ 64
 Critical Procedure – Timing of Gears .......................................................................... 64
 Bearings, Housings & Sprocket Assembly Details...................................................... 64
SECTION 7 LINE LUBRICATION ................................................................................................ 65
7.1 Recommended Lubricants .......................................................................................... 66
7.2 Importance of Clean & Well-Lubricated Carrier Transport Chain ................................ 67
7.3 Automatic Lubrication Overview .................................................................................. 67
7.4 Main Conveyor Chain Lubrication ............................................................................... 68
7.5 Carrier Bearing Lubrication ......................................................................................... 69
7.6 Pivoting Guide Lubrication .......................................................................................... 71
7.7 ATTACHMENTS ......................................................................................................... 72
 MSDS KLUBERFOOD NH1 CH 2-220 ....................................................................... 72
 MSDS Klüber Barrierta L55/2 ..................................................................................... 72
 KLUBERTEMP RHB 83 - 402 ..................................................................................... 72
 MSDS Klüber Hotemp 2000........................................................................................ 72
 Drawing of oven bearing greasing points.................................................................... 72
 Operation & Maintenance Manual for Dropsa Lubrication Systems ........................... 72
SECTION 8 OUTFEED MODULE ............................................................................................... 73
8.1 Description of Outfeed Module .................................................................................... 74
SECTION 9 CONVEYOR CIRCUIT SYSTEM ............................................................................. 76
9.1 Description of Conveyor Circuit System (CCS) ........................................................... 77
9.1.1 Function of Conveyor C1 ............................................................................................. 77
_______________________________________________________________________________

9.1.10 Function of Conveyor C10 .................................................................................... 82
9.1.11 Function of Conveyor C11 .................................................................................... 82
9.2 Air Pre-Release System .............................................................................................. 83
9.3 Robotic Product Depanning System – Dual Head....................................................... 85
9.4 Computerised Motion-Control Unit .............................................................................. 86
9.5 Industrial Robot System .............................................................................................. 86
9.6 Maintenance – P&P System ........................................................................................ 86
SECTION 10 GENERIC PREVENTATIVE MAINTENANCE SCHEDULE.................................... 87
SECTION 11 GENERIC SANITATION SCHEDULE .................................................................... 96
SECTION 12 TROUBLE SHOOTING ........................................................................................ 101
12.1 Basic Strategies for Preventing Mechanical Obstruction........................................... 102
SECTION 13 SPARE PARTS .................................................................................................... 106
13.1 Refer Separate Recommended Spare Parts Schedule ............................................. 106
SECTION 14 ANCILIARY EQUIPMENT .................................................................................... 107
14.1 ATTACHMENTS ....................................................................................................... 107
 Comas Injector .......................................................................................................... 107
 Dubor Pan Greaser ................................................................................................... 107
 ABB 6640 Robot ....................................................................................................... 107
SECTION 15 HMI TOUCHSCREEN .......................................................................................... 108
15.1 ATTACHMENTS ....................................................................................................... 108
Touchscreen Operations Manual......................................................................................... 108
_______________________________________________________________________________
SECTION 1
SAFETY NOTICE
This manual should be read and fully understood by all

operators & maintenance personnel before operating & working
on Auto-Bake machinery. The purpose of safety warnings and
procedures contained within this manual is to ensure all
personnel working on Auto-Bake equipment do so in a safe
manner. Please ensure all operators and maintenance
personnel are sufficiently trained to operate and/or maintain the
machine in the areas they are assigned, and are fully aware of
all potential hazards.
_______________________________________________________________________________
1.1 Definition of Symbols

The below symbols may be used in isolation or combination throughout this manual. Where
used, these symbols are intended to alert personnel of potential risk, either to themselves or
to the equipment, and/or convey important messages regarding the safe operation &
maintenance of this equipment.
Symbol Definitions
Risk to operators, maintenance personnel or equipment
Risk of electrical shock
Important Message
Maintenance Personnel
Electrician
General Operator
Extreme danger
_______________________________________________________________________________
1.2 General Safety Checks
• Ensure all operators, maintenance and sanitation personnel read these instructions
carefully and fully understand the contents before working on the Auto-Bake line.
• Ensure all operators are fully trained on the particular Auto-Bake equipment they are
responsible for, and that they are fully aware of emergency stop locations and the
correct start up procedure for the system.
• Ensure all guards are in place before starting equipment and ensure that safety
interlocks, where installed, are operative. Never remove a guard without first isolating
all power to the machine. Ensure all emergency stops, lanyards and safety interlocks
are in good working condition and will stop the line when activated.
IMPORTANT: Under no circumstances should emergency stops

and lanyards be used for routine stopping of the Auto-Bake
Line and ancillary equipment.
• Whenever an emergency stop is activated a designated person should be made

responsible for investigating the reason for emergency stop. Process controls should
be put in place to prevent the line being re-started until thorough checks have been
carried out and reported. By activating an emergency stop, equipment is
immediately de-energized, irrespective of where it happens to be in terms of
completing programmed cycles. Sudden de-energizing may cause momentarily loss
of memory to PLC systems, or result in some limit switches being triggered out of
sequence when attempting to restart the line. If this occurs, manual resetting of
program start sequences is usually required.
IMPORTANT: The Auto-Bake process should only be

stopped routinely via the HMI touch screen.
_______________________________________________________________________________
WARNING: Prior to removing guards, main electrical

isolators and main compressed air supply valves should
be ‘locked-out & tagged’. All energy should be exhausted
from pneumatic systems so that equipment cannot be
inadvertently activated when cleaning or carrying out
routine maintenance.
• Ensure start-up alarm is in good working condition and clearly audible from all
operating stations on the Auto-Bake line.
• Ensure motor overload systems are in good working condition and that sensitivity
settings are checked regularly by qualified engineering personnel.
• Prior to starting up the conveyor system, check and remove any objects that may
have been placed & left on the machine, and ensure all pans and grills are correctly
replaced in their carriers following routine cleaning or maintenance operations.
• Ensure all sensors are kept clean and operational.
1.3 Lock-Out Procedure
Please note the following lock-out procedure, which is to be followed prior to entering the
chain path area of an operational machine:
• Call your supervisor.
• Identify with your supervisor the area of the machine in which you will be working.
• Identify the drive that powers that specific area of the machine, and identify the
electrical isolator for that drive.
_______________________________________________________________________________
• Ask your supervisor to isolate the drive by turning the electrical isolator to the ‘off’
position.
• Place compliant ‘red electrical lockout clasp’ through the isolator switch handle and
close the clasp.
• Place your personal, engraved padlock through one of the holes in the clasp and
close the padlock.
• Ask your supervisor to try and start the machine. Failure to start confirms the lock-out
has been successful.
• You may now enter the machine.
• Once you have completed your task, and do not intend going back into the machine,
remove your padlocks. Advise your supervisor that you have finished and that you do
not intend going back into the machine.
• Once all locks are removed, the supervisor may switch on the isolator in readiness
for machine start-up.
IMPORTANT: Once your lock has been removed, do not enter

the machine. If you need to re-enter the machine, the above
lock out procedure must be re-implemented. This lock-out
procedure is for your safety. Please follow it diligently.
_______________________________________________________________________________
SECTION 2
GENERAL DESCRIPTION
OVERVIEW
IMPORTANT: The Auto-Bake line has been designed to operate

at a maximum capacity of 16 pans per minute. If line speed
exceeds this, the product transfer unit and drive system may
either operate below specification or incur damage.
Do Not Exceed Recommended Maximum Speed!
_______________________________________________________________________________
2.1 System Process

This Auto-Bake Serpentine™ line comprises a Free-Tray continuous loop chain system
incorporating an LTS 6-Zone Convection Heated 218-Pan Baking Oven c/w combined
439-Pan Ambient Coolers. The system incorporates two closed-loop carrier transport
chains (one located at each side of the machine), which are fitted with equispaced and
oppositely-aligned extended chain pins that engage with and propel pan carriers. Baking
pans ride on these carriers which are transported continuously and at constant speed
throughout the entire chain circuit. Chain speeds are determined for each product (being
baked) by its required bake-time.
Auto-Bake’s Free-Tray system feeds product-deposited pans continuously into the oven
infeed module, transferring each pan at line speed onto a converging vacant host carrier as
it journeys around the Auto-Bake closed-loop chain circuit. A system of conveyors is
incorporated to transport trays ejected at the oven outfeed module all the way back to the
oven infeed module, with trays passing various process stations en-route.
Starting at the beginning of the process, space along the conveyor circuit is provided for
operators to manually insert paper liners into recently cleaned empty pans, and/or to
accommodate an ancillary Paper Cup Denester (supplied by others where incorporated). If
product is deposited directly into pan cavities, a roll in/out pan greaser caters for this, and is
located immediately upstream of the Depositor station. The Depositor (supplied by others)
fills empty pan cavities or paper cups with product batter as the empty pans pass through
the station.
Pans enter the segmented 6-zone convection oven at low-level and travel along each
horizontal run in the first segment winding upwards along the Serpentine™ chain path to the
uppermost horizontal run. Pans enter the second segment of the oven at top level and travel
horizontally to the extreme outfeed end, whereupon they wind downwards this time along the
Serpentine™ chain path to the lowest horizontal run of the second segment, before exiting
the oven at the opposite end to which they entered.
Pans progress into the upper, then lower, Ambient Coolers (8-run & 9-run respectively),
entering at hi-level after passing the Product Inspection Station, Oven Drive Unit and
Overhead Pan Transfer System en-route. The pans riding in their host carriers traverse
downwards along the Serpentine™ chain path, where naturally rising hot air ensures each
subsequent horizontal run continues to be cooler than the one immediately above it. In
_______________________________________________________________________________
addition to natural convection, a series of fans assist in the removal of flash-heat from the
product and from the metal transport elements.
Upon exiting the Ambient Coolers at low-level, carriers & pans continue into the Outfeed
Module whereupon the pans are separated and ejected onto the first of 11 system
conveyors (nominated C1-C11), C1 being the 5m Injector conveyor located immediately
downstream of the Outfeed Module, and C-11 being the 90º conveyor feeding newly-
deposited pans back into the Oven Infeed Module.
Product can be filled on demand by an ancillary Injector (by others) which straddles C1.
Products baked directly in the pan cavities (as opposed to paper cups) are partially liberated
from the baking cavities by a purpose built pre-release manifold located immediately
downstream of the Injector mounted to C1. The pre-release manifold is fitted with
strategically located nozzles that blast hi-pressure air between the outer perimeter of each
individual product and the cavity in which it was baked. Pans now containing ‘loosened’
product are subsequently transferred via C2 & C3 to the Robotic Product Depanning
System, where product is transferred onto one of two take-away conveyors (by others).
Empty pans are transported from the robot enclosure via C4, then to the entrance of the in-
line Colussi Pan Washer via C5. Pans enter the washer tunnel (right way up) and emerge
clean & dry as they proceed onto C6, which is 15m long. Water in the Colussi washer is
heated by steam injected into the tank’s heat-exchangers. A 350 Kw Simons Boiler supplied
by Auto-Bake generates the necessary steam. Operators can stand either side of C6 at a
comfortable distance apart when manually inserting paper cups into pan cavities. A future
Paper Cup Denester can be accommodated downstream on C7, which also caters for two
additional equipment stations, including a Pan Greaser (Dubor) & Batter Depositor
(Suncrest). Two stainless steel slat-belts incorporating equally pitched welded dog plates
positively propel & locate the pans as they pass under each process stations.
C8 is a straight conveyor that declines approximately 200mm over its length joining onto a
90º conveyor, C9. C10 is a short straight conveyor bridging the two 90º conveyors (C9 &
C11), and is ideal for loading/unloading pans in to/out of the system when product changes
are being undertaken. Several conveyors including C10 have pivoting lift-over side guides
for centralising the shorter croissant trays when loading. These loading guides simply pivot
back out of the way when the longer Fudgee Bar & Ring Cake pans are in production.
_______________________________________________________________________________
Main equipment supplied by Auto-Bake includes:
• Oven Infeed Module (including Free-Tray Loading System) – 4 Metre

• Serpentine™ Gas-Fired Convection Heated Oven (218 Pans)
• Product Inspection Station – 2.5 Metre
• Oven Drive Unit c/w Vertical Pan Transfer System (VPTS)
• Serpentine™ MK 126-8 Ambient Cooler c/w 20 Fans (207 Pans)
• Serpentine™ MK 126-9 Ambient Cooler c/w 20 Fans (232 Pans)
• Cooler-Mounted Drive & Chain Take-Up System
• Outfeed Module - 3 Metre (including Free-Tray Unloading System)

• Automatic Lubrication System for Conveyor Chain & Carrier Bearings
• Robotic Product Depanning System – Dual Head
• Conveyor Circuit System (CCS)
• Pan Washer & Dryer Unit – Colussi
• Pan Greaser - Dubor
• Steam Generator – Simons Boilers
• Electrical Control Cabinet (MCC), PLC & HMI (Touchscreen)
Note: In addition to the following overview of principle equipment, please refer subsequent
chapters for detailed descriptions of Infeed Module, Oven, Ambient Coolers, Conveyor
Circuit System, Outfeed Module, & Robotic Product Depanning System.
Above drawing also attached as PDF, please refer PDM-7375-K
_______________________________________________________________________________
NOTE:
Please refer respective operation and maintenance manuals
for all ancillary equipment not supplied by Auto-Bake
2.2 Oven Infeed Module – 4m (including Free-Tray Loading

System)
Duty
Clean pans are conveyed from C11 conveyor by two mechanically-driven slat-belts and
loaded at designated line speed (as determined by the oven bake time) into continually re-
circulating carriers. The Infeed module has the following features:
• Full perimeter safety cage to protect operators from moving mechanical transmission
components such as chains & sprockets. This cage can only be assessed when the
Auto-Bake line has been powered-down. This is achieved without electrical interlocks but
rather by a series of mechanical locks & keys.
• An industrial PLC integrated HMI (Touch Screen) control unit designed to enable easy
operator interface of oven and auxiliary controls. The HMI screen is mounted to a fixed
post located at the RH side of this module.
• Stainless steel hose-down spillages catch trays and guttering.
Construction
The Infeed module is manufactured from heavy gauge RHS and angle sections. Welded to
these are heavy-duty 12mm (1/2”) mild steel side plates, which are in turn strengthened by
angle and plate cross members. The Infeed section is fully protected by a zinc rich epoxy
coating. Guards, doors, panels & covers are manufactured from stainless steel sheets.
2.3 Serpentine™ Gas-Fired Convection Heated Oven - 218 Pans

Duty
To correctly bake the product as it is conveyed from the infeed end of the oven through the
various zones of heating, such that the product, on exiting from the oven, is fully baked to
specification. The oven is segmented into two separate Serpentine™ sections. Baking pans
containing deposited product (batter) ride in unique transport carriers and are introduced into
the oven at the bottom of the entry section. These carriers are then conveyed vertically to
_______________________________________________________________________________
the uppermost run of the first section of the oven in horizontal runs, transferring radially
around sprockets at each end of each horizontal level. Crossing a separating bulkhead over
to the second Serpentine™ section of the oven, carriers and their pillion baking pans then
proceed downwards to the lowest horizontal run in the second section, with carriers once
again transfer radially about each sprocket set located at the end of each horizontal run.
Fully baked product in pans exit the oven at the opposite end to which the pans entered,
emerging into the Product Inspection Station.
Direct-Fired Convection Heating System

The oven has six independently controlled heating zones, each zone incorporating a
dedicated direct-fired gas burner, a top/bottom heat deflector actuator, and a blower. Each
gas-fired burner has been sized to comfortably deliver enough energy to bake all products
within the customer’s nominated portfolio. Each burner is specified with a turn-down ratio
that will minimise the opportunities for the burner to shut down when its respective zone is
emptying of pans & product. In most cases, if the entire oven is completely empty, and has
been for some time, the burners will shut down until load is once again called for.
Cold air is pulled through each burner’s flame by the respective zone blower and heated to a
specific temperature as controlled via the size of the flame (the burner’s turn-down position).
The heated air is then pushed by the blower into diffuser plenums (plena) located above and
below each horizontal pass in each section of the oven. Each burner provides heating for 4
rows of plena (constituting that particular burner’s heating-zone). Each plenum has a row of
slits above and below where the heated air escapes and enters the oven baking chamber.
The percentage of air delivered from the top slits relative to the bottom slits of each plenum
is adjustable by PLC controlled actuators, hence enabling top & bottom heat profiles to be
selected at the HMI and saved to a specific recipe.
Oven Ventilation System

