Qimarox PD2 User manual

User Manual
Pallet dispenser PD2
Version 2.0 - 21/04/2022
For serial number PD2 2200000 and higher
(Always check Specification sheet of machine for applicable version)

About this manual
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UM Pallet dispenser PD2 v2.0 EN
Qimarox B.V.
Nobelstraat 43
3846 CE Harderwijk
The Netherlands
Tel: [phone]
E-mail: [e-mail]
Internet: www.qimarox.com
Copyright © Qimarox B.V.
All rights reserved. No part of this publication may be reproduced, stored in a computer
database or published in any form or in any way electronically, mechanically, by means of
photocopying, recordings or in any manner without prior written permission from Qimarox.

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Table of contents
1About this manual 5
1.1 Introduction ......................................................................................................................... 5
1.2 Product documentation....................................................................................................... 6
1.3 Source language................................................................................................................. 6
1.4 Symbols used in the manual............................................................................................... 6
1.5 Terminology list................................................................................................................... 6
1.6 Further support and information.......................................................................................... 7
2General 8
2.1 Machine identification.......................................................................................................... 8
2.2 Machine layout drawing and specifications ........................................................................ 8
2.3 CE Installation instructions.................................................................................................. 9
2.4 Warranty.............................................................................................................................. 9
2.5 Liability .............................................................................................................................. 10
2.6 CE Declaration of Conformity ........................................................................................... 10
3Safety 11
3.1 Intended use of the machine............................................................................................. 11
3.2 User types and qualifications............................................................................................ 11
3.3 Safety instructions............................................................................................................. 12
3.4 Safety provisions............................................................................................................... 14
3.5 Electrical safety................................................................................................................. 18
3.6 Sound level ....................................................................................................................... 18
3.7 Personal safety ................................................................................................................. 18
3.8 Residual risks.................................................................................................................... 19
3.9 Machine end of life and disposal....................................................................................... 20
4Description 22
4.1 General overview.............................................................................................................. 22
4.2 Sensors............................................................................................................................. 23
4.3 Connection unit................................................................................................................. 24
4.4 Machine in a conveyor system.......................................................................................... 25
4.5 Specifications.................................................................................................................... 29
5Installation 30
5.1 Delivery ............................................................................................................................. 30
5.2 Unpacking ......................................................................................................................... 30
5.3 Location............................................................................................................................. 30
5.4 On-site transport ............................................................................................................... 30
5.5 Preparations for a Qimarox installation (optional)............................................................. 31
5.6 Installing the machine ....................................................................................................... 32
6Maintenance 34
6.1 General ............................................................................................................................. 34
6.2 Specific safety regulations ................................................................................................ 34
6.3 Preventive maintenance schedule.................................................................................... 36
6.4 Cleaning............................................................................................................................ 37
7Troubleshooting 38

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8EC declaration of conformity 39
CE Installation instructions.......................................................................................................... 41
9Electrical drawings 42
10 Pneumatic circuit diagram 43
10.1 General data ..................................................................................................................... 43

About this manual
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1 About this manual
1.1 Introduction
This manual provides information about the Pallet dispenser (pallet de-
stacker/stacker) PD2 machine that is used for de-stacking empty pallets awaiting to be
used in a pallet conveyor system or stacking empty pallets coming from a conveyor
system. Henceforth the Pallet dispenser PD2 will be referred to as the ‘machine’.
Note
Make sure this manual is always available with the machine.
This manual is intended for:
•Retailers/Original Equipment Manufacturers (OEM), project engineers and
mechanics.
•Operators, installation and maintenance engineers and other users.
It is important to carefully read this manual as soon as possible after purchase of the
machine. Before operating the machine this manual should be read by all users.
System integrators/OEMs
This manual explains machine configurations that can be used to set up the machine.
It also provides mandatory installation instructions for the System integrator/OEM,
necessary for the machine to comply with EU regulations (CE) and instructions for
installation of the machine on site.
Note
The text of this manual was written assuming that the integrator
followed the EC Installation instructions completely...
Users
This manual gives safety and maintenance instructions and instructions for
troubleshooting. Operating instructions are found in the operating manual (OM) of the
system, provided by the System integrator/OEM.

