0750609 Bernatello's Foods

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Project Scope: The customer has requested an install estimate related to the recent sale on WO 2020148. The MFT team will be installing this new feeder to the customer's new Syntegon equipment. The MFT team will also make upgrades tot he two existing 600HWD feeders that Bernatello's owns. One of the older feeder will also be mounted to the new Syntegon equipment. From there the MFT team will update the two existing HWD APLs with taller legs and dial these in to feed into the 600HWD feeders at a 30 degree angle.
Equipment Summary: New Feeder WO 2020148: New Feeder SN: 2042-06700 Previously sold Equipment WO 2018068: Older feeder SN: 1825-13968 Older feeder SN: 1825-13967
Work Done: Work done by Matthew on 01-29-21 Travel: 1 hr. Onsite: 3 hrs. Work performed 01-29-21: copied email sent to Barry at Syntegon I arrived to see the erratic behavior from the feeder that was explained to David from Mike. The problem is the pitch of your lugs is smaller than the pitch of the products in the feeder. The feeder is set to accutipping speed match, so it does everything it can to drop a product at the exact same speed the collator is moving, but since it’s always behind we got the erratic behavior. I showed Mike how to setup the Lug-Web repeat in our feeder software, that is used for this exact situation. The lug setting (feeder) was set to 500 and the web (your lug conveyor) was set to 300. Once this was setup the feeder was able to hit the pockets with accuracy no matter the speed change. Mike, Bryan and I discussed the current need for a belt or hold down strap, of some sort, to ensure the warped pizza disks stay in their respective pockets. In the future to avoid the need for a hold down strap I would suggest having a 30% gap setup in your lug spacing, the lug pitch being 1.3 times the given product. That way we would be able to run the feeder closer to a 1 to 1 speed match removing the need to increase the speed of the feeder to keep up. While onsite we ensured the encoder was wired properly and giving us the correct value, both of which were correct. I also used our internal trigger option to ensure the start pulses you were sending to the feeder were not the root cause of the poor performance. 2/18/21 drive to appleton 8hrs travel Bernie & Tuan 2/19/21 We decided to show up at Bernatellos a few hours earlier than expected. We started out with moving all 3 feeders right next to each other so we could work on them. Then the operator pointed out how worn out the feed belts on the existing feeders are. They looked bad and definitely needed to be changed out. Unfortunately, we didn’t bring the Hygenic Kit along so changing the belts out wasn’t possible this morning. We spent almost all day figuring out the wiring portion. The new feeder got the encoder cable wired so it’s done and ready to be put back online. However, it’s still sitting and waiting on the other suppliers to get done with their stuff. Tomorrow we will continue with rewiring the existing feeders and making sure they’re identical and working properly. 8hrs onsite Bernie & Tuan 2/20/21 The new feeder with APL and Remote Keypad had been mounted in place near the wall. The same thing for the second feeder on the production side. We initially ran into some problems with the schematics. We figured that out and changed from the 5-pin connector to 8-pin female connector coming out of the Remote Keypad. We also had the two existing feeders wired accordingly to be able to plug into the Keypad. 9.5 hrs onsite Bernie & Tuan 2/21/21 See entry in wrike by Tuan 6.5hrs onsite Bernie & Tuan Drove to Owen, WI to meet Matt to get laptop so software could be upgraded. Tuan went back with Matt and I went back to Appleton 6.5 hrs travel Bernie 2/22/21 Went in to start software upgrades, Matt walked me thru it, upon finishing the keypad didn't work. Matt talked to Dave and Dave showed where find a file to download to motherboard, tried doing that but that file had to connect to our server to work (no WIFI in area where feeder is) they got me an internet line, between me Matt and Shane got connected but the file still would not load. Got a hold of Nicole one she got up to speed she put a local file on laptop, still would not load. After all that Nicole brought up that going from version 4 to 5 the flash card had to be updated also. Went to Best Buy and got a memory card reader, after getting back Nicole remotely redid the card downloaded the file and it took, once that happened the mother board was locked and missing the keycodes, Nicole put the numbers in for me. Downloaded settings from new to this one (s/n 1822-06676) 10hrs onsite Bernie 2/23/21 Went in at 5;30am for start up, something was wrong with the signal from Syengon, they fixed it, tried running but the feeder would not feed, found that encoder was not running talked with Greg B. and instructed on what wires to change because encoder was running backwards, still encoder pulses. Greg looked at data sheet and explained the pin out, I had wired it backwards, rewired and all was good. Finished dialing in feeder and APL (s/n 182206676). Asked for power for the second feeder, had Nicole redo second feeder flash card while waiting. Still no power so I went to the maint. shop and found a110vac cord, wired it myself then upgraded software, worked with Dave to get motherboard unlocked and put in key codes, checked motor direction all good. 8hrs onsite Bernie 03/18/2021 5hrs Travel Each - Clay and Peter 03/19/2021 Arrived at the site at 8am. Walked through safety specifics with Steve at Bernatello's and we were lead out to the equipment. Peter and I started on the wiring cleanup/repairs to the two machines that were online. Worked on these updates for approx. 3 hrs. Broke for lunch. Finished wiring shortly after lunch. Peter noticed that the feeder belts on the older machine online needed to be changed out because they were very worn. This took approx. 2hrs. The customer had attempted to use their own weld on belt material to avoid dismantling the machine for a belt change. The material was not working for them. Also, the customer had used non-stainless key stock during a previous belt change and this material had been rusting within the clamping collar of the Feed Belt Drive Shaft. We cleaned this up as best we could during reinstall and also put in the correct stainless keystock replacement. Once the feed belts were changed Peter also noticed that one of the bearing on the lower nose roller of the discharge was completely deteriorated. With this, it was decided to swap the discharge from the older machine that was not online to the older machine that was online. This Took approx. 1.5hrs. Once the discharge was swapped Peter worked on dialing in the older of the two machines online with the 15" product rounds. While Peter did this I worked on the wiring cleanup/upgrades to the 3rd machine. Peter made a few minor software adjustments to the machine and we got it dialed into the line with minimal jerkiness. The biggest help was lowering the accutipping lock factor from 100 to 85. We tested this with simulated pizzas on the line and Bernatello's maintenance staff was happy with how the line was running. Peter took a software back up of this machine and duplicated it to the new machine online. We then dialed this machine in for the 9" product rounds. Peter also showed the maintenance tech on hand where the Accutipping Lock Factor setting was in the menu and had him change it on this machine. Once dialed in, we moved over to the 3rd machine, powered it on and uploaded the backup file of the other two machines to this one so they are all the same. Because we stole the discharge from this machine we could not run circles through it, but we duplicated everything we could to it so is should be the same as the other 2 machines. 12hrs Onsite 5hrs Travel Peter and Clay
Repair Quotation Notes: Completed By:

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Edit	XID	Part Number	Serial Number	Part Name	Complete	Total Hours	Hours Remaining	Qty	Cost	Price	Discount	Cal Price	On Hand
Edit	48915			LABOR - HOUR ON SITE (54.5 HRS @ $215) - BERNIE, TUAN, MATT (4)	Set Complete		0 hrs	1		$11,717.50	0.00	$11,717.50
Edit	48916			LABOR - OT HOURS ON SITE	Set Complete		0 hrs	3		$322.50	0.00	$967.50
Edit	48917			LABOR - TRAVEL (29.5 HRS @ $115) - BERNIE AND TUAN	Set Complete		0 hrs	1		$3,392.50	0.00	$3,392.50
Edit	48918			LABOR - ADDITIONAL CHARGES	Set Complete		0 hrs	0		$0.00
Edit	48919			TRAVEL EXPENSES - MILEAGE	Set Complete		0 hrs	1	$687.27	$557.89	0.00	$557.89
Edit	48920			TRAVEL EXPENSES - AIRFARE, CHANGE FEES, LUGGAGE	Set Complete		0 hrs	1		$0.00
Edit	48921			TRAVEL EXPENSES - HOTEL	Set Complete		0 hrs	1	$1,106.89	$1,306.13	0.00	$1,306.13
Edit	48922			TRAVEL EXPENSES - PARKING, MEALS, GAS	Set Complete		0 hrs	1	$824.64	$949.48	0.00	$949.48
Edit	48923			SERVICE TRIP PRE-TRAVEL PREP FEE	Set Complete		0 hrs	1		$250.00
Edit	50513			HOURS ON SITE (PETER / CLAY 3/19)	Set Complete		0 hrs	24		$215.00	0.00	$5,160.00
Edit	50514			TRAVEL HOURS (PETER / CLAY 3/18 & 3/19)	Set Complete		0 hrs	20		$115.00	0.00	$2,300.00
Edit	50515			HOTEL (PETER & CLAY)	Set Complete		0 hrs	1	$186.28	$219.81	0.00	$219.81
Edit	50516			MILEAGE (PETER & CLAY)	Set Complete		0 hrs	1	$328.16	$387.23	0.00	$387.23
Edit	50517			SERVICE TRIP PRE-TRAVEL PREP FEE (PETER & CLAY)	Set Complete		0 hrs	1		$250.00	0.00	$250.00
Edit	50518			COURTESY CREDIT FROM SERVICE	Set Complete		0 hrs	1		($4,000.00)	0.00	($4,000.00)
Edit	50519	4125106		STRIPPER WHEEL ASSY 600 SHORT LR	Set Complete		0 hrs	1		$2,360.00	0.00	$2,360.00	0
Edit	50520			CORE CHARGE CREDIT	Set Complete		0 hrs	1		($1,215.00)	0.00	($1,215.00)
Edit	50521	1192429		FEED BELT FDA EPDM 65A 488 LG S	Set Complete		0 hrs	5		$179.00	100.00	$0.00	25
Edit	51501			COURTESY CREDIT	Set Complete		0 hrs	-1		$2,500.00	0.00	($2,500.00)

+ denotes that software settings are available for this piece of equipment.

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			*PRODUCT STACK SHELVES ARE NOT INCLUDED WITH BASE-PICK WHAT IS NEEDED*


			**ALL ITEMS BELOW ARE INCLUDED IN COSTING & PRICING PN 9740001**