Products of combustion and excessive moisture in the oven are vented via a fan assisted
ducting system mounted directly on top of the oven roof. A variable speed fan (controlled by
a frequency inverter) is used to govern the velocity of extracted air. The inverter frequency
settings can be selected at the HMI and saved to a specific recipe.
Oven Bearings
The sprocket assemblies in the oven incorporate heavy-duty bearings that are pre-lubricated
with special high temperature grease.
_______________________________________________________________________________
Only the recommended grease should be used for the bearings! The bearings have
been charged with grease at the Auto-Bake factory, and only the same grease should
be used. Do not mix greases or utilize any other make of grease!
Please refer to the lubrication schedule for details on the greases to be used. The oven
bearings use Barrierta L55/2 manufactured by Klüber. Each sprocket assembly has a
readily accessible greasing point allowing for periodic maintenance. The oven bearings are
protected against ingress of foreign material by ‘Nilos’ ring seals. All other bearings external
to the oven are standard clearance, pre-packed with specific food-safe grease, including in
some cases, Barrierta L55/2 where bearings are still relatively hot within close proximity of
the oven. (Refer to drawing at the rear of this section showing oven bearing greasing points.)
Environment
Flues are required to extract moisture from the baking environment and to extract products
of combustion. Flues are not supplied by Auto-Bake.
Please note that flues will require cleaning on a periodic basis to remove any fat or
similar build up on the wall of the flues. Such build up, unless removed, may present
a fire danger.
Oven Doors
All side doors are hinged, such that the interior of the oven is accessible for periodic
inspection, maintenance and cleaning. A window on either side of the oven allows for visual
product inspection during baking. Oven door panels are manufactured from No 4 polished
stainless steel.
Construction
The oven is constructed from welded heavy gauge RHS and angle sections. Members are
protected against corrosion by a zinc rich epoxy coating and lined with low heat transfer
insulation material, such as ‘Superwool’ or similar. Guards, doors, panels & covers are
manufactured from stainless steel sheets.
_______________________________________________________________________________
2.4 Product Inspection Station – 2.5m

Duty
The inspection station allows the oven operator to scrutinise product exiting the oven so that
fine-tune adjustments as required can be determined and implemented to achieve the
desired bake quality.
Construction
The Product Inspection Station is manufactured from heavy-gauge RHS steel members
welded to 12mm thick steel side-plates. Members are protected against corrosion by a zinc
rich epoxy coating. Guards and covers are manufactured from stainless steel sheets.
2.5 Oven Drive Unit c/w Vertical Pan Transfer System (VPTS)
Duty
The Drive Unit provides carrier transport chain propulsion via a speed-variable 3-phase
electric motor. Where multiple drive units are incorporated, the oven drive is the master and
all other drives are slaves to the oven drive. Synchronised motors are used which are
‘homed’ on start-up with the aid of linear encoders. These encoders are mounted to the
chain tensioner slides located downstream of the slave drive(s). Power and torque are
transmitted via a reduction hollow shaft gearbox coupled directly to the electric motor. The
drive unit is fitted with an on-board mechanical overload system as described below, which
is designed to protect the transport system chain & carriers. Line speeds can be individually
set (and saved to recipe) at the HMI touch screen.
The Vertical Pan Transfer System (VPTS) comprises sets of standard LTS sprockets &
guides in conjunction with vertical elevator rails that guide the pan carriers directly to the
upper-most run of the Ambient cooler, whilst maintaining the carriers in a level plane during
the vertical ascent.
2.5.1 Mechanical Overload System
A mechanical overload limit switch is fitted to the drive unit. In normal running conditions this
switch is in the ‘depressed’ position, held by a torque arm mounted to the gearbox housing.
As reaction torque builds up due to increased load on the conveyor chain, the motor/gearbox
assembly will pivot allowing the limit switch to slowly release from its fully depressed state. If
_______________________________________________________________________________
sufficient load is encountered, the limit switch will trip stopping the entire production line in
the process. The sensitivity of the overload system is controlled via a programmable
pressure regulator, which is pre-set by Auto-Bake to control precise air pressure servicing
the overload air cylinder. The overload air cylinder applies force to the torque arm such that
it provides resistance to the natural reaction of the pivoting gearbox as load is encountered.
By increasing this resistance (by increasing air pressure), the effort required to trip the
overload limit switch also increases. The system is hence more sensitive to mechanical
overload when the overload cylinder air supply pressure is set as low as possible, without
incurring nuisance stoppages.
2.5.2 Chain Tensioning System
As is common with all chain-driven mechanisms, loose carrier transport chain is generated
immediately downstream of each drive unit. As such, all drive units incorporate a dedicated
dynamic chain tensioning system which in most cases is located as near as possible
downstream to the propulsion unit it serves. The LHS & RHS carrier transport chains are
engaged with tensioning sprockets mounted to slide plates. Each slide plate is connected to
a dedicated air cylinder plumbed in parallel and controlled by a common pressure regulator.
An air pressure switch is pre-set to a minimum value, as deemed appropriate to safely drive
all pneumatic-controlled devises on board. When air pressure drops below this value the line
is programmed to stop and a corresponding alarm will be annunciated on the HMI.
Construction
The Drive Modules are manufactured from heavy gauge RHS and angle sections. Welded to
these are heavy-duty 12mm (1/2”) mild steel side plates that are in turn strengthened by
angle and plate cross members as required. Members are protected against corrosion by a
zinc rich epoxy coating. Guards and covers are manufactured from stainless steel sheets.
2.6 Serpentine™ MK 126-8/9 Ambient Coolers – 207/232 Pans

Duty
A total of 17 horizontal runs accommodating 439 pans of cooling are available by virtue of
piggy-backing two Mk126 Ambient Coolers, one on top of the other. The upper Cooler
_______________________________________________________________________________
incorporates 8 horizontal passes whilst the lower unit incorporates one additional pass to
continue product flow towards the outfeed end of the Auto-Bake line. Trays emerge from the
lower cooler at the lowest horizontal pass whereupon they enter into the Outfeed Module.
Each Mk 126 Ambient Cooler module is fitted with side-mounted fans that pull ambient air
across the path of product as it travels along the horizontal runs, thus exhausting flash heat
to the side of the machine away from the product zone. This process assists depanning by
allowing the product to cool sufficiently for handling purposes. The Ambient Cooler dwell
time is nominally calculated based on an accepted ratio with the oven dwell time, which can
vary depending on whether a refrigerated cooler is incorporated downstream, and in some
cases, on special instructions from customers. In this case the exact ratio is 218:439 (oven
pans: cooler pans), or 200% cooling relative to baking.
Ambient Coolers can be enclosed within an insulated room (supplied by others) or open to
the factory, depending on conditions and customer requirements.
Construction
Ambient Cooler modules are manufactured from welded heavy gauge RHS and angle
sections. Members are protected against corrosion by a zinc rich epoxy coating. Guards and
covers are manufactured from stainless steel sheets.
2.7 Cooler-Mounted Drive & Chain Take-Up System

Duty
The Cooler-Mounted Drive Unit provides additional conveyor chain propulsion via a speed-
variable 3-phase electric motor with identical performance specification to that of the Oven
Drive. This auxiliary drive system is located at the outfeed end of the upper cooler, such that
it is approx half way between the Oven Drive & Outfeed Drive to share load equally. Power
and torque are transmitted via a reduction hollow shaft gearbox coupled directly to the
electric motor. The Drive Unit is fitted with an on-board mechanical overload system as
described previously in the Oven Drive section.
The chain tensioning system resides at the opposite end of the cooler (infeed end) taking up
slack chain generated on the downstream side of the propulsion unit. This chain tensioning
system is similar in design and operation as described previously in the Oven Drive section.
_______________________________________________________________________________
2.8 Outfeed Module – 3m c/w Drive Unit & Main Chain Take-Up
Duty
Baked product exiting the cooler is conveyed to the Outfeed section where the tray transfer
system is located. The tray transfer mechanism pushes the trays from the carriers and onto
the take-away conveyor. The empty carrier frames then return to the infeed to receive fresh
trays and product.
The Outfeed Module Drive Unit provides additional conveyor chain propulsion via a speed-
variable 3-phase electric motor with identical performance specification to that of the Oven
Drive. Power and torque are transmitted via a reduction hollow shaft gearbox coupled
directly to the electric motor. The Drive Unit is fitted with an on-board mechanical overload
system as described previously in the Oven Drive section.
The main [carrier transport] chain tensioning system also resides in the Outfeed Module.
This chain tensioning system is similar in design and operation as described previously in
the Oven Drive section except the take-up slides may have additional travel capacity (usually
500mm linearly), which enables one complete tray-pitch of chain to be removed as/when
these slides approach limit of travel.
Construction
The Outfeed Module is manufactured from heavy gauge RHS and angle sections, which
form the base-frames. Welded to these are heavy-duty 12mm (1/2”) mild steel side plates
that are in turn strengthened by angle and plate cross members. The Outfeed Module is fully
protected by metallic coating. Guards and covers are manufactured in No 4 polished
stainless steel.
2.9 Automatic Lubrication System (Chain & Carrier Bearings)
Duty
An automatic chain and carrier bearing lubrication system manufactured by Dropsa is
installed at the front end of the infeed module (Please refer applicable section in this
manual). Recommended lubricant is KLUBERFOOD NH1 CH 2-220 made by Klüber.
_______________________________________________________________________________
2.10 Robotic Product Depanning System – Dual Head

Duty
The system incorporates an ABB 6400 series industrial robot tooled with dual Auto-Bake
needle heads. There are specific needle heads provided for each product type, as
nominated by the customer. Heads can be changed easily without tools. The robot is housed
within a perimeter safety cage which can only be assessed when the robot has been
powered-down. This is achieved without electrical interlocks but rather by a series of
mechanical locks & keys, similar to the Infeed Module safety cage.
2.11 Conveyor Circuit System (CCS)

Duty
The CCS comprises 11 conveyors as briefly described in the general description section of
this overview. The conveyors are nominated C1 to C11 in order of tray flow, C1 being the
first conveyor after the pans are ejected at the Outfeed Module, and, C11 being the last
conveyor before the pans are re-introduced back into the Auto-Bake line at the Infeed
Module. In conjunction with the Colussi In-Line Pan Washer, the CCS conveyors bridge the
gap between the Outfeed & Infeed Modules, hence forming a continuous tray transport
circuit. Each conveyor has a unique function, some are equipped with brakes, some with
gates, and others with positive traction pusher dogs welded to the transport slats. These will
be described in more details in the CCS section of this manual.
2.12 Pan Washer & Dryer - Colussi

Duty (Please refer Colussi Operating manual)
An in-line tunnel washer/dryer manufactured by Colussi in Italy has been incorporated into
the Auto-Bake line and forms part of the continuous tray transport circuit. Soiled pans can be
automatically & continuously fed into the washer, right way up, directly after being depanned.
For certain products which are deposited onto pans off-line, and depanned off-line (such as
croissants for example), these pans can be brought back to the Auto-Bake line for cleaning
(after depanning) and manually fed into the Colussi wash section tunnel. Here, pans would
be loaded onto C5 conveyor, just before the washer entrance, and then manually removed
and palletised as the clean/dry pans emerge from the tunnel.
2.13 Pan Greaser - Dubor

Duty (Please refer Dubor Operating manual)
A Dubor pan greaser unit has been incorporated for greasing Ring Cake pans, which are
baked directly in the pan cavities. The unit is located at the first of three process stations
incorporated into C7 conveyor, and can be rolled in/rolled out for cleaning and servicing.
_______________________________________________________________________________
2.14 Steam Generator – Simons Boilers

Duty (Please refer Simons Operating manual)
A standard industrial 350Kw LPG-fired steam generator c/w timer-controlled blowdown
function, accompanying blowdown tank, and a 340 litre stainless steel feed water tank has
been incorporated to supply steam to the Colussi Washer for water heating.
2.15 Electrical Control Cabinet (MCC) & HMI (Touch Screen

Control)
Duty
The MCC is located adjacent to the Infeed Module. This cabinet contains all the contactors,
variable speed drives, relays, switchgear and a PLC which controls the line functions. A HMI
touch screen interface is located on one of the main cabinet doors, which displays real-time
comprehensive data regarding the system’s status and allows operators to control all
necessary line functions. There is provision to store the product parameters (menu) such as
bake time, oven zone temperatures, chain lubrication frequency, etc. in the PLC memory to
allow for quick changeover between production runs without having to re-program for each
product. Once programmed, the production line operator is only required to select a product
menu which will in turn set all parameters automatically. A VPN link allows for remote
diagnostic assistance of the main PLC, if required.
2.16 ATTACHMENTS
 Production Line Drawing
 Services Information
 Tray/Product Drawings
 Line and Factory Layout
 Colussi Pan Washer & Dyer Operating Instructions Manual
 Dubor Pan Greaser Operating Instructions Manual
 Simons Steam Generator (Boiler) Operating Instructions Manual
_______________________________________________________________________________
SECTION 3
OVEN INFEED MODULE
_______________________________________________________________________________
3.1 Oven Infeed Module
Trays carrying deposited product are transferred horizontally from upstream conveyor (C11)
into the Infeed Module, maintained on the machine centreline by fixed tray guides (for Ring
Cake & Fudgee Bar pans), or retractable tray guides (for Croissant pans). Trays are
presented wide edge leading onto two rows of flat-top conveyor belts which are set at the
same working height as C11. The Infeed Module flat-top conveyor belts continually circulate
when the line is running at a constant line-speed ratio, by way of mechanically gearing
coupled directly to the carrier transport chain idler sprockets located at the oven end of
this module.
Each loaded tray travels along the infeed section riding on top of the flat-top conveyor belts a
distance of some 1.5 metres approximately, whereupon they are prevented from progressing
any further by way of two pneumatically operated pivoting gates. These gates are
controlled via the PLC to swing upwards at a strategic moment in time; blocking the path of
each tray in sequence until the Auto-Bake carrier to be merged with is at the correct relative
position.
As the trays continue to feed into the infeed section from upstream processing, accumulating
behind the tray being held back by the pivoting gates, it will be necessary to create a ‘gap’
between each subsequently released tray. This gap is required to ensure the pivoting gates
can swing up freely and detain the next tray without hitting the preceding tray released.
_______________________________________________________________________________
Since all trays are propelled by the flat-top conveyor belts, which are travelling at a constant
speed, detaining the next tray is accomplished by injecting brake pins upwards from
underneath the trays at just the right height as to thwart the tray’s forward momentum. These
pins are connected to pneumatic cylinders controlled via the PLC and are retracted when a
sufficient gap has been created. At the appropriate time the pivoting gates will swing
downwards again out of the trays path, allowing the liberated tray to continue on its way
riding on the flat-top conveyor belts, which continuously slide beneath the tray unabated by
gate operation.
The speed of the flat-top conveyor belts has been mechanically geared to run approximately
25% faster than the average line speed, taking into account all known product types
nominated by the customer. Whilst this actual percentage ratio will change slightly as
different line speeds are called for, the flat-top conveyor belts will always be travelling faster
than the linear line speed due to the fixed mechanical linkage employed.
The faster speed of the flat-top conveyor belts is required to ensure the released tray can
accelerate along the remaining length of the infeed section fast enough to shunt up behind
two rows of tray pusher dogs, that are pushing the preceding tray forward towards the
oven. It is essential the tray in transfer reaches the preceding pair of pusher dogs in plenty of
time before the next pair of pusher dogs coming around on the pusher dog chain-circuit
block off passage. There are two pusher dog chain-circuits, each mechanically driven by
the same carrier transport chain idler sprockets as the flat-top conveyor belts. However,
unlike the flat top conveyor belts, the dog chain-circuits are geared to run at exactly the
same linear speed as the Auto-Bake carrier transport chain.
Tray support is transferred from the flat-top conveyor belts onto two cantilevered tray slide
arms some distance downstream of where the trays first shunts up against the back of the
pusher dogs. The ‘dead-bed’ working surface of the tray slide arms is fixed about 2mm
below the flat top belts so that the trays are unimpeded whilst travelling over these slides
when riding on the flat-top conveyor belts. As the horizontal travel limit of the flat-top
conveyor belts is reached, the leading edge of the tray in transfer will slowly ‘ride off’ these
belts and rest on the dead-bed surface of the slide arms, said 2mm below, slowing down in
the process since traction from the flat-top conveyor belts has now become impeded. By this
time the entire tray in transfer is forward on the slide arms, well beyond the centreline of the
rear tray pusher dog chain sprockets.
_______________________________________________________________________________
The slowing down affect caused by the front of the tray now riding on the dead-bed slide
arms enables the next set of pusher dogs (attached to the pusher dog chain-circuit) to catch
and shunt up behind the slowed-down tray. The subject tray is then pushed forward towards
the oven by the pair of chain dogs travelling at the same linear speed as the Auto-Bake
carrier transport system. As this set of pusher dogs reach the end of their horizontal travel
and rotate radially about their respective drive sprockets, the tray they are pushing is shoved
to a final resting point just in time to be transported away by the next passing carrier in the
circuit.
At all times the transferred trays remain horizontal and are supported on the slide arms right
up to the point the carriers are at Top Dead Centre of the Infeed Module’s carrier transport
chain idler sprockets, hence there is no perceivable interruption to the horizontal trajectory of
the trays during the entire transfer process. As the carrier proceeds into the oven it drags the
captured tray with it, sliding the tray gently from the tips of the tray slide arms, from whence
the tray will be wholly supported in the carrier frame.
_______________________________________________________________________________
SECTION 4
GAS-FIRED
CONVECTION-218 PAN
BAKING OVEN
_______________________________________________________________________________
Prelude
The oven utilises the Auto-Bake Serpentine™ continuous conveying system incorporating
two identical sections divided by an insulated bulkhead. This is often referred to as a ‘back to
back’ oven. The only difference between the two sections of this oven is that the pans travel
from the bottom to the top of the oven in the first section and from top to bottom of the oven
in the second section. Some of the following images depict a typical single-section oven,
which can be taken to represent any of the two sections in this ‘back to back’ oven. Each
section is identical in all manner of operation other than the vertical direction in which the
trays travel.
Overview
Pans with deposited product are conveyed in carriers from the Infeed Module into the oven,
through 6 zones of heating (3 zones per section) such that the product on exiting the oven is
fully baked to specification. Carriers & pans enter at the bottom of the oven’s first section
and are conveyed in horizontal passes along the length of the oven, transferring vertically
around sprockets at the end of each level to move to the next horizontal run above. Having
completed the full circuit through the first section of the baking chamber, pans are conveyed
from the end of the top level through the internal bulkhead wall into the second section of the
oven. From here pans wind downwards to the bottom run in the second section, in the exact
same manner as they did in the first section, exiting the oven from the opposite end to which
they entered.
The oven essentially consists of 2 Serpentine™ system modules, mounted back to back as
described in the above prelude. The oven has capacity to accommodate a total of 218
carriers at any given time. Each of the two segregated sections of the oven incorporates a
separate heating system comprising 3 gas burners, 3 combustion chambers, 3 turbulence
fans, 3 sets of air ducting, and, 12 diffuser plates, capable of directing discharged hot air
from the top or bottom (of each plate) in varying proportions. These diffuser plates cover the
vast majority of the area above and below the travelling baking pans, and are referred to as
heating plena (plural of plenum). Each of the two oven modules is configured with 3 heating
zones, therefore 6 heating zones in the entire oven. Temperature in each heating zone can
be controlled to a different set point, and each zone of plena can be biased top to bottom in
terms of hot air discharged (in either direction from 0-100%). Each heating zone is divided
equally, i.e. 4 rows of plena per zone.
These features combine to provide flexibility in the baking profile, as is often required where
a customer’s product portfolio is considerable.
_______________________________________________________________________________
4.1 Description of Heating System