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1.2 Product documentation
Document
Reference
Machine manual (this
document)1
UM Pallet dispenser PD2 v2.0 EN
Machine layout drawing2
Layout drawing [serial number]
Specification sheet2
Specifications [serial number]
Electrical drawings1or 2
Electrical drawing [serial number]
Machine test manual1
TM Pallet dispenser PDx v1.0 EN
1Generic information 2Machine specific information
Note
The operating instructions are found in the Operating
manual (OM), which is supplied by the System
integrator/OEM.
CAUTION
Make sure you use the correct version of the
documentation for the machine. The correct version
is found in the Specification sheet.
1.3 Source language
This manual is an “Original manual” and was originally written in the English language.
1.4 Symbols used in the manual
The following symbols are used in this manual.
WARNING
Risk of serious injury to the user and/or serious damage to the
machine if the instructions are not accurately followed.
CAUTION
Risk of light or medium injury and/or damage to the machine if
the instructions are not accurately followed.
Note
To provide additional information to the user about a task or
issue.
1.5 Terminology list
The table below explains common terms used in this manual.

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Term
Definition
Machine
The Pallet dispenser PD2
Transportation
surface
A non-driven surface intended for transportation of
products. For example: a roller deck
Palletising
system
Combination of machines that is used for palletising
Fenced area
Area around the machine that unauthorized personnel
cannot enter for
safety reasons.
1.6 Further support and information
Qimarox can supply additional expertise and support services, for:
Training
Global support
Service contracts
For more information, please contact Qimarox.

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2 General
2.1 Machine identification
The machine identification is given on the type plate. The type plate is located at the
back of the machine on one of the side plates of the frame. Refer to the specification
sheet of this serial number, for specifications of this machine and applicable pallets.
2.2 Machine layout drawing and specifications
After a machine order is placed, a machine drawing and specification sheet is sent for
approval. After approval the machine drawing and specification sheet are sent as a
reference for this manual. The machine drawing and specification sheet include:
•Machine serial number
•Pallet dimensions and mass
•Machine dimensions and mass
•Machine configuration
•Machine capacity
•Maximum load
The machine can only be used according to the specifications given in this manual,
the machine layout drawing and the specifications sheet. If you want to use the
machine outside these specifications, you must contact Qimarox to check if this is
possible. Inappropriate and/or modified use of the machine can result in dangerous
safety issues and/or damage. You must obtain written confirmation from Qimarox
before using the machine in a modified or unspecified manner. Qimarox cannot be
held liable for any accidents and/or damages that may occur through inappropriate
unauthorized use of the machine.
Machine maximum load is both in weight and in number of pallets. Both maxima have
to be observed. The type plate and a warning sticker indicates the values. The

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warning sticker must be easily visible when loading pallets into the machine. See the
picture below for possible positions.
2.3 CE Installation instructions
The machine is intended to be integrated into a transport or into a palletizing system
by a System integrator/OEM. Certain items, such as emergency stops, safety controls,
safety fencing, and a control cabinet are logically part of the transport or palletizing
system, and are not supplied with the machine. The System integrator/OEM has to
add these items following the CE Installation instructions on the EC Declaration of
conformity, for the machine to comply with EU regulations (CE).
For the CE installation, instructions see chapter 8.
WARNING
Before the CE Installation instructions have been met
completely, the machine must not be used.
The scope of supply and CE installation instructions are agreed upon between
Qimarox and the System integrator/OEM at the time of sale of the machine.
2.4 Warranty
The scope and duration of the warranty is agreed upon when an order is placed for
the machine. The warranty only applies if the machine is used according to the
specifications and if the user and maintenance instructions are observed. The
warranty does not cover wearing the parts.
The machine warranty is null and void in cases of:
Unskilled use.
Inadequate maintenance.

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Unskilled maintenance.
Modifications made to the machine without prior written permission from
Qimarox.
2.5 Liability
Qimarox believes to the best of its knowledge that the information in this user manual
is accurate. In the event that technical or typographical errors exist, Qimarox reserves
the right to make changes to subsequent editions of this user manual without prior
notice to holders of this edition. The reader should consult Qimarox if errors are
suspected. In no event shall Qimarox be liable for any damages arising out of or
related to this user manual or the information contained in it. Except as specified
herein, Qimarox makes no warranties, express or implied, and expressly disclaims
any warranty of non-infringement, merchantability or fitness for a particular purpose.
Customer’s right to recover damages caused by fault or negligence on the part of
Qimarox shall be limited to the amount paid to Qimarox by the customer. Qimarox
shall not be liable for damages resulting from loss of data, profits, use of products, or
incidental or consequential damages, even if advised of the possibility thereof. This
limitation of liability of Qimarox will apply regardless of the form of action, whether in
contract or tort, including negligence. Any action against Qimarox must be brought
within one (1) year after that cause of action accrues. Qimarox is not liable for
damages, accidents, unsafe conditions, defects, malfunctions, or service failures
caused by the following:
Owner’s or user’s failure to follow Qimarox’s installation, operation and
maintenance instructions, including but not limited to neglecting warnings or
regulations as shown on the machine or in this manual.
Usage of the machine for other applications, or under other circumstances
than indicated in this user manual. This includes abuse, misuse or negligent
acts.
Modifications of any kind to the machine. This includes the replacement of
parts with parts that are not specified in this manual.
Insufficient or improper maintenance.
2.6 CE Declaration of Conformity
Qimarox has determined the design of the machine and therefore supplies the EC
declaration of conformity of the machine. The declaration is only valid after the CE
Installation instructions on the EC declaration of conformity have been met completely.
An example of the declaration is given in chapter 8.
For the specific declaration of the machine, refer either to the Specifications sheet or
to the separate document supplied with the documentation of the machine.

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3 Safety
3.1 Intended use of the machine
The machine is exclusively intended for the stacking of empty pallets described in this
manual. Refer to chapter 4 for a detailed description of the specifications of use.
The machine is always set up within a larger transport system in which empty pallets
are loaded on and off the machine.
WARNING
Any other use of the machine is strictly forbidden.
WARNING
It is strictly forbidden to lift persons with the machine or to stand on
the pallets or lifting frame.
WARNING
It is strictly forbidden to overload the machine with too much weight or
with too many pallets. See specification sheet or type plate and sticker
“Max load” on the machine.
WARNING
It is strictly forbidden to use the machine with pallets out of spec or of
insufficient quality. See specification sheet.
3.2 User types and qualifications
The following user types are referred to in this manual:
The operator
The mechanical installer
The electrical installer
The maintenance engineer
Only qualified personnel may operate the machine. A qualified operator has
experience with operating machinery and is informed about the contents of this
manual. An operator must be familiar with the contents of Chapters 1, 2, 3 and 4 and
with the Operating Manual.
An electrical installer is only qualified if a person has attended appropriate training
and/or attained appropriate industry standard recognized qualifications. Qimarox can
provide training if required.
The maintenance engineer must be familiar with the full content of this manual and
with the Operating Manual. All maintenance work should be performed by qualified
maintenance personnel