The oven has 2 separate baking chambers with each chamber divided into three separate
heating zones. Each heating zone comprising the following system elements:
• Turbulence (re-circulation) fan

• Combustion chamber
• Gas burner (direct-fired into combustion chamber)
• Ducting from combustion chamber to each air plenum in zone
• 4 rows of air plena
• Return ducting from oven chamber to respective turbulence fan
Overview of Convection Oven Heating Components
The operation of each zone’s gas burner is identical. Prior to start-up of the gas burners,
each oven baking chamber must be purged. The time period for the purge cycle is
determined by the size of the oven and the exhaust fan speed. During the purge cycle the
extraction fan will operate at full speed to maximize the evacuation of air (with potential un-
combusted gas) from the oven chamber. The turbulence fans also operate at maximum
speed to assist with mixing the air within the oven chamber. After the purge cycle has been
completed, the extraction and turbulence fan speeds can be adjusted between 40% and
100% to achieve the desired baking performance. If at any point during the purge cycle the
pressure differential switches fail to detect air flow (an inverter/fan motor fault, for example),
_______________________________________________________________________________
the purge cycle is programmed to start again from the beginning of the cycle, as a safety
precaution.
Re-circulated air is extracted from the oven chamber in each zone by each zone’s
turbulence (recirculation) fan. These fans are powered by variable speed AC drives allowing
for volumetric airflow adjustment. The air is drawn through the combustion chamber where it
is heated by a gas burner; the burner is directly-fired into the combustion chamber and heats
the re-circulating air. Safe operation of these fans is verified by a differential air pressure
switch connected across the inlet and outlet ducting (of each fan), which prove sufficient air
flow is detected at any given time.
There are 3 LH & 3 RH turbulence fans identified as follows:

AEROVENT: BCL-530CW/220/HE Centrifugal Fan - 3.5 m³/s @ 640Pa, 1740 RPM
7.5Kw 220V - 3Ph 60Hz Max-E2 High Efficiency Motor - Clockwise Handing
AEROVENT: BCL-530ACW/220/HE Centrifugal Fan - 3.5 m³/s @ 640Pa, 1740 RPM

7.5Kw 220V - 3Ph 60Hz Max-E2 High Efficiency Motor - Anti-Clockwise Handing
(Please refer to fan manual for comprehensive information on fan operation and
maintenance at the rear of this section)
4.2 Gas Train
Typical Components of Gas Train

(Please refer to the manuals at the rear of this section for details on each component)
_______________________________________________________________________________
4.3 Detailed Purge Process

The oven baking chambers must be purged prior to igniting any of the gas burners. The
duration of the purge cycle is usually 3 minutes, as determined by the size of the oven
chambers and the capacity of the extraction fans.
A minimum 5 total room-exchanges (i.e. the sum

volume of all baking chambers) must occur before the
purge cycle is deemed to have been safely executed.
Every fan in the heating system (including oven extraction, oven turbulence and gas-fired
burner) is equipped with a dedicated differential pressure switch to prove that each particular
fan is pulling sufficient airflow when called upon to do so. The differential pressures are
taken between the intake side and discharge side of each fan. Before commencing each
purge cycle the PLC must first check all pressure differential switches throughout the entire
system are operating correctly, insomuch they signal the PLC as soon as a ‘no-flow’
situation has been detected. To do this, each time an attempt to start the burners is initiated
the PLC shuts down all oven fans & closes all extraction dampers. If operating correctly,
each pressure differential switch will then send a ‘no flow’ signal to the PLC which upon
receiving, confirms the purge sequence is safe to commence.
4.3.1 PLC-Automated Purge Sequence

All extraction dampers are fully opened and all extraction & turbulence fans are run at
maximum speed for the duration of the entire purge cycle. A timer relay (in the MCC) will
commence timing the purge cycle of each burner once airflow is detected from every fan in
the oven upon start-up being initiated. Once the timer relay has timed out, the ‘Oven
Chamber Purged’ relay in the MCC will latch, but only if the following conditions remain true:
• All Turbulence Over-Temperature relays remain healthy (K61, K62, K63)
• All Exhaust Over-Temperature relays remain healthy (K64)
• All Burner Over-Temperature relays remain healthy (K103, K203, K303)
• All Exhaust and Turbulence Fans Differential Pressure Switches detect air flow.
(Note: All extraction dampers are permitted to move from their fully-opened position at this
time)
Once the Purge Process is complete the PLC will send a ‘Burner Run Signal’ (which can be
seen on the Burner Status Popup on the Touch screen). Only at this time can the extraction
fans and turbulence fans revert to their programmed set point.
_______________________________________________________________________________
When the ‘Oven Chamber Purged’ relay is latched and the ‘Burner Run Signal’ is on (i.e.
K101/201/301 are all closed), and, both the Min Gas Pressure & Max Gas Pressure switches
are healthy, each burner will be started by an individual Burner Flame Safeguard Controller
(a.k.a. burner controller or LFL). There is a dedicated burner controller for each burner in the
oven.
4.4 Burner Start-Up Sequencing

Once the PLC has initiated burner start-up, each burner controller will commence a
sequencing process simultaneously as follows:
• Check burner fan pressure switch indicates ‘no air flow’.
• Check flame rod indicates ‘no flame’
• Start burner fan
• Check burner fan, applicable turbulence fan, and common extraction fan pressure
switches all indicate ‘air flow’.
• A spark is initiated with the burner control valve at zero output
• After 3 seconds, the Start Gas (Pilot Gas) valves are energised
• After a further 3 seconds, the spark is turned off and Flame Rods monitor the start
gas flame. If no flame is detected, the burner controller “locks out” and requires a
manual reset – in this case, the entire sequence is started again
• Once Pilot Flame has operated satisfactorily without spark for 5 seconds, the Main
Gas valves are energised
• Following 3 seconds of Main Gas valve open, the Start Gas (Pilot) valves are closed
• The main flame is checked by the flame rod for 5 seconds and providing the flame is
stable, the burner control is released to modulation.
4.5 Temperature Control

The air temperature is monitored at the exit of the combustion chamber with an industrial
temperature probe (k-type thermocouple); this probe is connected to the PLC control unit
and is used to modulate the burner. The gas burner output is variable and has a specific
turn-down ratio (40:1 for example). This ensures the oven can produce heat between the
rated maximum output value and 1/40th of the maximum output (using 40:1 turn-down ratio
as an example). Whilst the oven is heating up the burner will be operating at maximum
output, but when it reaches temperature the output will be modulating to hold the air
temperature at the required set-point. The PLC control unit has a PID controller that
_______________________________________________________________________________
regulates the air temperature within 2ºC of the set-point. A second thermocouple is mounted
at the exit of each combustion chamber and is connected to a temperature control relay that
functions as an over-temperature relay. This serves to shut down the burner if a temperature
in excess of 400ºC is detected.
Typical Convection Oven Heating Zones

The heated air exiting the combustion chamber passes into 2 sets of ducting which deliver
equally to the left and right side of the oven. Within the oven an air plenum is fitted above
and below each level of the Serpentine transportation path. The air plenum is divided into
two sides to receive the air from the delivery ducting of the left and right sides. The air plena
are fitted with a further divider plate to separate top and bottom outlets.
The top/bottom divider position is adjustable to vary the ratio of heat supplied to the top and
bottom as required by the baking process. Electric actuators are fitted to control and adjust
the position of the top/bottom heat dividers.
Within the oven the air temperature of each level of the Serpentine conveying system is
monitored with a temperature probe connected to the PLC I/O modules. These probes are
intended to measure the actual air temperature of the baking chamber at each level, to
provide feedback for analysis only.
_______________________________________________________________________________
Touchscreen Panel – Heat Parameters
The following parameters are monitored:
• Burner output
• Turbulence fan speed
• Delivery air temperature
• Delivery damper position
• Zone temperature
• Exhaust fan speed % or exhaust damper position %
4.6 Oven Exhaust System

In addition to the heating zones, the oven is also equipped with an exhaust (a.k.a. extraction)
system. The function of the exhaust system is to remove excessive moisture from the oven
that is created during the baking process. It also serves to vent ‘products of the combustion’
to atmosphere. The exhaust fan is powered by a constant speed motor. Operation of the
exhaust fan is verified by a differential pressure air pressure switch connected across the
inlet and outlet ducting of the fan. There is one extraction fan in each section of the oven,
two in total, identified as:
AEROVENT: BCL375/220 Floor-Mounted Centrifugal Fan - 1.0 m³/s @ 375 Pa

1390 RPM - 1.5Kw 220V - 3Ph 60Hz Max-E2 High Efficiency Motor
Moisture extracted from the product during the baking process is converted to steam. If
allowed to build up inside the baking chamber the steam would continue to raise the
humidity level within the oven and subsequently slow down the moisture extraction rate
necessary to complete baking within a defined period of time.
_______________________________________________________________________________
Residual moisture levels in baked-off product would also be affected if excessive steam
within the baking chamber were not vented. The baker can control residual moisture level
and optimize bake times by manually setting the exhaust damper position on the HMI,
displayed as a percentage of its fully open position i.e. 100% means the damper is fully
open.
4.7 Pan Too-High Sensor

A ‘Pan Too-High’ sensor is located at the entrance to the oven. This sensor consists of a
stainless steel flap connected via a hinging rod to a limit switch.
The purpose of the sensor is to stop the oven conveyor when a pan is not positioned
correctly on the carrier, or has been damaged to some degree. There is a possibility of a jam
in the oven circuit if such a pan is allowed to pass into the oven beyond this point.
4.8 Oven Cleaning – Annual Schedule

WARNING: Ensure high-level cleaning is undertaken
safely using approved mobile platform apparatus and
safety harness as and when required in compliance
with local OH&S guidelines.
Lock-off drives before commencing cleaning!

Please refer Generic Sanitation Schedule in relevant section of this manual for daily, weekly
& monthly oven cleaning recommendations. The annual schedule below, which also appears
in the Generic Sanitation Schedule describes the procedure for undertaking major deep-
cleaning of the oven. It assumes typical baking conditions have prevailed during a 12 month
period. The frequency of this deep-clean operation may be increased or decreased
depending on actual operating conditions.
1. Remove pans from carriers and cycle empty carriers into the oven such that the
entire oven is void of pans. Note: If oven is in particularly poor state and requires
aggressive scraping to remove product build-up on heater plates/plena, then
additional space can be provided by removing enough carriers from the chain circuit
to accommodate a full vacant row inside the oven. If this is done, start the line and
move the vacant section of chain to the uppermost row in the oven. Lock-off
drives on each occasion after incrementing gap, before re-commencing oven
cleaning! Carry out cleaning operation as described below, incrementing gap to the
next row below, as each subsequent row has been completed.
2. Cover all electrical switches, sensors, thermal couples, and viewing door ventilation
apertures such that all electrical components are completely watertight.
_______________________________________________________________________________
3. Open oven doors. Starting from the top of the oven and working down, loosen burnt
material that has spilt onto the heater plates/plena with suitable hand held scrapers.
Use extended handle or pole for scraping middle section of plenum if unable to reach
with hand held scrapers. Thoroughly clean framework including sprocket columns,
sprockets, thermal plates of any stubborn product residue, dust, paper cases,
greases and oils etc.
4. Brush product residue from the heater plates/plena allowing it to fall down below
where it can be collected and disposed of more readily. Remove residue that has
collected on ledges or oven frames, using industrial vacuum cleaners where
necessary.
5. Working from the top level down, use compressed air to remove smaller loosened
product, making sure all oven doors are open to allow airborne product to escape
oven.
6. Scrape and remove grease & residue from chain rails and sprocket areas.
7. Using a suitable cleaning agent (as recommended by expert from Ecolab/similar

organization upon inspecting condition of oven), spray all internal oven surfaces
including walls, door liners (except viewing doors), floor, ceiling, chain rails, heater
plates, sprocket assembles and turbulence manifolds. Allow soaking for a period of
time as recommended by visiting expert.
8. Working from the top level down, use town-pressure hot/warm water hose to wash
out oven internally, making sure all scraped residue and cleaning agent has been
thoroughly flushed away. DO NOT spray directly at viewing doors!
9. Use commercially available stainless steel aerosol cleaning products (such as 3M

brand), or baby oil with soft clean wipers to polish doors and panels.
10. Replace all carriers if removed, and replace all baking pans, ensuring any damaged
units are not put back into the baking circuit.
11. Clean turbulence/exhaust fan support frames and drip trays.
12. Ensure all personnel are clear of the line. Unlock drives and commence start-up
procedure.
_______________________________________________________________________________
4.9 ATTACHMENTS
 AeroVent Fan Operation & Maintenance Instructions
 Eclipse Burner Manuals (Design and Installation)
 Eclipse Air Heat Burners – Model AH
 Eclipse Butterfly Valves and Belimo Servo Motors
 Burner Fan Manual – Moro
 Krom Schroder Pressure Switches
 Siemens LFL Series – Burner Flame Safeguard Control
 Schematic of Gas Supply Chain
 MSDS Superwool 607 Triple T
_______________________________________________________________________________
SECTION 5
DRIVE SYSTEMS
for
CARRIER TRANSPORT CHAIN
_______________________________________________________________________________
5.1 Description of Drive Units

There are three drive units used on the Auto Bake system:
• Master Drive Module. Main drive of the system located directly after the oven
inspection module (in most cases), and master to the two remaining Drive Modules.
• Secondary Drive Module. Slave to the Master Drive Module, usually located within
the Outfeed Module.
• Auxiliary Drive Module. Slave to the Master Drive Module, located in the Upper
Ambient Cooler Module in this case.
Oven Drive Unit – Drive #1 (Master)
Cooler-Mounted Drive Unit – Drive #2 (Auxiliary) c/w Cooler-Mounted Chain Take-Up
Outfeed Module Drive Unit – Drive #3 (Secondary)
_______________________________________________________________________________
5.2 Drive Modules