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3.3 Safety instructions
3.3.1 General
Comply with the safety regulations given in this manual. Deviation from these
regulations can lead to unacceptable risks.
Never close doors (if present) in the fenced area of the machine, when a person is
inside this area.
Switch off the machine, secure the main power supply switch in the off position
with a padlock and make sure that the air service unit is switched off to prevent
the machine from being switched on while personnel is working within the fenced
area. After making sure that the machine is completely switched off, it is
necessary to vent all cylinders in order to create a safe environment to work in.
See section 6.2
Comply with all relevant local legislation and regulations.
Always wear the prescribed personal protective equipment when working on the
machine. See section 3.7
Be aware that unexpected movements in automatic mode of the machine can
occur.
Check the correct operation of the safety devices regularly.
Do not set the main switch to the ON position when persons are in contact with
the machine.
Never start the machine if persons are in contact with the machine or are inside
the fenced area.
3.3.2 Set up
Connect the machine in accordance with the local laws and regulations
concerning health and safety.
Before putting the machine into use, check if the machine has been set up in
accordance with the instructions in this manual and with the layout drawing.
Make sure that the system into which the machine is integrated, complies with all
relevant health and safety directives and regulations and that the hazards that
may be present at the transitions between the machine and system or other items,
are sufficiently removed.
3.3.3 Starting the machine
Do not switch the main power supply on when persons are in contact with the
machine.
Do not switch the air service unit on when persons are in contact with the
machine.
Do not start the machine when persons are in contact with the machine.
Do not start the machine when persons are present in the fenced area of the
machine.
Before the machine is put into operation, all machine parts must comply with all
relevant health and safety directives and regulations.
3.3.4 During machine operation
Keep your hands and feet away from danger zones.
Make sure you do not wear loose clothing and secure long or loose hair.
Make sure that no persons or objects are within the range of any moving parts of
the machine.

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Make sure that users know and observe all safety rules with regard to the machine
and the environment in which it operates.
3.3.5 Maintenance and repair
See also the specific safety regulations for maintenance and repair in section 6.2
Turn off the power supply to the machine with the main power supply switch
before starting any maintenance or repair tasks. Secure the main power supply
switch in the off position with a padlock.
Switch off air service unit before starting any maintenance or repair tasks. After
the air service unit is switched off, it is necessary to vent all cylinders See section
6.2.
Replace damaged or defective parts before putting the machine back into
operation.
Changes and modifications that may affect the safety of the machine can only be
carried out when these changes and modifications comply with the relevant
regulations, legislation, directives and recognized industry standards.
If changes and modifications are outside the scope of specifications given by
Qimarox in this manual and Qimarox has not granted permission changes and
modifications, then the changes and modifications will entirely be the responsibility
of those persons responsible for carrying out the changes and modifications.
Electrical installation tasks must only be carried out by qualified personnel.
Safety devices should never be bypassed or removed.
Remove any tools or objects left on or in the machine before starting the machine.
After having completed maintenance activities, always put all safety provisions (fencing,
covers and other) that have been removed in place again.
Take the appropriate measures for safety when working at heights.
3.3.6 Fork length
Make sure the forks support the pallets over their full length. Ideally the tip of the fork should
protrude slightly from the front of the stack. When the fork protrudes further that’s not a
problem.
WARNING
Danger of stack or pallets falling. Using the machine pallet too long will cause
the stack to fall forward or might cause pallets to fall from the top of the stack.
3.3.7 Fork adjustment
To ensure that the pallets are stacked and de-stacked safely, the distance between the forks
must be adjusted according to the size of the pallet. There must be at least 50mm distance
between forks and pallet blocks.
WARNING
Danger of stack or pallets falling. Incorrectly adjusted forks might cause the
stack to fall over or might cause pallets to fall from the top of the stack.
Contact Qimarox with any deviation of pallet sizes for the required lift finger position to match
that specific pallet size!

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3.3.8 Pallet quality
A good quality of pallet is essential for the efficiency and safety of the machine. Pallets
should be suitable for automated handling and stacking. No missing parts, no nails,
screws or splinters sticking out that might disrupt the handling or stacking of the pallet.
WARNING
Danger of stack or pallets falling. Unsuitable pallets might cause
the stack to fall forward or sideways or might cause pallets to
fall from the top of the stack.
3.3.9 Side restraint adjustment
To prevent the stack from falling sideways the side restraints must me positioned close to the
stack. This would mean about 40mm between stack and restraint on each side.
3.4 Safety provisions
3.4.1 Safety equipment
Check the correct operation of the safety devices monthly.
You must not disassemble, bypass or disable any safety equipment on the machine.
The machine must not be started and must be immediately taken out of operation if even
a single item of machine safety equipment is defective.
After maintenance tasks are completed, always replace all safety equipment that has
been removed from the machine.
The following safety equipment is part of the machine:
Covers
Safety labels
Emergency stops
Area safety fencing
Safety circuits
Interlocking door switches (and possibly safety light screens)
Safety quick exhaust valve
Some part of the safety equipment may be supplied by the System integrator/OEM. See the
CE installation instructions in in chapter 8. Before the CE Installation instructions have been
met completely, the machine must not be used.
In case of non-compliance with the required safety measures, the EC Declaration of
Conformity will become null and void.
3.4.2 Safety labels
WARNING
Replace labels on the machine if they become unreadable or damaged.

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The following safety labels are applied on the machine:
Residual pneumatic energy / cylinder under pressure
The following safety labels are present near apertures in the area fencing:
Note
These labels are supplied by System integrator/OEM.

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No entry. Authorised personnel only
oat safety light curtains that can be interrupted during operation.
oat doors that can be opened during operation.
No reaching in
oAt single pallet infeed and outfeed openings (only when necessary).
The following labels icons are present on the control cabinet:
Note
The labels on the control cabinet are supplied by System integrator/OEM.
Electrical hazard
oif hazardous electrical voltage is present.
Read the Manual before use
oat the main switch of the machine
3.4.3 Safety fencing
Qimarox requires a protection fenced area around the machine. Any access doors must be
secured with interlocking door switches. When a person enters the fenced area, the machine
must stop immediately.

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Openings in the fenced area must be designed such that they protect persons against
reaching the danger zone. When this is not possible, these openings must be equipped with a
safety light curtain.
Interlocking door switches and (if present) safety light curtains must be included in the safety
circuits. Unsafe access must stop the machine immediately.
The safety fencing must be strong enough against the forces of a pallet falling or a stack of
pallets toppling.
For specific requirements to the safety fencing, see the CE installation instructions in in
chapter 8.
Make sure that the fenced area complies with local law and rules for protection against
danger.
If Qimarox supplies the safety fencing, the specifications will be included in the machine layout
drawing.
3.4.4 Safety controls
Performance level
Emergency stops and safety circuits must be designed according to a so-called Performance
Level (PL) corresponding with the current standard for safety functions of a machine or a
machine. For required PL of this machine see the CE installation instructions in in chapter 8.
Emergency stops
The machine must have one or more emergency stops included in the safety circuits. When
one of the emergency stop buttons is pressed, the main power and air supply and the control
current of the machine are switched off immediately. For specific requirements, see the CE
installation instructions in in chapter 8.
Safety circuit
The machine must have safety circuits. Unsafe access must stop the machine immediately.
For specific requirements, see the CE installation instructions in in chapter 8.
3.4.5 Safety quick exhaust valve
The machine is driven by compressed air. To eliminate the danger of potential energy, the air
supply must be controlled using a quick exhaust valve with a Performance Level PL d
category 3 or higher. The safety quick exhaust valve must be included in the safety circuits. It
must shut off the air supply and release the air immediately when:
Personnel safety is at risk
An emergency stop is triggered
Access doors of safety fencing are opened
A power failure occurs
CAUTION
Some pneumatic cylinders cannot be vented but have check valves instead.
See section 6.2 for special safety regulations.
In addition, the quick exhaust valve has a slow-start function. When the air supply is
restored again, the pressure is built up slowly to prevent abrupt motions of machine parts.

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3.4.6 Check valves
To prevent the carriers and lifting forks to lower by gravity when the air is released from the
machine, the cylinders have been fitted with check valves. This also prevents the stack from
falling.
WARNING
Danger potential energy and moving parts. Check valves keep air trapped inside
the cylinder. This can cause a cylinder to move when for instance an air tube or
blockage is removed. Before maintenance or repair, it is necessary to vent all
cylinders. See section 6.2 for special safety regulations.
For safety reasons the check valve for closing the lifting arm is short-circuited in the following
positions:
Carrier middle position for a de-stacker
Carrier bottom position for a stacker
WARNING
Danger of stack or pallets falling. When de-stacking, NEVER keep the pallet
stack suspended in the middle position. In an emergency stop the lifting arms
are depressurised in the middle position and the stack will drop.
3.5 Electrical safety
-
3.6 Sound level
The A-weighted emission sound pressure level LpA at workstations does not exceed 70dB(A).
Note
The sound pressure level applies to typical pallets made of wood or plastic.
Pallets made of other materials might increase the sound level.
3.7 Personal safety
For your own safety use personal protective equipment.
Always wear proper personal protective equipment when working with, on or near the
machine.
The following table gives an overview of the required personal protective equipment