All Drive Modules incorporate a shaft mounted motor/gearbox assembly protected by a
safety mechanical overload system. The mechanical overload systems are identical for all
drive module types. The Master Drive Module governs the line speed at which baking trays
are conveyed through the oven. Usually positioned directly after the oven inspection station,
the Master Drive Module speed is pre-selected to suit the product being baked. The Master
Drive does not ramp up or down during normal operation, it remains constant at set speed.
An air pressure switch is installed at each Drive Module to ensure there is sufficient pressure
to correctly operate the system. The pressure switch is electrically interlocked to the main
control system to shut the line down on safety in case of low air pressure failure. Should the
air pressure go below the set point, the line will stop, an audible alarm will sound and the
HMI will annunciate ‘Low Air Pressure’. The line will not re-start until the pressure is
restored.
The Drive units provide power from the shaft-mounted motor/gearbox via a common Drive
Cross-Shaft. Output torque is dispatched equally via Drive Sprocket Assemblies mounted
directly to the Drive Cross Shaft, propelling the Carrier Transport Conveyor Chains
incorporated on each side of the machine. The transport chain used in the system is 50.8mm
(2”) pitch roller type fitted with extended chain pins every 11 links to suit the width of baking
trays used on this machine (nominally 500mm), hence referred to as 558.8mm (22”) ‘tray’
pitch chain. Hardened-stainless steel ferules incorporated in the carrier end-assemblies
engage with these extended chain pins. When setting up the carrier transport conveyor
chain alignment, adjustable drive sprockets that can be rotated slightly and locked in position
are used to achieve accurate pin alignment from one side of the system to the other. The
main conveyor chain tensioning, overload & pneumatic control systems are described later
in this section.
_______________________________________________________________________________
5.3 Power Transmission Motor/Gearbox Unit

The power transmission is by a hollow shaft, helical bevel motor/gearbox unit. The unit
delivers torque via a 3-phase motor coupled directly to the reduction gearbox. The motor
power and gearbox reduction ratio has been sized to suit the calculated loads and line
speeds relative to the customer’s needs. Gearboxes supplied with the drive units require no
regular maintenance other than periodic inspection of oil levels. Oil top-up may be required.
Please refer to the attached ‘SEW’ manufacturer’s manuals for maintenance instructions at
the end of this section.
The Motor/Gearbox unit fitted on all three Drive Modules is identified as follows:
SEW Helical Bevel Gearmotor, 70.46/FINITE Ratio – 3.0Kw Motor - 3Ph 220V 60Hz
Part No. KA87DRE100LC4/ES7C/V-147 (Mounting Position M2)
Shaft Position B, C/W Forced Cooling Vent 220V single phase 60Hz - Speed 1455/21
Terminal Box Position 270º - Encoders Supplied & fitted by SEW
5.4 Drive Speed Synchronisation

A variable frequency inverter controls each drive motor. Line speed is governed by
parameter settings accessible through HMI screen menus.
Drive # 1 is always denoted as the Master Drive and Drive # 2 (and Drive #3 where
incorporated) is denoted the Slave Drive(s). All drives are fitted with encoder feedback
motors. Drive #1 is also fitted with a linear transducer mounted to one of its take-up slides.
Here, the transducer sends information back to the PLC to slow down or speed up the next
downstream drive (Drive #2), as initiated whenever the take-up slide roams beyond a pre-
determined range within its travel limits, hence maintaining drive speed synchronisation on
an average basis. Where a third Drive Module is incorporated, a second linear transducer is
mounted to one of the take-up slides on Drive #2, where it fulfils the same duty as the first
transducer in governing speed synchronisation, this time between Drives 2 & 3.
_______________________________________________________________________________
Typical operation of linear transducers in synchronising motor speeds: At start up,

Drive # 1 runs up to the set speed determined by the bake time of the oven as inputted by
the operator at the HMI. Drive #2 runs up to a speed within a synchronization band and its
speed is adjusted by a set proportion until the linear transducer has moved to a central
position. At this point, drives #2 is synchronized with the master drive and its speed is locked
in to the master drive speed. If, due to load considerations or other factors, a drive moves
(i.e. slows down or speeds up) out of the acceptable synchronization band as determined by
the linear transducer, then it will reposition itself automatically until it is resynchronized with
Drive #1.
5.5 Mechanical Overload System

The drive units incorporate a mechanical overload protection system. The gearbox is
coupled via a hollow output shaft directly to the drive cross shaft. The gearbox is not
anchored to the machine frame in any way, instead it is allowed to pivot naturally about the
axis of the main drive shaft as torque reaction to chain loads occur. A torque arm is bolted to
the side of the gearbox which restricts movement between an adjustable stop in one
direction and the coupled Overload Air Cylinder in the other direction. The adjustable stop
supports the gearbox when air pressure to the cylinder is turned off during maintenance or
sanitation etc.
Typical Overload Bracket and Switch
The overload cylinder is mounted in such a way as to provide resistance to the natural
pivoting action of the gearbox when reacting to varying chain loads. Sufficient resistance is
maintained by applying the correct air pressure to the cylinder to hold the overload limit
_______________________________________________________________________________
switch in the closed position. In the event that the gearbox is subjected to unusually high
chain loads, the gearbox will pivot against the resistance offered by the air cylinder/s,
allowing the overload limit switch to be released from its normal operating position. The
overload limit switch is normally depressed against the overload bracket and when fully
released will trip, causing the conveyor system to stop instantaneously. The sensitivity of
the overload system on each drive module is dependent on the air pressure applied to the
respective overload cylinder. The pressure setting for each drive module is determined
during commissioning when full production loads are established.
Typical Pneumatic Control Panel

A programmable pressure regulator is used to set and control correct overload protection.
Once optimum pressure settings have been established, only minor pressure adjustments
can be made without changing pre-set programming parameters, determined during
commissioning. Only a qualified programming technician/engineer should attempt to make
any post-commissioning changes to the PLC program, and only then once consultation and
agreement with Auto-Bake has been undertaken. A user ID password protects the line from
unauthorized tampering of this critical protective system. Should circumstance change
affecting chain drag following commissioning (such as insufficient chain lubrication for
example), the pre-set air pressure setting may prove insufficient and the line may stop
unduly, without apparent cause. In which case the audible alarm will sound and the HMI
touch screen will show ‘Drive Overloaded’.
_______________________________________________________________________________
In this instance, the overload system is probably reacting to chain surge as a consequence
of extremely dry chain, thus giving maintenance personnel prior warning the chain is in need
of lubrication. A quick check by maintenance to ensure the chain is free from any mechanical
obstruction should be undertaken. If all is well, the chain lubrication system reservoir should
be checked and filled, and the chain lubrication system manually engaged. Generally the line
will run with minor nuisance trips until such time the chain lubrication takes hold, however,
should the chain be excessively dry at this time, it may be necessary for the overload
pressure setting to be increased, ever so slightly, in order to propel the line. Only at this time
should maintenance personnel access the necessary password protected fields and make
the adjustments to the pressure setting.
After the line settles down following successful

chain lubrication, it is imperative that the maintenance technician reinstates the
original overload setting. Failure to do this will render the line ‘under-protected’
should a future mechanical obstruction occur, possibly resulting in unnecessary
damage to the carrier transport system.
In the event of any overload annunciation displayed on the HMI

touch screen, operators should contact maintenance personnel and have them check
the chain circuit for any mechanical obstruction that may have occurred. Under no
circumstance should an operator endeavour to start the line after a ‘second’ attempt
has failed.
The pressure setting for the Overload Sensitivity Regulator should be as low as
possible; it should enable the line to start-up and run smoothly, but will stop the line at the
slightest interference outside of normal operating conditions. The load encountered during
normal operating conditions governs the optimum pressure settings. System load will vary
during the start up and run out phases of production runs, and will also vary from one
product to another depending on selected line speed, product and pan weight. Therefore
the optimum pressure settings will involve a learning curve, erring at all times on the side of
safety.
_______________________________________________________________________________
It is better to incur a nuisance trip, say once per day, rather than run the system under
protected. As such, it may be necessary to change post-commissioning settings should a
previously untested product be brought into service, or other circumstances change affecting
normal operation (such as line speed changes for example). Should this be the case, please
contact Auto-Bake before attempting to make any changes to the post-commissioning
pressure setting.
In the event of chain path obstruction, serious transport

component damage may occur if the overload pressure is inadvertently set too high. If
the continuous operation of the line requires that a higher than previously established
overload pressure be adopted, then check the system for a possible fault.
Typical cause may be dry conveyor chain due to inadequate lubrication (as used in above
example), or, chain take-up pressure set too high or too low. Should neither be the case,
please check for possible chain path obstruction. If no obstruction is found, check sprocket
bearings for noisy operation and replace suspect parts immediately. There should be no
need to alter the setting after commissioning except where a new ‘untested’ product or line
speed has been introduced into service.
Only authorised personnel should make such adjustment
5.6 Main Chain Take-Up System

Every drive module incorporates a chain take up assembly to arrest loose chain that is
naturally generated immediately downstream of each propulsion station. Where more than
one drive module is used in any given chain circuit there will be a Main Chain Take-Up
System incorporated into one of these drive modules. The Main Chain Take-Up System only
differs from standard chain take-up assemblies by virtue of the stroke length of the cylinders
and slides. Here, whereas the standard take-up assemblies require only short stroke
cylinders & slides, typically 150mm, the Main Chain Take-Up System incorporates 500mm
stroke cylinders and slides. This additional travel distance is necessary to accommodate
removal of a full ‘tray pitch’ of chain as/when required.
IMPORTANT: Over the life-cycle of the carrier transport chain, several ‘tray-pitches’
can be safely removed before the chain needs to be replaced with new. Auto-Bake
recommends replacing carrier transport chain after it has stretched 1% of its original
length o/a. In this particular case, the line comes equipped with 445 trays; therefore
4.45 tray-pitches of chain can be safely removed. Rounding up to the next tray-pitch,
by the time the 5th tray-pitch of chain is due for removal, please replace the chain!
_______________________________________________________________________________
The Main Chain Take-Up system is situated on the ‘slack’ side of the nominated drive unit
and comprises a Chain Take-Up Cylinder mounted on each side of the machine. Each of
these cylinders is connected to their respective side Take-Up Slide assembly, which consists
of a slide plate and pair of slide rails. Tension Sprockets, which form part of the Tension
Slide assembly, engage with the conveyor chain. The Tension Slide assembly also ensures
that chain pin alignment is maintained.
There are two take-up cylinders per take-up system, (one per side of m/c). These connect in
parallel to a pressure-regulated air supply. The pressure setting is determined during
commissioning when full production loads are established. The customer’s maintenance
department should record the correct pressure setting and conduct daily checks to ensure
that the setting is maintained.
Due to normal settling in and normal wear/stretch

of the chains, the Main take-up cylinders will over time reach the end of their designed
travel. Just prior to this time, it is required to remove one tray pitch (a.k.a. carrier
pitch) from both chains. Care must be taken to remove the same amount from both
sides and to remove precisely one carrier/tray pitch only, i.e. 10 Links 508mm pitched
trays (20”), 11 links 558.8mm pitched trays (22”), and so forth. Where fitted, a travel
limit sensor will trigger an alarm on the HMI and annunciate that it is time to remove a
tray pitch of chain. The same sensor will also trigger the ‘red’ flashing light on the
stack beacon. Please refer to the “Procedure for the Removal of a Pitch of Chain” in
the Attachments section at the back of this chapter.
The pressure settings for the Chain Take-Up regulator should be as low as possible. It
should be set so that chain slack is ‘just’ eliminated. Excessive chain tension is
unnecessary and will result in accelerated wear of transmission components and
could cause the mechanical overload system to engage unnecessarily. The optimum
pressure setting may therefore involve some learning curve, erring at all times on the
side of safety.
Typical Main Chain Take-Up System
_______________________________________________________________________________
5.7 Drive System Maintenance
Refer Generic Maintenance (P.M) Schedule. The Chain Tensioner pressure

regulator is fitted with a filter unit. It is recommended that the filter is visually checked and
cleaned on a monthly basis; however, this may vary depending on quality of supplied air.
The slide plates and rails should receive a light coating of food-safe grease as required to
maintain coverage. All pillar block bearings require no additional maintenance other than
periodic inspection for wear.
5.8 Air Supply

It is the user’s responsibility to provide clean & dry compressed air adequately delivered to
the Auto-Bake line at 620-690 KPa (90-100 psi) continuously.
Compressed air that is not delivered in a clean and/or dry condition, or is

delivered in excess of 100 psi, can damage or cause premature failure of Auto-Bake
equipment, which is designed to operate in the standard commercial industrial range
as specified above.
Other OEM warranties of pneumatic equipment used on the Auto-Bake

line may be void if damage to components is proven by excessive pressure or
impurities in the compressed air supply. An Air Service Unit is supplied with each
overload system, comprising a mist separator, air filter, and when required, a mist
lubricator. The mist separator collects small amounts of water vapour that may be
present in the air supply and should be drained regularly. The filter unit should be
inspected monthly and cleaned as required; however, more frequent inspection may
be necessary depending on quality of supplied air.
5.9 Air Pressure Switch

In the event that air supply pressure drops below a predetermined level, or has been
inadvertently switched off, an Air Pressure Switch connected to the overload system’s air
supply line will sense low air pressure. When low air pressure is detected, the line will stop
instantly or be prevented from starting up, (which ever may be the case). In the event that
the line has stopped or cannot be started because the low air pressure switch has been
_______________________________________________________________________________
activated, the fault ‘Low Air Pressure’ will register on the HMI touch screen, as too, an
audible alarm will also be triggered.
If adding ancillary equipment on or about the Auto-

Bake line that may consume additional compressed air, extreme care should be
undertaken to ensure the Auto-Bake line is not starved of air.
5.10 ATTACHMENTS
 Motor Gearbox Catalogues
 Drawing of Main/Master Drive
 Schematic of Chain Tension and Overload Pneumatic Circuit
 Procedure for the Removal of a Pitch of Chain
_______________________________________________________________________________
SECTION 6
CONVEYOR SPROCKET
SYSTEM
_______________________________________________________________________________
6.1 Chain Idler & Levelling Sprocket Assemblies

The tray transport chains that run through the entire Auto-Bake system are carried on
sprockets which are of similar size and style. There is a difference however in the bearing
‘clearance’ designation (either C3 or C4), the type of lubrication used in the bearings, and
the type of bearing seals used in oven sprocket assemblies versus sprocket assemblies
used elsewhere throughout the line. Each oven sprocket assembly incorporates a metal
‘Nilos’ shield on the outside face of each bearing. These Nilos shields protect the bearings
from ingress of foreign material, and also help retain the grease within the bearings and
sprocket housings.
Each oven sprocket assembly has a readily accessible greasing point located at the end of
each sprocket shaft that allows for periodic lubrication of the oven bearings.
Only KLUBER BARRIERTA L55/2 should be

used in the oven bearings!
(Please refer Generic Lubrication Schedule in this manual)
The ball bearings fitted to all sprocket assemblies other than those in the oven are of the
more common type with standard clearance designation. These are pre-lubricated with
grease and sealed, therefore requiring no further maintenance during their expected
lifecycle.
The bearing housings for the oven-sprockets are the same design as those for the cooler-
sprockets, also their removal and replacement from the machine is performed in the same
manner. After relaxing the conveyor chain tension fully, the bearing housing c/w bearings
can be removed without disturbing the idler-sprockets/shafts, i.e. the sprocket can be left
engaged with the conveyor-chain.
_______________________________________________________________________________
6.2 Chain Idler & Levelling Sprocket Assembly & Removal
If it is intended to remove the idler-sprocket, as well as, or instead of,

withdrawing the bearing housing, it will be necessary to take out about five pan-carriers at a
sprocket to be withdrawn. To remove a bearing housing and/or an idler-sprocket,
perform the following steps: -
Note: Only qualified personnel experienced with equipment of

this type and who use ‘Best Work Safety Practices’ should carry
out this work.
Note: Stop the system and isolate the power-supply to prevent

unauthorized or inadvertent starting. TAG (Padlock) the isolating
switch. Turn off and TAG the air-supply to the pneumatic-cylinders
that tension the drive-module chain-tensioning sprockets, exhaust the
energy in the cylinders.
1. Fully relax the static tension of the chain on the sprocket to be removed by rotating
the sprocket in both directions to create maximum chain slack. Use a suitable lever to
rotate the sprocket in question as not to damage the parts.
2. Should the chain want to ‘run’ back, use a heavy duty ‘C’ clamp or similar ‘safe’
clamping device to prevent this occurring. Take care not to over-clamp the chain and
risk damaging it, or other components. If the clamp does not fit or clamp correctly,
discard it and obtain one that will.
Note: Prior to disconnecting the main conveyor chain or

removing a bearing housing, always ensure chain tension has
been backed-off fully.
3. There are a number of sprocket assemblies coupled by cross-shafts located at the

outfeed end of the Oven & Coolers. These cross-shafts ensure conveyor chain pin
alignment is maintained.
4. If it is the intention to service only the cross-shaft bearing-housing, remove the

bearing retaining screw and cap washer, taking care to mark the position of the
timing gear and its relationship to the adjoining timing gear train prior to removing
it, and then remove the bearing-housing flange screws. The bearing housing can
now be slid out from the cross-shaft being serviced.
_______________________________________________________________________________
IMPORTANT:
The relationship between the steel chain sprocket and the alumin’m
levelling sprocket is very important; if the position of the carrier
bearing support tooth valley on the alumin’m levelling sprocket is out
of alignment with the corresponding tooth valley on the chain
sprocket (i.e. corresponding sprocket teeth are not synchronously
timed @ TDC), the carrier bearings will not engage in the levelling
sprocket correctly. This can lead to component damage. This degree
of care similarly applies to cross-shafts and all other timing
assemblies throughout the machine.
Auto-Bake have incorporated brightly painted timing dimples on each

timing gear to assist re-assembly of existing components, should
these gear sets need servicing, however, these timing marks are not
to be used if new steel or alumin’m sprockets are used to replace
worn/damaged existing counterparts, or, in cases where the existing
gear sets may have been subjected to severe torsional loads that may
have altered the precision of these timing marks.
In all cases, please use the Auto-Bake supplied timing jig

when setting or checking the relationship between the steel
and alumin’m sprockets.
_______________________________________________________________________________
6.3 Procedure for Setting/Checking Timing on LTS Sprocket Sets
Warning: It is absolutely essential that the extended chain pins used

for setting the timing between chain sprockets & corresponding alumin’m sprockets
are in pristine condition; if any of these chain pins are bent it will throw out the timing
of that particular sprocket set, which could lead to serious component damage and
production downtime.
1 Timing between the chain sprocket teeth and alumin’m levelling sprocket teeth can be
adjusted by sliding out the central idler timing gear from its stub shaft. This enables the
alumin’m levelling sprocket to freewheel.
2 Engage Auto-Bake supplied timing jig between the chain sprocket & alumin’m levelling
sprocket set, adopting either of the applicable methods shown below (depending if chain
connected).
3 The timing jig locator cylinder will ride upwards on the side of the levelling sprocket tooth
if timing is incorrect, as shown in below left image. When timing is correct, the timing jig
locator cylinder will sit snugly between the teeth of the levelling sprocket as shown in
below right image.
Incorrect Timing Correct Timing
_______________________________________________________________________________
4 Select any tooth valley of the alumin’m levelling sprocket initially, drop timing jig locator
cylinder into this valley as shown below and hold down firmly, then attempt to slide
central idler timing gear back onto stub shaft and engage with mating gears. If the
central idler timing gear fails to slide easily [with equidistant backlash] between mating
gears, i.e. ‘best fit’, remove central idler timing gear, raise timing jig locator cylinder
away from tooth valley and rotate alumin’m sprocket 1 tooth (in any direction). Drop
timing jig locator cylinder into new valley and hold firm, then attempt once again to slide
central idler timing gear back onto stub shaft. Repeat this process for all 14 teeth of the
alumin’m levelling sprocket (if necessary) to establish ‘best fit’.
All timing gear assemblies are set and locked at time of installation and commissioning. It is
important that these settings are not altered by anyone who does not have a full knowledge
and understanding of their application in the system.
If it is intended to remove the steel idler-sprocket and/or the alumin’m levelling sprocket from
the machine, then all cams and guides that may impede this operation will need to be
removed beforehand. Chain sprockets can be removed by moving them inwards whilst the
chain is still engaged, until such point the chain can be slipped off the sprocket.
NOTE: Sprockets and housings are reassembled in

reverse order as removed.
6.4 Cross-Shaft System

A system of cross-shafts is fitted to the Auto-Bake ovens and coolers to assist in maintaining
the square alignment of the baking trays during their passage through the machine. These
cross-shafts serve to couple the idler sprockets on one side of the machine to those opposite
at various selected points, and are positively aligned with identical spur gears as used
elsewhere throughout the transport system. The cross-shafts are carried on ball bearings
with similar specifications to those for the normal idler sprockets in their respective locations,
i.e. high-temperature bearings in the oven and normal ball bearings in the cooler etc.
_______________________________________________________________________________
IMPORTANT:
The radial alignment between opposing chain sprockets geared to
cross-shafts is very important. Cross-shafts serve two purposes.
Firstly, by virtue of their regular spacing throughout a typical line they
ensure transport carriers are square to the machine’s longitudinal axis
as they negotiate 180º sprocket rotations. Secondly, irregular or
localised chain stretch on one side of the machine (relative to the
other side) will be ‘contained’ between upstream and downstream
cross-shaft assemblies geared to respective chain sprockets. This
results in the ‘un-stretched’ side chain pulling more of the carrier load
than the ‘stretched’ side chain (between two consecutive sets of
cross-shafts), hence tending to auto-correct unevenly stretched chain
over time.
As per Level-Tray System (LTS) timing gears, Auto-Bake have

incorporated brightly painted timing marks (dimples) on each mating
cross-shaft timing gear to assist re-assembly of existing components.
In the event the timing gear connected to either the cross-shaft or the
steel chain sprocket ever needs to be replaced, then it is imperative
that the cross-shaft assembly be re-timed as per the procedure below.
Typical Cross-Shaft Gear Train

If re-timing cross-shaft assemblies becomes necessary it is
recommended that jigs (or similar) to those depicted below
be used. Auto-Bake can supply OEM jigs on request, which
are explained in following sections.
_______________________________________________________________________________
6.5 Procedure for Checking Cross-Shaft Alignment
1 If possible, stop the machine when the extended chain pins are at TDC (or as near as
possible to TDC), riding on the sprocket set connected to the cross-shaft being checked.

switch.
2 Measure distance from the machine column to either the extended chain pins (if on/near
TDC), or, the actual chain sprocket tooth nearest to, but not yet passed, TDC. If
checking via extended chain pins, please ensure these pins are in pristine condition and
are not bent in any way.
3 If pins/sprocket tooth are misaligned by more than 10mm please schedule a rectification
service in near future.
6.6 Conditions for Re-Setting Alignment of Cross-Shafts
In context of the following procedures the ‘Cross-Shaft Assembly’ includes all transmission
components connecting the chain sprocket on one side of the machine to the chain sprocket
on the opposite side of the machine (it does not therefore include alumin’m levelling
sprockets and levelling sprocket timing gears). There are several conditions to consider
before attempting to re-set cross-shaft alignment, and, depending on which condition is most
applicable, a different procedure may be required. These conditions are identified as follows:
• Condition #1 – Original ‘Cross-Shaft Assembly’ still exists (with all original transmission
components) and has been disassembled for routine servicing (e.g. changing bearings
by way of controlled line stop where all timing mark are aligned - per below image), and,
all transmission components are in good working condition (i.e. minimal additional
backlash has developed since new).
_______________________________________________________________________________
Controlled stop with all timing marks aligned
• Condition #2 – Original ‘Cross-Shaft Assembly’ still exists (with all original transmission
components), but upon checking cross-shaft alignment as per previously described
‘checking’ procedure, deduced extended chain pins were out of alignment by more than
10mm due to wear & tear (excessive backlash).
• Condition #3 – New ‘Cross-Shaft Assembly’ transmission component(s) is fitted to

replace worn original transmission component.
6.7 Procedure for Re-Setting Cross-Shaft Assembly Alignment –

Condition #1

out this work.

1 There is no need to disengage transport chain from the steel idler sprockets for routine
servicing of cross-shaft assemblies (unless the steel sprockets are in need of being
replaced, in which case Condition #3 would apply). Carriers can be removed either side
of the cross-shaft assembly being serviced if so required to improve access.
2 All ‘Cross-Shaft Assembly’ components should be reassembled in reverse order to

which they were disassembled (i.e. all original timing gears should be mated to original
shafts).
3 It may be necessary to leave one or both sides cross-shaft assembly intermediate timing
gears (red/blue dimpled gears) disengaged initially if timing marks are difficult to align.
This allows corresponding LH & RH steel chain sprockets to rotate (slightly)
independently of each other. If so, go to step 4. If intermediate timing gears can be
_______________________________________________________________________________
aligned with original timing marks and engaged with mating gears without needing to
proceed to step 4, please proceed to step 5.
4 Rotate LH steel chain sprockets and/or LH cross-shaft ‘flat’ with lever/adjustable wrench
as described in below images to align mating timing gears so that the LH intermediate
timing gear can be engaged, ensuring all original timing marks are correctly aligned.
Repeat when assembling RH intermediate timing gear.
5 Engage intermediate timing gears so that the original timing marks (dimples) all line up
as indicated below.
6 Replace intermediate cross-shaft timing gear retainer plates and fasten securely.
7 Check all is in readiness to re-start the line, when safe to do so, run the line for several
minutes to allow the new cross-shaft setting to bed-in, then stop and check extended
chain pin alignment as previously described. Do this several times to ensure timing is
consistently held.

Condition #2

out this work.
_______________________________________________________________________________

switch. For this procedure carrier transport chain should
not be removed and normal chain tension should be
maintained (i.e. do not turn off [or back off] air pressure
to chain take-up cylinders).
The intermediate cross-shaft timing gear can be removed and then immediately re-engaged
with mating timing gears, having been indexed by 1-tooth relative to the original setting. This
procedure is only required on one side of the machine, the opposite side will remain as
originally supplied. This will move the position of the extended chain pins on one side
relative to the opposite side chain pin by 14mm. So, if a 10mm discrepancy exists, this
procedure will correct the misalignment back to just 4mm when the gear is indexed in the
appropriate direction.
Note: The original ‘red’ or ‘blue’

timing dimples will no longer be
relevant on the side where the timing
gear has been indexed, and this
information should be logged into the
maintenance records. Alternatively, a
new timing dimple can be drilled into
the indexed timing gear and painted
the correct colour, removing the
original dimple with a grinder.
1 To remove the intermediate cross-shaft timing gear it will first be necessary to neutralise
loading on the timing teeth by rotating either the applicable chain sprocket or cross-
shaft. This can be done as depicted in below images.
_______________________________________________________________________________
2 Slide intermediate cross-shaft timing gear off stub shaft.
3 Rotate chain sprocket or cross-shaft enough to be able to re-engage intermediate cross-

shaft timing gear back onto stub shaft, indexing gear engagement 1-tooth in appropriate
direction from original setting relative to either the ‘red’ dimpled cross-shaft timing gear
(if turning the cross-shaft) or ‘blue’ dimpled chain sprocket timing gear (if turning the
chain sprocket).
4 Replace intermediate cross-shaft timing gear retainer plate and fasten securely.
consistently held.

Condition #3
out this work.

When replacing any ‘Cross-Shaft Assembly’ components it will be necessary to re-set

alignment of the chain sprockets. The following procedure to re-set alignment is only
required on the side where new components have been fitted; the opposite side ‘Cross-Shaft
Assembly’ should not be disturbed. New timing gears, chain sprocket/shaft assemblies,
cross-shaft stubs etc. are supplied by Auto-Bake without pre-drilled ‘Nordberg’ dowel holes;
these must therefore be drilled in-situ as part of this re-setting procedure.
_______________________________________________________________________________
1 If possible, stop the machine when the extended chain pins are at TDC (or as near as
possible to TDC), riding on the sprocket set connected to the cross-shaft being serviced.
2 Disassemble ‘Cross-Shaft Assembly’ as required to liberate the redundant components

in readiness for replacing with new.
Typical Removal of Timing Gear
3 Re-assemble ‘Cross-Shaft Assembly’ with required new components; all remaining

original transmission components should be reassembled in reverse order to which they
were disassembled (i.e. all original timing gears should be mated to original shafts with
Nordberg dowels inserted). New components cannot be dowelled at this time.
Example: New timing gear on existing shaft - no pre-drilled dowel holes
_______________________________________________________________________________
4 Ensure carrier transport chain is engaged with all chain sprockets on both sides of the
machine; then reinstate air-supply to the chain take-up cylinders, ensuring chain is
tensioned normally.
5 Rotate applicable ‘Cross-Shaft Assembly’ chain sprocket (on same side of machine that
has been fitted with new transmission components) until the extended chain pins on
each side of the machine are aligned to within +/- 1mm of each other, (as measured per
checking procedure described previously). Since full chain tension is applied it will be
necessary to use either a lever (similarly as described in previous procedures, depicted
in below image) or pull the chain with suitable Come-A-Long. Once extended chain pins
are aligned correctly, clamp chains to rails or wedge chain sprockets to prevent chain
pin alignment slipping whilst new ‘Nordberg’ dowel holes are drilled into the new
components.
Use lever to rotate chain sprocket to align extended chain pins
6 Using Auto-Bake supplied drilling jig, re-drill new ‘Nordberg’ dowel holes into shaft &
timing gear. If original shaft remains, rotate drilling jig so that new holes are approx 90º
to original holes. Likewise if timing gear is original, position new holes 90º to original
holes in timing gear.
Timing Gear Drilling Jig
Note: Always use a

brand new Ø1/4” drill
bit when drilling new
Nordberg Dowell holes,
as a blunt drill bit will
drill oversize and hence
compromise required
interference fit.
Position drilling jig such that new holes are drilled approx 90º to original holes, then tighten retainer bolt &
drill holes
_______________________________________________________________________________
7 Bolt Auto-Bake supplied ‘Nordberg Dowel Insertion Jig’ to the timing gear shaft as
shown below, being careful to position the hollowed sides such that the newly drilled
dowel holes are exposed. This jig pulls together and holds firmly the cross-shaft & timing
gear assembly, allowing the ¼” dowel pins to be knocked into the new dowel holes
without pushing the shaft away. Use suitable pin punch or Auto-Bake supplied ‘Dowel
Pin Punch’ to knock pins into newly drilled dowel holes.
Nordberg Dowel Insertion Jig Dowel Pin Punch Insert dowel into hollowed end
Inserted ¼” Dowel Knock dowels into new dowel holes
Drive dowel pins in as far as possible using the special hollowed-out ‘Dowel Pin Punch’, then knock pin in fully
(until flush with gear) with conventional pin punch.
8 Replace intermediate cross-shaft timing gear retainer plate and fasten securely.
consistently held.
_______________________________________________________________________________
6.10 Transmission and Gear Train Lubrication

Each pair of chain idler and levelling sprocket assemblies is coupled together by a gear train.
The gear train ensures that sprocket timing between the two assemblies is maintained at all
times so that smooth transition occurs as the carrier bearings engage with the alumin’m
levelling sprocket. The oven cross-shaft assemblies also incorporate a gear train. In each
case, gear trains need to be lubricated on a regular basis, using KLUBER HOTEMP
2000 open gear lubricant throughout the machine. The frequency of lubrication required
depends on customer usage cycles. As a precaution however, it is recommended that the
gears be examined weekly and lubricated if they appear dry.
WARNING: The machine must be stopped and

locked out when doing this – open gears are
extremely hazardous!
6.11 ATTACHMENTS
 Position of bearing housings and sprocket assemblies
 Identification of guide types
 Critical Procedure – Timing of Gears
 Bearings, Housings & Sprocket Assembly Details
_______________________________________________________________________________
SECTION 7
LINE LUBRICATION
VERY IMPORTANT
_______________________________________________________________________________
7.1 Recommended Lubricants

Generic Lubrication Schedule
NOTE: It is extremely important to lubricate the
Auto-Bake line regularly using only Klüber products
in accordance with the lubrication schedule below.
Application Point Lubricant Application Method Frequency

Oven Bearings Grease Gun with 3 pumps per housing
Barrierta L55/2
Chain Idler Sprocket 800g cartridge once per month

Barrierta L55/2
Alum’m Levelling Sprocket 800g cartridge once per month
Oven Bearings Grease Gun with 1 pump per gear

Barrierta L55/2
Central Idler Gear 800g cartridge once per month

Barrierta L55/2
Cross Shafts 800g cartridge once per month
Oven Turbulence Fans
Grease Gun with 1 pump per bearing
(plummer and/or flange Barrierta L55/2
800g cartridge twice per month
bearings)
Oven Exhaust Fan(s)
Grease Gun with 1 pump per bearing
(plummer and/or flange Barrierta L55/2
800g cartridge twice per month
bearings)
Carrier Transport Chains
KLUBERFOOD Dropsa Lubrication Automatic
&
NH1 CH 2-220 PLUS Unit check oil levels daily
Carrier Bearings
Transmission Chains KLUBERFOOD
Brush (manually) once per month
(throughout line) NH1 CH 2-220 PLUS
Open Gears
KLUBERFOOD
(throughout line excluding Apply with oil can once per month
NH1 CH 2-220 PLUS
oven)
Open Gears in Oven HOTEMP 2000 Apply with oil can once per month
Plenum Damper Linkages

Grease Gun with 1 pump per linkage
Convection Ovens Barrierta L55/2
800g cartridge once per month
(where incorporated)
2 pumps per
Flange Bearings - General (small) bearing
Grease Gun with
(excluding Oven & Tray Barrierta L55/2 3 pumps per
800g cartridge
Wash) (large) bearing
twice per year
Flange Bearings
Tray Wash Filter Belt Grease Gun with 2 pumps per bearing
Barrierta L55/2
Drive/Idler Shafts 800g cartridge once per month
Flange Bearings
Grease Gun with 2 pumps per bearing
Tray Wash Exhaust Fans Barrierta L55/2
800g cartridge once per month
Remove assembly
from oven, strip &
Pivoting Guides in Oven Barrierta L55/2 twice per year
clean, re-grease
manually
_______________________________________________________________________________
7.2 Importance of Clean & Well-Lubricated Carrier Transport