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Safety sign
Description
When required
Protective clothing. No
loose clothing or long
hair.
Maintenance
Cleaning
Foot protection
Production
Maintenance
Cleaning
3.8 Residual risks
The machine is intended to be integrated into an automated palletizing or pallet conveyor
system.
Qimarox has attempted to protect against as many hazards as possible, either though inherent
safe design or by shielding off the dangers. Machine users should be aware of the following
residual risks before working with the machine:
3.8.1 Falling of stack or pallets
When the path of the lifting forks is blocked during inserting the stack might be pushed over
forward. A damaged or unsuitable pallet in the stack might cause a stack falling forward or
sideways. When a pallet is halfway under the stack and the stack is lowered, the stack might
fall.
The stack of pallets is kept from falling from the machine by the following measures:
Back- and side restraints for the stack
Check valves on the pneumatic cylinders of the carrier.
Sensors to detect that the lifting forks are in position.
Limitation of force moving the forks by limiting the air pressure.
The stack of pallets could fall from the machine under the following conditions
Pallets are not suitable for automated stacking. See section 3.3.8
A mechanical or pneumatic fault in the machine.
A fault in the control or the programming of the machine.
For a de-stacker - The stack is kept suspended with the carrier in the mid position.
Overloading the stacker with weight or number of pallets.
To minimise the risk of a stack falling the following directions must be followed:
Only use pallets suitable for stacking. See section 3.3.8
Keep the stack resting on the transport surface between cycles. Do not keep in
suspended position.
For a de-stacker: NEVER keep the stack suspended in the mid position.
Use area fencing of sufficient strength and height.
Keep working or traffic areas away from the open side of the area fencing.
Set the air pressure driving the fork as low as possible.

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3.8.2 Pallets falling from the stack
When the stack falls or becomes sloped through incorrect handling, pallets might also fall from
the top of the stack.
For measures, conditions and directions see section 3.8.1
3.8.3 Potential pneumatic energy
Because of the use of check valves, pneumatic energy is stored inside the pneumatic lifting
cylinder when the air supply is switched off. This can cause the cylinder to move when for
instance an air tube or blockage is removed.
See the specific maintenance and repair instructions in section 6.2
3.8.4 Potential gravitational energy
When the lifting cylinder is vented of trapped air for repair and maintenance, the cylinder and
machine parts may start moving, thus creating crushing and other hazards.
See the specific maintenance and repair instructions in section 6.2
3.8.5 Rapid movement of forks at start-up
After a stop and release of air from the machine, the pneumatic pressure is restored slowly to
the cylinder driving the forks. When the forks were stopped between their end positions they
might move rapidly. Through their mass and speed, great forces might occur.
The following measures were taken to prevent rapid fork speeds at start-up:
Using a pressure regulator valve on the fork cylinder.
Using of a quick exhaust valve has a slow-start function
The forks could move rapidly under the following conditions
Air pressure set too high.
Slow-start ramp up time set too low.
To minimise the risk of rapid fork movement rapidly the following directions must be followed:
Set the air pressure driving the fork as low as possible.
Set the slow-start ramp-up time to the value described in section 10.1 or longer.
3.9 Machine end of life and disposal
Proper use and maintenance of the machine will not involve any environmental risks.
When the machine is no longer useable, the machine should be dismantled and
disposed of in an environmentally responsible manner.
WARNING
Observe all relevant legislation, regulations, instructions and
precautions with regard to health and safety when dismantling
the machine.
Observe all relevant legislation, regulations, instructions and
precautions with regard to the disposal of products in the
environment.