Chain
NOTE: It is extremely important that the Main (carrier) Transport Chains be

maintained in a very CLEAN condition and regularly & reliably lubricated.
The importance of this requirement cannot be over emphasized!
Failure to maintain the conveyor chains in good condition in any baking system will
inevitably result in long and costly breakdowns to the entire baking system!
Equally important is the oil type used for lubrication of the Main Conveying Chains.
The use of incorrect oil can result in ineffective lubrication. This can damage the
oven components and generate dangerous fumes and/or smoke if the oil burns.
Problems arising from chain neglect may include the following:
• Excessive wear on the idler-sprockets, drive-sprockets and the pan carriers.
• Greatly reduced chain life.
• Chains wearing more on one side of the machine than the other, causing the pans to
skew out of square.
• Possible chain-link or chain-pin breakage.
• Increased continuous loading on the chain system (Note: this can also make it difficult to
set correct overload protection).
7.3 Automatic Lubrication Overview

A totally self-contained automatic lubrication system is installed on the main conveyor chain
loop, located at the front end of the Infeed Module. The function of the lubrication system is
to apply a measured amount of lubricant oil to the main conveyor chain and to apply a
measured amount of lubricant oil to each of the carrier bearings.
An air circuit controls the lubricator. Turning off the air supply isolating valve to the lubricator
will manually stop it. The lubricator is controlled by the PLC from where it can be
_______________________________________________________________________________
programmed (on/off cycles) via an electro-pneumatic solenoid valve. The on/off and pump
cycle duration, and dosage time, are controlled electronically via the HMI touch screen.
The initial control for the lubricator has been programmed

simply to start and stop with the main drive until such time as a pattern of use
emerges. When this is established the lubricator program can be reviewed and
changed as required. The settings at time of commissioning are only a guide; final
settings should be made when the condition of the chain has been monitored for a
while and fully understood.
Typical Lubrication System - Dropsa units depicted located front end Infeed Module
7.4 Main Conveyor Chain Lubrication

The automatic lubrication system applies an adjustable amount of oil directly onto each and
every chain link as the chain passes below the spray nozzles. A single pneumatic oil pump
positively displaces oil to a block of dividing valves as/when it is energized by the PLC.
There is a dedicated dividing valve for each spray nozzle, each metering a precise volume of
oil into respective feeder tubes, as and when the oil pump is energized. Between each pump
stroke there are individual pulses of atomized air introduced into the divider valve mixing
chamber, each pulse coinciding with the passing of every chain link. A shaft encoder driven
by the infeed chain sprockets enables very accurate targeting of the spray nozzles. There
are two spray nozzles per chain, (4 in total per chain circuit), each located directly above the
inboard and outboard chain plates.
_______________________________________________________________________________
Targeting Carrier Transport Chain Elements Typical chain oiling nozzles – 4 in total
Once in the oven, the oil administered onto the chain links runs down between the chain
plates and onto the chain pin, where it provides vital lubrication between the pin and bush
interface. The atomized spray pattern ensures adequate lubrication also reaches the working
surfaces of the chain roller, in particular the bore of the roller and the mating external surface
of the chain bush.
7.5 Carrier Bearing Lubrication

The automatic lubrication system applies an adjustable amount of oil directly onto each and
every carrier bearing, as the carriers pass the target area. A single pneumatic oil pump
positively displaces oil to a block of dividing valves as and when it is energized by the PLC.
_______________________________________________________________________________
There is a dedicated dividing valve for each spray nozzle, each metering a precise volume of
oil into respective feeder tubes, as/when the oil pump is energized. Between each pump
stroke there are individual pulses of atomized air introduced into the divider valve mixing
chamber, each pulse coinciding with the passing of every carrier. A shaft encoder driven by
the infeed chain sprockets enables very accurate targeting of the spray nozzles. There are
four spray nozzles per side, one dedicated for each carrier bearing, (8 in total per chain
circuit).
Typical Carrier Bearing Lubrication Nozzles
NOTE: Accurate oil targeting is paramount to chain & bearing

longevity, and the well keeping of the line in general. Precise targeting
will vary slightly as line speeds increase or decrease, therefore it is
crucial that, as each and every recipe is introduced into service, the
accuracy of the spray patterns are checked and adjusted (via the HMI
touch screen) so that optimum placement is achieved. In the case of
the carrier bearings for example, there is a fine-line between hitting the
carrier bearings and completely missing them. Oil residue on the floor
around the target area is a sure sign the spray nozzles are missing
their intended target. The target parameters can be saved to each
recipe so that automatic adjustment is made whenever a particular
recipe is selected.
_______________________________________________________________________________
Whilst pumps are positive displacement type the amount of oil

required for each shot is miniscule. As such, if oil with a high cling factor is to be
used then a higher pump operating pressure may be required to maintain uniform
direction of oil from the delivery nozzles.
The cubic capacity of the lubricating oil reservoir is 6 litres (approx 2 US gallon). Each
reservoir is fitted with a low level sensor, which provides an analogue signal. The low
level switch can be hardwired back to an available PLC I/O block enabling a suitable
message to be displayed on the user interface touch screen. There is one reservoir
for each circuit.
Care should be taken to ensure that only clean, new oil is used in the system to
prevent damage to the pump system or clogging of the fine nozzles. Routine daily
checks by the maintenance personnel should ensure that the oil level in the reservoir
is adequate and a visual check of the deposit point of the lubricant shot to ensure that
all is functioning correctly. This takes only minutes to do.
Industry experience shows never to fully trust any automated lubricating system.
Always check! Never underestimate the importance of correct lubrication in any
continuous automated system especially when an oven is involved.
It is important that the changes made to the oiler at the touch screen are checked
through to each formulation, i.e. the changes made only affect the specific product
which is selected.
7.6 Pivoting Guide Lubrication
Oven Pivoting Guides

There is a single deep-groove ball bearing in each pivoting guide assembly. These bearings
must be removed, washed out with kerosene, dried with clean compressed air, and then re-
packed with Klüber Barrierta L55/2 grease once every 6 months. It is recommended that the
bearing be washed with White Spirits (a.k.a. Mineral Spirits) after being dried following the
kerosene wash. To remove pivoting guide, remove split pin and withdraw from respective
stub-shaft.
Cooler Pivoting Guides

There is a single deep-groove ball bearing in each pivoting guide assembly. These bearings
are sealed & pre-packed with grease requiring no further maintenance.
_______________________________________________________________________________
7.7 ATTACHMENTS
 MSDS KLUBERFOOD NH1 CH 2-220
 MSDS Klüber Barrierta L55/2
 KLUBERTEMP RHB 83 - 402
 MSDS Klüber Hotemp 2000
 Drawing of oven bearing greasing points
 Operation & Maintenance Manual for Dropsa Lubrication Systems
_______________________________________________________________________________
SECTION 8
OUTFEED MODULE
_______________________________________________________________________________
8.1 Description of Outfeed Module

As carriers & trays exit the lower Ambient Cooler they enter the Outfeed Module, where the
trays (with baked product on board) are separated from their host carriers and ejected
downstream. The trays are separated from the carriers as they pass vertically downwards
through the Depanning Zone. Here, each carrier passes through a series of plastic lined tray
supports strategically positioned to prevent the tray from passing any further, supporting the
tray and its payload securely, whilst at the same time allowing the carrier to pass through
unabated. The liberated pans are then pushed outwards clear of the Depanning Zone by a
mechanically linked Off-Load Pusher assembly (OLP).
The OLP assembly is integral with the secondary drive unit, incorporating a crank wheel for
propulsion that is driven directly by a transmission chain connected to one of the carrier
transport chain idler sprockets within the Outfeed Module. A series of crank arms and slide
arrangements connect to a pair of Pusher Arms, which in turn bolt to the actual Pusher
Bar. The Pusher Bar is a channel section member with a UHMW-PE strip inserted to prevent
metal to metal contact with the trays.
_______________________________________________________________________________
Because the Off-Load Pusher assembly is mechanically linked to the carrier transport chain
circuit, the Pusher Bar movement is synchronized with the carriers. The timing chain ensures
the pusher movement always complete the pan off-load cycle and is retracted before the
next descending free-tray carrier passes through the Depanning Zone, irrespective of line
speed.
The separated pan is pushed away from the Auto-Bake line onto conveyor (C1), which is
located in-line immediately downstream of the Outfeed Module. This transfer conveyor
moves trays away from the Auto-Bake line and under the Injection Unit (manufactured by
Comas). When the pusher bar is fully extended the pan is fully on-board this conveyor. The
extended position of the pusher arm is detected by an inductive sensor, which is mounted
within the right hand side of the outfeed/drive module.
Outfeed Module (LHS shown with covers removed)
Empty carriers travel back towards the oven infeed module passing under the lower Ambient
Cooler en-route.
NOTE: The main [carrier transport] chain tensioning

system resides in the Outfeed Module. This chain
tensioning system is similar in design and operation as
described previously in the Oven Drive section except
the take-up slides have additional travel capacity
(500mm), which enables one complete tray-pitch of chain
to be removed as/when these slides approach limit of
travel.
_______________________________________________________________________________
SECTION 9
CONVEYOR CIRCUIT
SYSTEM
(CCS)
_______________________________________________________________________________
9.1 Description of Conveyor Circuit System (CCS)

The CCS comprises 11 conveyors, identified as C1 through to C11 in the same order as the
trays flow. These conveyors form a bridging circuit that transports pans (with or without
product) ejected from the Outfeed Module through various ancillary work stations all the way
back to the Infeed Module. Conveyor C1 is the conveyor immediately downstream from the
Outfeed Module, whilst conveyor C11 is the conveyor immediately upstream of the Infeed
Module.
9.1.1 Function of Conveyor C1

Conveyor C1 is a 4.8m long straight Slat-Belt conveyor that takes pans away from the Auto-
Bake Outfeed Module, under the Comas Injector Unit (not shown) and then onto C2 for
transferring pans wide-edge leading into the Robotic Depanning Enclosure. This conveyor
also accommodates the Ring Cake Pre-Release System at its outfeed end. Pans are
assisted crossing over onto C2 via a pair of mechanically driven tray transfer support chains.
The conveyor is equipped with tray brakes for holding pans securely when product is being
injected and then releasing pans in sequence. Side guides are adjustable to accommodate
varying pan widths. This conveyor has a dedicated drive Gearmotor.
Conveyor C1 c/w Ring Cake Pre-Release System
_______________________________________________________________________________

Conveyor C2 is the first of four 90º transfer conveyors incorporated within the CCS. It runs a
flexible plastic mesh belt that rides on a stainless steel dead-bed enabling pans to sit directly
on top of the belting whilst traversing wide-edge leading radially about the conveyor’s
geometric centroid. The belt is mechanically linked to and driven from C3 conveyor
downstream. Pans are protected from being inadvertently knocked out of formation by
passer-by operators by way of inner and outer side rails. Conveyor C2 runs continuously and
is not equipped with brakes or gates.
Conveyor C2

Conveyor C3 is a straight Slat-Belt conveyor approx 1.4m in length. It delivers pans wide-
edge leading from C2 into the Robotic Depanning enclosure, marshalling the pans via
special tray brakes to hold and release in sequence with the robot cycle. Side guides are
adjustable to accommodate varying pan widths. This conveyor is driven by a Gearmotor
which also drives C2 conveyor via mechanical linkages.
Conveyor C3
_______________________________________________________________________________

Conveyor C4 is the second of four 90º transfer conveyors incorporated into the CCS and
uses the same belting and pan guide arrangement as described for C2. It delivers pans
wide-edge leading from the robot enclosure (C3) to the straight conveyor (C5) feeding pans
into the Pan Washer. The C4 conveyor belt is driven by mechanical linkages connected to
downstream conveyor C5 and runs continuously when in operation. C4 is not equipped with
brakes or gates.
Conveyor C4
Conveyor C5 is a straight Slat-Belt conveyor approx 9.2m in length that delivers pans wide-
edge leading from C4 conveyor to the entrance tunnel of the Colussi in-line tray washer. This
conveyor is driven by a Gearmotor which also drives C4 conveyor via mechanical linkages.
C5 is not equipped with brakes or gates. All standard length pans (Ring Cake & Fudge Bar)
are automatically fed directly into the Colussi washer on C5 centreline. When shorter
Croissant trays are to be washed & dried, these are manually loaded onto C5 at the
immediate entrance of the Colussi Washer, and then manually removed from the system as
soon as the clean trays emerge from the washer. When manually loading the Croissant trays
onto C5, the trays are not loaded on the conveyor’s centreline, instead they are biased to the
left side, resting against the left side tray guide rail. This enables the shorter Croissant pans
to pass safely through the Colussi Washer riding on only the central and left side transport
chains.
Conveyor C5
_______________________________________________________________________________

Conveyor C6 is a straight Slat-Belt conveyor approx 15m in length that delivers pans wide-
edge leading from the Colussi Tray Washer & Drier Unit to the ancillary equipment work
station conveyor (C7). This conveyor is driven by a dedicated Gearmotor located at the
discharge end and runs continuously when in operation. It has adjustable side guides fitted
with a tray brake/gate system at the discharge end to cater for varying length trays. The
sequencing of the tray brake & gate system ensures pans are released and fed into C7 in a
timely fashion, as is essential since C7 is a stainless steel Slat-Belt conveyor with welded
dogs for positive tray propulsion. The plastic material used on C6 belting ensures these belts
can slide harmlessly under the trays whenever the trays are held back by the brake/gate
system. Pans are assisted crossing over onto C7 via a pair of mechanically driven tray
transfer support chains. Being 15m long, C6 conveyor provides ample floor space for
operators to stand either side of when manually inserting paper liners into passing Fudgee
Bar pans.
Conveyor C6
Conveyor C7 is a straight stainless steel ‘dogged’ Slat-Belt conveyor approx 7.8m in length
that positively conveys pans wide-edge leading from C6 to C8 via three ancillary equipment
workstations. Here, a Dubor Pan Greaser occupies Work Station #1, and the customer’s
own Depositor occupies Work Station #3. Work Station #2 is available for future ancillary
equipment, such as a Paper Cup Denester. Each work station has adjustable side guides to
ensure centreline accuracy of trays whilst travelling under respective ancillary machines. The
conveyor is not fitted with tray brakes or gates. It is propelled by mechanical linkages
connected to next downstream conveyor (C8).
Conveyor C7
_______________________________________________________________________________

Conveyor C8 is a declined straight Slat-Belt conveyor approx 4.9m in length that delivers
pans wide-edge leading from the ancillary work stations conveyor (C7) to the third in line 90º
transfer conveyor within the CCS loop (C9). Conveyor C8 runs continuously, declining
approx 200mm over its length. It is driven by a dedicated Gearmotor located at the discharge
end which also propels upstream conveyor C7, as previously described. Near the outfeed
end of this conveyor a pair of LH & RH ‘lift-over’ tray guides are incorporated that can be
swung into play when manually loading Croissant trays that have been deposited with
product off-line. These guides assist operators in centralising the position of the shorter trays
to ensure they subsequently load centrally into the Auto-Bake Infeed Module. These guides
are swung back out of harm’s way once the entire system has been fully loaded with trays,
and are not deployed at all when running standard length Fudgee Bar & Ring Cake pans.
Conveyor C8
Conveyor C9 is the third in line of four 90º transfer conveyors incorporated into the CCS and
wide-edge leading from the decline conveyor (C8) to the straight conveyor (C10), which
provides propulsion to this conveyor via connecting mechanical linkages. C9 is not equipped
with brakes or gates.
Conveyor C9
_______________________________________________________________________________

Conveyor C10 is a straight stainless steel Slat-Belt conveyor approx 1.4m in length that
delivers pans wide-edge between the last two 90º transfer conveyors in the CCS loop (C9 &
C11). This conveyor is set at a comfortable working height and also comes equipped with a
pair of LH & RH ‘lift-over’ tray guides, as described previously for manually loading pre-
deposited Croissant trays. This conveyor is driven by a Gearmotor located at the discharge
end and runs continuously when in operation. The gear motor also drives upstream
conveyor (C9) as described earlier. Conveyor C10 serves as the ideal location for loading
Croissant pans into the Auto-Bake system by virtue of its close proximity to the Infeed
Module. The conveyor is also ideally suited for loading and unloading standard length pans
between production runs, however, there are many other ideal locations along the CCS that
are equally suited for this purpose as well.
Conveyor C10
Conveyor C11 is the last in line of four 90º transfer conveyors incorporated into the CCS and
wide-edge leading from conveyor C10 to the Infeed Module. C11 is the only 90º transfer
conveyor with its own dedicated drive gear motor; in all other aspects it is identical to the
other three 90º conveyors.
Conveyor C11
_______________________________________________________________________________
9.2 Air Pre-Release System

A pre-release manifold customised to suit Ring Cake, is located on conveyor C1 immediately
downstream of the Comas Injector. The pre-release manifold comprises an inner and outer
tube where compressed air is introduced into the inner tube at regulated air pressure. The
inner tube has a series of holes oriented at the top of the tube where air escapes into the
outer tube, pressurising this tube evenly across the length of the manifold. Located at the
bottom of the outer tube are a series of long diffuser tubes each with a special air-blast
nozzle welded to the discharge end. The diffuser tubes are spaced apart such that there is
one located either side of each product along the lateral row (across the width of the
machine), targeting the common frontier between the outer extremity of the product and the
corresponding cavity wall.
As the pans pass under the diffuser tubes a jet of air penetrates between the product and
the cavity wall, tearing bondage & propelling the product upwards away from the captive
cavity. A special hold-down plate prevents the now hovering product from escaping; allowing
the product to fall gently back into the cavity it was baked in once the effect of the air blast
abates. The product, whilst now sitting in the same cavity, is no longer ‘bonded’ to this
cavity; it is loose and ready to be depanned.
An adjustable support frame located at each end of the pre-release manifold enables the
manifold to be lowered easily (without tools) during Ring Cake production, and then raised
back up again out of the way when Ring Cake production has been completed.
Ring Cake Air Pre-Release System depicted in the ‘lowered’ position
_______________________________________________________________________________
Typical Air Pre-Release Manifold Assembly c/w adjustable hold-down plate
Typical construction – inner & outer tubes, diffuser tubes, air blast nozzles &
hold-down plate
Typial Air Pre-Release Manifold Assembly Cross-Section
_______________________________________________________________________________
9.3 Robotic Product Depanning System – Dual Head
The Auto-Bake line is equipped with a Robotic Product Depanning System (a.k.a. Pick and
Place, or, P&P) located downstream of the Outfeed Module within the Conveyor Circuit
System (CCS). The P&P has been developed especially for handling products that are
baked on the Auto-Bake Level Tray System (LTS) series ovens. This particular system is
referred to as a dual-head system as there are two individual needle heads attached to the
robot tool head, servicing two pans simultaneously at a time. The P&P system consists of
the following main elements:
1. Computerised/PLC Motion-Control System

2. ABB IRB 6640 Industrial Robot System
3. Customised Dual Needle Heads
The essential principal of the P&P system is to pick product out of the baking pans and
deliver this product to the downstream conveyor for further processing. This task is
accomplished by positioning the needle head in correct alignment directly over the particular
pan where product is to be removed. At a signal from the controlling PLC, the robot tool arm
supporting the needle head descends to a precise depth allowing the ‘retracted’ needles to
hover just above the top surface of the product in each cavity. At the appropriate time, the
needles are extended and penetrate deep into the baked product. The ‘curved’ trajectory of
each needle impales the product in such a way that the product remains ‘captured’ by the
_______________________________________________________________________________
needle as the robot tool arm pulls away. The needle head with its payload of product firmly in
its grasp moves to a new position above the take-away conveyor. The needles retract
liberating the product on demand. Upon release, the needle head returns to the pick-up point
once again in readiness for the next cycle.
Typical Needle Head
9.4 Computerised Motion-Control Unit

The robot controls are integrated with the machine’s main PLC system. The operation of the
robot is locked into the main PLC program. Such operator-variables as the pick-up and put-
down height of the needle head are adjusted on the operator’s PLC slave screen, located on
a control console adjacent to the P&P unit.
9.5 Industrial Robot System

The robot used is identified as follows:
ABB IRB 6640 Industrial Robot System – 2.8m Reach – 185Kg Capacity – 220V 60Hz
Part No. RB6640/2.8/185/220
Please refer to the ABB manual for details on this robot.
9.6 Maintenance – P&P System
The Auto Bake P&P system requires little day-to-day attention, apart from routine
cleaning of the needle heads. Small pneumatic cylinders operate needle actuation. The air-
supply to these cylinders passes through a combined pressure-regulator and filter-unit. The
air-pressure should not be set excessively high and the filter-unit bowl must be drained
routinely.
Refer to the separate manual for, Daily, Weekly and Monthly, ‘Operation, Care and
Maintenance’ of the ABB IRB 6640 ROBOT unit.
_______________________________________________________________________________
SECTION 10
GENERIC PREVENTATIVE
MAINTENANCE
SCHEDULE
for
AUTO-BAKE SUPPLIED EQUIPMENT (only)
PLEASE REFER RELEVANT OEM MANUALS FOR EQUIPMENT NOT
MANUFACTURED OR SUPPLIED BY AUTO-BAKE
Mechanic Electrician Operator

The following pages should be printed and displayed in an
appropriate location for Maintenance & Operational personnel.
Follow safe working practices and standard electrical,

mechanical & pneumatic ‘lock-off’ procedures if any work is to be
carried out involving the conveyor path or equipment likely to
cause injury, such as moving carriers & baking pans, chains, gears
& sprockets etc.
_______________________________________________________________________________
MAINTENANCE (P.M.) DAILY SCHEDULE

SECTION ACTIVITY NOTES/SPECIAL INSTRUCTIONS
Operators can assist greatly by alerting

General Listen and look for tell-tale signs and sounds Maintenance of any unusual noises, or if
that might indicate maintenance attention is the line appears to be operating
required. Operators should report any ‘differently’ than normal.
observations to the Maintenance Dept.
Low-level sensor incorporated in
reservoir will annunciate alarm on HMI if
oil level drops too far. Please refer below
Check oil reservoir levels & fill if low. images.
Chain &
Carrier
Bearing
Lube
System
Checking oil level & filling reservoir
_______________________________________________________________________________
MAINTENANCE (P.M.) WEEKLY SCHEDULE

Repair Dropsa Unit if fault detected.
Note: Chain spray trajectory (as governed by

solenoid valve timing) should be set to
Carry out visual checks to ensure Dropsa ensure atomised droplets of lube oil are
Units are working correctly and that oil landing between the inner and outer chain
spray is hitting intended target (chain and plates and directly above the chain pins (as
carrier bearings). With any new recipe indicated by yellow arrows in ‘Chain
introduced, check & re-set trajectory (if Lubrication Target’ images below). Automatic
required), checking at regular intervals until adjustment of trajectory to suit recipe-driven
repeatability is assured that the intended line speeds has been incorporated in latest
target is being hit consistently. model Auto-Bake lines, however, it is still
highly recommended that targeting of oil
trajectory be checked at regular intervals as
described here. Fine-tune adjustments
It ‘cannot be overstated’ how should be made (as/when required) and any
important it is to operate the Auto-Bake changes should be saved & locked into
system with ‘pristine clean’ chain & carrier specific recipe.
bearings ‘at all times’, to ensure oil can
flow and migrate deep into the critical Carrier bearing spray trajectory should be set
Chain & moving elements of the chain & carrier to ensure all 4 pairs of carrier bearings (one
Carrier bearings as they pass through the hot pair of bearings per carrier end pin) on each
Bearing oven. Equally important, the oil must hit carrier end is reached (as indicated by yellow
Lube intended target as described in adjacent arrows in ‘Carrier Bearings Lubrication
System column & below images. Target’ image below).
Chain Lubrication Target
Carrier Bearings Lubrication Target
_______________________________________________________________________________
MAINTENANCE (P.M.) WEEKLY SCHEDULE cont…

Chain &
Carrier If dirty, increase chain & carrier bearing
Bearing wash cycles (if Tray Wash incorporated).
Condition Check condition of chain & carrier bearings
Drive Unit Check mechanical overload system(s) is

operating correctly and will stop the line Regulator pressure settings are engraved
Mechanical
whenever the overload limit switch has on label located near respective Drive Unit,
Overload
been released from normally depressed as determined during/post commissioning.
Protection
state. Check programmable pressure Replace/repair components if defective.
System
regulator(s) setting is as per associated
label(s), and that the unit is operating
reliably.
Compressed Replace/repair components if defective.

Air Units Visually check air service units & Drain filter bowls containing water.
pneumatic equipment are in good
condition, and are functioning correctly.
Rotary
Brush Tray
Cleaner Replace brush if worn or shedding bristles.
where Check operation & condition of brush
incorporated
Pre-Release
&
Pre-Cleaner Check operation & condition of pre- Repair any damaged or bent diffuser tubes.
Manifolds cleaner & pre-release manifolds, air
where diffuser tubes and pneumatic control
incorporated system.
Product
Depanning
Systems Check operation & condition of product Replace/repair components if defective.
where depanning heads, control mechanisms,
incorporated needles/vacuum cups, robot (per OEM
instructions), etc.
_______________________________________________________________________________
MAINTENANCE (P.M.) TWICE-MONTHLY SCHEDULE

Refer Generic Lubrication Schedule.

Oven Lubricate turbulence & exhaust fan bearings
Check condition of turbulence & exhaust fan
Replace if worn or damaged
vee-belts
_______________________________________________________________________________
MAINTENANCE (P.M.) MONTHLY SCHEDULE

Replace/repair components if defective.

Check for broken or missing carrier end
bearings, split pins or snap rings.
Check #1: Check carrier end pins in ‘plan
view’ by standing directly over the top of
Visually check carrier end pins are square and passing carriers at a suitable location
parallel. Replace all carrier ends with defective along the LHS & RHS of the Infeed
pin(s). New and/or repaired carrier ends must module. Look down directly at the carrier
be checked before being inserted back into the ends in a perpendicular fashion to detect
line, to ensure dimensional compliance per any pins that are not square (‘splayed’
below images. inwards or outwards). Once all splayed
carrier ends have been replaced, use
Auto-Bake jig to check 254mm
dimension. If the jig struggles to fit over
the two upper pins, replace carrier ends.
Check #2: Check carrier end pins in ‘end

view’ by crouching down at the extreme
end of the Infeed module, looking along
the line of carrier ends as they move
away from the viewer towards the oven
(per side image). Check LHS & RHS carrier
General ends separately. Any carrier ends that are
detected with pins pointing upwards or
Visually check carrier pins ‘end view’ from this downwards should be replaced.
vantage point
Plan View End View

Look for smooth carrier transfer at each
sprocket rotation throughout the line. If
Visually check timing as carriers engage caused by ‘rogue’ carrier, remove
alumin’m levelling sprockets. If timing is immediately. Use Auto-Bake supplied
out, please check & re-set timing as described Timing Jig whenever re-setting timing of
in Section 6 of this manual. any LTS sprocket sets.
Should any E-Stop be found to be
defective it should be replaced
Check operation of emergency stops (E-stop), immediately. Should any E-Stop be
lanyard settings and safety interlocks such as disassembled for any reason its operation
oven doors etc. must be checked by an authorised person
prior to handing the machine back to
production personnel.
_______________________________________________________________________________
MAINTENANCE (P.M.) MONTHLY SCHEDULE cont…


Lubricate all open gears.

Lubricate all oven bearings.
Oven
Numbers represent grease gun ‘pumps’
Check #1: Ensure take-up slides have

ample travel remaining as not to
Check chain take-up slides ‘bottom-out’ prior to the next scheduled
inspection. If slides are approaching end
of travel limit, please schedule removal
Note: Never replace chain from one
of one ‘carrier-pitch’ of transport chain
side of the machine without replacing exact
from opposing sides of the machine.
same section of chain on opposite side of the
machine, regardless if opposite side chain Check #2: Ensure take-up slides are
appears to be in good condition! This rule aligned (LHS to RHS) within 5mm. If
applies equally whenever repairs are take-up slides are out of alignment by
undertaken to replace a damaged or severed more than 5mm, monitor uneven chain
carrier drive pin (extended chain pin) using stretch very closely (over time) to ensure
standard 3-link repair kit. In such case, take-up slide misalignment does not
always replace the opposite side chain pin exceed 10mm. If take-up slides are
Drive
using standard 3-link repair kit regardless if misaligned by more than 10mm, replace
Module(s)
the opposite side pin is in good repair. This any section of chain within the chain
will ensure the o/a length of chain on both circuit (where uneven stretching has
sides of the machine remain equal (as closely occurred) with new ‘pre-pitched’ chain,
as possible) under normal operating or if in good condition, used ‘pre-
conditions. pitched’ chain.
Checking for take-up travel & uneven chain stretch
_______________________________________________________________________________
MAINTENANCE (P.M.) MONTHLY SCHEDULE cont…

Operators should notify Maintenance if
Outfeed belt is damaged in any way.
Check condition of turnover belt & associated Replace/repair if defective.
transmission components.
Tray Wash Check condition of steam exhaust fan vee-
Replace if worn or damaged
Unit belts
where
incorporated Check condition of pumps & blowers Replace/repair components if defective.
Thermal Oil Refer relevant section of this manual for

Heating Check operation of secondary skid pumps more details, and additional OEM
System (also primary pump if supplied by Auto- manuals if Primary System supplied by
where Bake). Look for leaks and listen for any others. Replace/repair components if
incorporated unusual noise. Check operation of Baelze defective.
modulating valves.
Carry out lubrication of all open gears,
General
transmission chains, flange bearings etc. Refer Generic Lubrication Schedule.
Lubrication
throughout entire line.
_______________________________________________________________________________
MAINTENANCE (P.M.) TWICE-ANNUAL SCHEDULE

Or any time after maintenance work has been carried out
Visually check retaining bolts & screws on all Tighten/replace as required.

sprocket assemblies and components
throughout the system are held securely and
are in good condition.
Tighten if loose.
Visually check all Level Tray Guides are
securely fastened.
Carriers should be parallel to each other
and be squarely aligned at each cross-
General
Inspect carriers at every cross-shaft sprocket shaft sprocket turn throughout the
turn to ensure they are reasonably square to machine. Corresponding chain pins on
the machine. each side of the cross-shaft should be
aligned to within 5mm (or better). If
alignment is out by more than 5mm,
check condition of cross-shaft &
couplings, and replace as required.
Check for excessive or uneven wear on all Replace/repair components if defective.

critical carrier transport elements such as
chain, sprockets, levelling guides, chain rails,
etc., and check for noisy bearings throughout.
Flange &
Plummer Refer Generic Lubrication Schedule.
Bearings Lubricate flange/plummer bearings
throughout
Refer to gearbox manufacturer’s
Drive
information for correct level and
Unit(s)
Check all gearbox oil levels. periodic changing of oil.
_______________________________________________________________________________
SECTION 11
GENERIC SANITATION
SCHEDULE
for
AUTO-BAKE SUPPLIED EQUIPMENT (only)
PLEASE REFER RELEVANT OEM MANUALS FOR EQUIPMENT NOT
MANUFACTURED OR SUPPLIED BY AUTO-BAKE
The following pages should be printed and displayed in an

appropriate location for Maintenance & Operational personnel.
Follow safe working practices and standard electrical,

mechanical & pneumatic ‘lock-off’ procedures if any work is to be
carried out involving the conveyor path or equipment likely to
cause injury, such as moving carriers & baking pans, chains, gears
& sprockets etc.
IMPORTANT: If a hosepipe
is to be used all electrical
devices must be properly
protected and fully sealed
with heavy-duty plastic
bags or similar to prevent
water ingress. Auto-Bake
will accept no responsibility
to damage of devices
created by water ingress.
Stainless steel panels around the oven and

adjacent modules may become tarnished over time,
particularly if not cleaned and polished regularly.
_______________________________________________________________________________
SANITATION - DAILY SCHEDULE

SECTION ACTIVITY
Remove baking pans. Clean catch trays and general area using suitable utensils (brush, vacuum, hose
pipe or cleaning cloths. etc.).
Wipe clean stainless steel panels.
Infeed Touch the Auto-Bake logo on the screen and hold for 15 seconds (top right hand corner) to allow
safe cleaning of the touch screen.
Sweep/mop surrounding floor area.
Reinstate baking pans.
Wipe clean stainless steel panels & doors (where easily assessable).
Oven Clean drip pan (where incorporated) located at the entrance of the oven.
Coolers, Drives, Wipe clean stainless steel panels (where easily assessable).
Bridge &
Elevators, etc. Sweep/mop surrounding floor area.
where incorporated
Remove baking pans, covers & panels (as required to improve access). Clean catch trays and general
area using suitable utensils (brush, vacuum, hose pipe or cleaning cloths. etc.).
Clean out debris drawers (where incorporated) from beneath the Outfeed module.
Remove conveyor (where incorporated) from beneath the Outfeed module.
Outfeed If turn-over belt is dirty, wipe clean all accessible areas of the belt. Restart machine and stop again
to access more of the belt. Lock-off drives on each occasion before re-comencing cleaning!
Wipe clean stainless steel panels.
Clean & reinstate conveyor (where incorporated).
Reinstate baking pans, covers, panels & debris drawers.
Note: If P&P system has been supplied by others please follow Supplier’s OEM Sanitation
instructions!
Robotic/Linear
Wipe clean suction cups/needles (where incorporated), between shifts or at product changeovers.
P&P
where incorporated
Close all doors, hatches and cages when Sanitation activities complete.
Wipe clean all stainless steel panels (where easily assessable).
If pans are returning dirty, remove wash & rinse spray-tubes and check for clogged nozzles & clean.
Note: Tubes are of different configurations; ensure they are replaced correctly, as removed!
Tray Wash & If chains & carrier bearings are returning dirty, remove chain & carrier bearing spray tubes and
Dryer check for clogged nozzles and clean.
where incorporated If filter belt appears dirty, remove belt cleaning spray tube and check for clogged nozzles and clean.
If pans are still returning dirty after cleaning spray tube nozzles, empty the washer and clean the
tanks, ensuring all debris has been removed and the tanks are completely clean.
If pans are not returning dry, check for clogged dryer air-knifes and clean.
_______________________________________________________________________________
SANITATION - WEEKLY SCHEDULE

SECTION ACTIVITY
Remove side panels. Brush and/or vacuum side plates and base frame.
Clean photo eyes and lubrication sensors (where incorporated).
Infeed
Wipe clean “E” stop buttons.
Hose down & mop floor beneath the machine and surrounding area.
Open oven doors. Clean ‘loose’ foreign material & residue from within oven chamber.
Oven Clean viewing doors inside and out, open polycarbonate cover and wipe clean halogen lights.
Clean lens cover on safety photo-cell beam located on both sides of the line, at each end of the
oven.
Coolers, Drives, Remove mesh panels, guards & covers. Clean ‘loose’ foreign material & residue from within
Bridge & modules.
Elevators, etc. Hose down & mop floor beneath the machine and surrounding area.
where incorporated Wipe clean “E” stop buttons.
Remove side panels. Clean ‘loose’ foreign material & residue from within module.
Clean accessible areas of the turn-over belt with hot soapy water. Restart machine and stop again to
Outfeed access more of the belt. Lock-off drives on each occasion before re-comencing cleaning!
Wipe clean photo eyes (where incorporated).
Hose down & mop floor beneath the machine and surrounding area ( avoid wetting robot!).
Note: If P&P system has been supplied by others please follow Supplier’s OEM Sanitation
instructions!
Robotic/Linear
Remove all debris from the robot arm and head, brushing, wiping or vacuuming only.
P&P
where incorporated
Clean vacuum head & cups/needle head & needles (where incorporated) with hot-soapy water and
dry.
Remove all the wash & rinse spray-tubes and clean thoroughly, ensuring all nozzles are 100% clear.
Note: Tubes are of different configurations; ensure they are replaced correctly, as removed!
Remove all chain & carrier bearing spray tubes and clean thoroughly, ensuring all nozzles are 100%
clear.
Tray Wash & Remove filter belt cleaning spray tube and clean thoroughly, ensuring all nozzles are 100% clear.
Dryer Empty the washer and clean the tanks, ensuring that all debris is removed and the tanks are
where incorporated completely clean.
Clean dryer air-knifes, ensuring air slots are 100% clear.
Clean ‘loose’ foreign material & residue from within module.
_______________________________________________________________________________
SANITATION - MONTHLY SCHEDULE

SECTION ACTIVITY
Have Maintenance remove top end cover located at the start of infeed to improve access. Clean
product residue & excess lubricant from chain rails, sprockets, gears, and surrounding area.
Check encoder pulley belt and gears (where incorporated) are free of foreign material build-up,
Infeed clean if necessary (do not remove belt).
Polish s/s dress panels to remove stains ( more frequent polishing may be desirable if conditions
are particularly harsh).
Clean product residue & excess lubricant from chain rails, sprockets, gears, and surrounding area.
Oven Polish s/s doors & dress panels to remove stains ( more frequent polishing may be desirable if
conditions are particularly harsh).
Coolers, Drives, Clean product residue & excess lubricant from chain rails, sprockets, gears, and surrounding area.
Bridge &
Elevators, etc. Polish s/s dress panels to remove stains ( more frequent polishing may be desirable if conditions
where incorporated are particularly harsh).
Outfeed Polish s/s dress panels to remove stains ( more frequent polishing may be desirable if conditions
are particularly harsh).
Tray Wash & Check and replace blower and water make-up line filters (if fitted & dirty).
Dryer
where incorporated Polish s/s doors & dress panels to remove stains ( more frequent polishing may be desirable if
conditions are particularly harsh).
_______________________________________________________________________________
SANITATION - ANNUAL SCHEDULE

SECTION ACTIVITY
Remove side panels & infeed catch trays. Thoroughly clean stubborn product residue, dust, paper
Infeed
cases, grease & oil, etc. from framework (including sprocket columns, sprockets & base frame).
Remove pans from carriers and cycle empty carriers into the oven such that the entire oven is void
of pans. Note: If oven is in particularly poor state and requires aggressive scraping to remove
product build-up on heater plates/plena, then additional space can be provided by removing enough
Oven carriers from the chain circuit to accommodate a full vacant row inside the oven. If this is done, start
the line and move the vacant section of chain to the uppermost row in the oven. Lock-off drives on
each occasion after incrementing gap, before re-commencing oven cleaning! Carry out cleaning
operation as described below, incrementing gap to the next row below, as each subsequent row has
been completed.
Cover all electrical switches, sensors, thermal couples, and viewing door ventilation apertures such
that all electrical components are completely watertight.
Open oven doors. Starting from the top of the oven and working down, loosen burnt material that
has spilt onto the heater plates/plena with suitable hand held scrapers. Use extended handle or pole
for scraping middle section of plenum if unable to reach with hand held scrapers. Thoroughly clean
framework including sprocket columns, sprockets, thermal plates of any stubborn product residue,
dust, paper cases, greases and oils etc.
Brush product residue from the heater plates/plena allowing it to fall down below where it can be
collected and disposed of more readily. Remove residue that has collected on ledges or oven
frames, using industrial vacuum cleaners where necessary.
Working from the top level down, use compressed air to remove smaller loosened product, making
sure all oven doors are open to allow airborne product to escape oven.
Scrape and remove grease & residue from chain rails and sprocket areas.
Using a suitable cleaning agent (as recommended by expert from Ecolab/similar organization upon
inspecting condition of oven), spray all internal oven surfaces including walls, door liners (except
viewing doors), floor, ceiling, chain rails, heater plates, sprocket assembles and turbulence
manifolds. Allow soaking for a period of time as recommended by visiting expert.
Working from the top level down, use town-pressure hot/warm water hose to wash out oven
internally, making sure all scraped residue and cleaning agent has been thoroughly flushed away.
DO NOT spray directly at viewing doors!
Use commercially available stainless steel aerosol cleaning products (such as 3M brand), with soft
clean wipers to polish doors and panel.
Replace all carriers if removed, and replace all baking pans, ensuring any damaged units are not put
back into the baking circuit.
Clean turbulence/exhaust fan support frames and drip trays.
Ensure all personnel are clear of the line. Unlock drives and commence start-up procedure.
Coolers, Drives, Remove/open all covers, guards, doors & hatches as required. Thoroughly clean stubborn product
Bridge, Elevator
residue, dust, paper cases, grease & oil, etc. from framework (including sprocket columns, sprockets
etc.
& base frame).
where incorporated
Remove all side panels, covers & guards. Thoroughly clean stubborn product residue, dust, paper
Outfeed
cases, grease & oil, etc. from framework (including sprocket columns, sprockets & base frame).
Tray Wash/Dryer Remove/open all covers, guards, doors & hatches as required. Thoroughly clean stubborn residue,
where incorporated paper cases, grease, oil, etc. from framework (including sprocket columns, sprockets & base frame).
_______________________________________________________________________________
SECTION 12
TROUBLE SHOOTING
_______________________________________________________________________________
12.1 Basic Strategies for Preventing Mechanical Obstruction
1. If replacing missing carriers, chain pins must be checked for straightness. Any bent pins must be
replaced. When replacing chain pins, always replace same on both sides of the line, regardless
of whether the other side is damaged or not. Potential risk of jamming the line can result
if/when carriers are installed on bent pins!
2. Make sure all PM’s are completed. Auto-Bake ovens operate more reliably and efficiently
when well-maintained!
3. Make sure operators do not mistreat the machine in any way. Heavy-handed loading of trays onto
carriers, for example, can result in damage to carrier bearings. If unchecked, these bearings can
come apart and lose the tiny ball bearings. A single carrier bearing ‘ball’ can jam the Auto-
Bake machine if lodged between the chain and a sprocket tooth!
4. If the line happens to stop on mechanical overload, do not allow operators to restart the line
without a first having a qualified maintenance technician check out the root cause. If this is not
adhered to, it is recipe for disaster! The mechanics should do a quick ‘once-over’ of the line
before trying to restart. If no obvious cause for the stoppage is found, then, (and only then),
should the line be reset and restarted. If the line stops once more on overload, then there is very
likely a mechanical obstruction somewhere on the chain circuit. Never bypass overload
switches! If the line trips there is usually a very good reason for so doing. Not finding the root-
cause will spell trouble in the long run if ignored.
5. If a mechanical obstruction occurs, the timing on the sprockets must be checked in the general
area of the obstruction. No exceptions! Also, please check chain pin alignment in the same
vicinity.
6. If a mechanical obstruction occurs, please check all carriers in the general vicinity are straight and
not damaged in any way. It may not be the carrier(s) at the epicentre of the obstruction that
caused the fault. Likewise, it may not be the carrier(s) at the epicentre of the obstruction that are
damaged. A damaged carrier may have ‘caused’ the initial obstruction by first damaging
components in the area, then moving on unscathed for possibly several serpentine rows, before
the damaged it inflicted to the components previously causes subsequent carrier(s) to jam. Be
aware of this, it is a trap for young players!
7. Have maintenance technicians ‘walk the line’, once or twice a shift, remove covers and listen for
strange noises.
_______________________________________________________________________________
8. Allocate sufficient maintenance time to ensure the well-being of the Auto-Bake line generally. The
tasks can be broken down into small activities, for example, ‘check the oven this week’, ‘check the
drive next week’ and so forth.
9. Grease all bearings according to the PM’s, schedule tasks to actually go looking for loose bolts,
worn parts, timing errors, debris contamination, etc. The basic parts of the machine are the same
throughout the machine. Look for things that do not look right!
10. Fix the problem ‘as soon as possible’. Leaving chain misalignment or incorrectly timed sprockets
for ‘another day’, as an example, increases the opportunities for bending carriers or causing
damage elsewhere throughout the chain circuit.
11. Acquire a training setup from Auto-Bake, which consists of a set of LTS sprockets mounted in a
bench frame. This will allow training of maintenance technicians ‘off-line’ on how to time LTS
sprockets properly and how to change out bearings housed within these sprocket assemblies.
TROUBLE SHOOTING CHAIN PATH
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
Machine won't start. ‘E’ stop circuit is tripped. Check all safety switches and
re-set if necessary.
Mechanical overload is tripped. Check and clear mechanical

jam.
Re-set overload in Drive screen.

Check air pressure to Start up
pressure.
Check limit switch is made.
Check main air supply pressure.
Mechanical overload setting Chain not sufficiently Turn on chain oiler.

higher than at time of lubricated.
commissioning. Increase oiling frequency.
Increase oiling amount, observe

so there is no flooding of chain,
machine or floor.
Transport chain bearing failure. Replace where needed.
Bearing lubrication. Replace and or replenish where

needed.
Many carriers damaged in the Mechanical overload set too Adjust to setting at time of
event of a mechanical jam. high. commissioning.
_______________________________________________________________________________
Carriers not square to line. Chain pins out of alignment. Re-set cross-shaft in that area.
Chains of unequal lengths. Re-pitch chains. When

replacing chain, both sides of
the machine must be replaced
to ensure pin alignment.
Unequal chain wear. Lubricant amounts must be

even to both sides.
Mechanical jam. Clear machine of obstruction.
Slides not lubricated. Lubricate slide assembly

including rails against side
plates.
Chain surge Chain not sufficiently Increase oiling frequency.

lubricated.
Increase oiling amount, observe
so there is no flooding of chain,
machine or floor.
Carriers not located beneath Position of ancillary. Measure and check position.
ancillary equipment correctly.
Centering guide not adjusted. Position ancillary correctly,

then adjust centering guide.
Carriers not level in vertical Vertical guides not adjusted Re-set guides to have 1-1.5mm
transfer modules. correctly. clearance on both carrier
bearing and chain.
Adjusting block not set Re-set M10 bolt to adjust

correctly. vertical rails.
Carriers not level around turn Timing incorrect between Re-set timing: Refer Section 6
over sprocket. gears. attachment.
Idle gear between sprockets

loose or adjusted incorrectly.
Carriers have bent ferrules Timing incorrect between Re-set timing: Refer Section 6
(horizontally). gears. attachment.
Carriers have bent ferrules Personnel walking on carriers Instruct personnel not to walk
_______________________________________________________________________________
(vertically). and/or pans. on carriers/pans.
Mechanical obstruction. Remove obstruction.
TROUBLESHOOTING - PRODUCT
Depositing equipment not Signal from Auto-Bake. Check corresponding relay in
working.
Junction Box 1
Photo eye faulty. Check operation, clean.
Encoder faulty. Check operation.

Check belt is tracking within
guides, not ‘riding up’ guides.
Product not baked. Primary temp incorrect. Check temperature.
Incorrect formulation. Select correct formulation
Heater elements not operating Check elements and controllers

are working correctly.
Uneven colour. Turbulence fan. Check fan direction according to

fan/impellor not just motor
direction.
Check fan speed.
Check isolator.
Duct work obstruction. Remove obstruction.
Damage to top of product. Turbulence tube fallen. Re-fit and tighten fittings & grub
screw. Screw one side only to
allow for expansion.
Product on heater element Carry out intensive sanitation.

shrouds.
_______________________________________________________________________________
SECTION 13
SPARE PARTS
13.1 Refer Separate Recommended Spare Parts Schedule
_______________________________________________________________________________
SECTION 14
ANCILIARY EQUIPMENT
14.1 ATTACHMENTS
 Comas Injector
 Dubor Pan Greaser
 ABB 6640 Robot
_______________________________________________________________________________
SECTION 15
HMI TOUCHSCREEN
15.1 ATTACHMENTS
Touchscreen Operations Manual

Suncrest Line # 7 Maintenance and Operations Manual PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Suncrest Line # 7 Maintenance and Operations Manual PDF

Hochgeladen von

Copyright:

Verfügbare Formate

_______________________________________________________________________________

OPERATIONS & MAINTENANCE

 Schematic of Gas Supply Chain ................................................................................. 37

9.1.4 Function of Conveyor C4 ............................................................................................. 79

This manual should be read and fully understood by all

1.1 Definition of Symbols

Risk to operators, maintenance personnel or equipment

Risk of electrical shock

1.2 General Safety Checks

IMPORTANT: Under no circumstances should emergency stops

• Whenever an emergency stop is activated a designated person should be made

IMPORTANT: The Auto-Bake process should only be

WARNING: Prior to removing guards, main electrical

• Ensure all sensors are kept clean and operational.

1.3 Lock-Out Procedure

• Call your supervisor.

• You may now enter the machine.

IMPORTANT: Once your lock has been removed, do not enter

IMPORTANT: The Auto-Bake line has been designed to operate

2.1 System Process

Main equipment supplied by Auto-Bake includes:

• Oven Infeed Module (including Free-Tray Loading System) – 4 Metre

• Serpentine™ MK 126-9 Ambient Cooler c/w 20 Fans (232 Pans)

• Cooler-Mounted Drive & Chain Take-Up System

• Outfeed Module - 3 Metre (including Free-Tray Unloading System)

Above drawing also attached as PDF, please refer PDM-7375-K

2.2 Oven Infeed Module – 4m (including Free-Tray Loading

• Stainless steel hose-down spillages catch trays and guttering.

2.3 Serpentine™ Gas-Fired Convection Heated Oven - 218 Pans

Direct-Fired Convection Heating System

Oven Ventilation System

2.4 Product Inspection Station – 2.5m

2.5.1 Mechanical Overload System

2.5.2 Chain Tensioning System

2.6 Serpentine™ MK 126-8/9 Ambient Coolers – 207/232 Pans

2.7 Cooler-Mounted Drive & Chain Take-Up System

2.9 Automatic Lubrication System (Chain & Carrier Bearings)

2.10 Robotic Product Depanning System – Dual Head

2.11 Conveyor Circuit System (CCS)

2.12 Pan Washer & Dryer - Colussi

2.13 Pan Greaser - Dubor

2.14 Steam Generator – Simons Boilers

2.15 Electrical Control Cabinet (MCC) & HMI (Touch Screen

 Line and Factory Layout

 Colussi Pan Washer & Dyer Operating Instructions Manual

 Dubor Pan Greaser Operating Instructions Manual

 Simons Steam Generator (Boiler) Operating Instructions Manual

OVEN INFEED MODULE

3.1 Oven Infeed Module

4.1 Description of Heating System

• Turbulence (re-circulation) fan

Overview of Convection Oven Heating Components

There are 3 LH & 3 RH turbulence fans identified as follows:

AEROVENT: BCL-530ACW/220/HE Centrifugal Fan - 3.5 m³/s @ 640Pa, 1740 RPM

4.2 Gas Train

Typical Components of Gas Train

4.3 Detailed Purge Process

A minimum 5 total room-exchanges (i.e. the sum

4.3.1 PLC-Automated Purge Sequence

4.4 Burner Start-Up Sequencing

• Check burner fan pressure switch indicates ‘no air flow’.

• Check flame rod indicates ‘no flame’

• Start burner fan