Qimarox HR9 User manual

Operating manual HR9
QS21XXXX
Version 1.0 - 13/07/2021

About this manual
2
Operating manual HR9 –QS21XXXX
Qimarox
Nobelstraat 43
3846 CE Harderwijk
The Netherlands
Tel: [phone]
Fax: [phone]
Email: [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.

About this manual
Operating manual HR9 –QS203263
3
Table of contents
1ABOUT THIS MANUAL............................................................................................................................... 6
INTRODUCTION............................................................................................................................................ 6
VERSION..................................................................................................................................................... 6
SOURCE LANGUAGE ...................................................................................................................................... 6
SYMBOLS USED IN THE MANUAL ...................................................................................................................... 7
TERMINOLOGY LIST....................................................................................................................................... 7
FURTHER SUPPORT AND INFORMATION............................................................................................................. 7
2GENERAL .................................................................................................................................................. 8
WARRANTY................................................................................................................................................. 8
LIABILITY..................................................................................................................................................... 8
CE DECLARATION OF CONFORMITY.................................................................................................................. 8
3MACHINE PARTS....................................................................................................................................... 9
OVERALL VIEW............................................................................................................................................. 9
BELT CONVEYOR......................................................................................................................................... 10
TURN CONVEYOR........................................................................................................................................ 10
PRODUCT FORMATION ................................................................................................................................ 11
PRODUCT PUSHER ...................................................................................................................................... 11
LAYER PUSHER FORMATION .......................................................................................................................... 12
LAYER BUFFER............................................................................................................................................ 12
LAYER PUSHER LAYER PROCESSING ................................................................................................................. 13
STACKING PLATES ....................................................................................................................................... 13
REAR RESTRAINT ........................................................................................................................................ 14
SIDE RESTRAINTS ........................................................................................................................................ 14
PALLET LIFT ............................................................................................................................................... 15
PALLET HANDLING ...................................................................................................................................... 15
4OPERATING CONTROLS........................................................................................................................... 16
MAIN SWITCH ........................................................................................................................................... 17
EMERGENCY STOP ...................................................................................................................................... 17
PALLETISER CONTROL BUTTONS ..................................................................................................................... 18
STACK LIGHT PALLETISER .............................................................................................................................. 19
TOUCH PANEL PALLETISER ............................................................................................................................ 20
CONTROL PANEL GROUND FLOOR .................................................................................................................. 21
CONTROL PANEL ACCESS SAFETY DOOR ........................................................................................................... 22
CONTROL PANEL LIGHT GRID......................................................................................................................... 23
5PACKML.................................................................................................................................................. 24
PACKML MODE OVERVIEW .......................................................................................................................... 24
PACKML STATUS OVERVIEW......................................................................................................................... 25
PACKML ALARM SYSTEM ............................................................................................................................. 29
6OPERATING SCREENS.............................................................................................................................. 31
TEMPLATE STATUS BAR................................................................................................................................ 31
TEMPLATE NAVIGATION BAR......................................................................................................................... 31
TABS MENU............................................................................................................................................... 32

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Operating manual HR9 –QS21XXXX
KEYBOARDS............................................................................................................................................... 33
MAIN MENU ............................................................................................................................................. 34
Palletiser overview ........................................................................................................................ 34
Recovering the palletiser ............................................................................................................... 35
Production selection ...................................................................................................................... 39
Database ....................................................................................................................................... 41
Generate........................................................................................................................................ 43
PackML model ............................................................................................................................... 46
PROGRAM SETTINGS ................................................................................................................................... 47
Program database......................................................................................................................... 48
Program settings - General ........................................................................................................... 49
Program settings infeed ................................................................................................................ 50
Program settings turning .............................................................................................................. 51
Program settings formation .......................................................................................................... 52
Program settings layer pusher ...................................................................................................... 53
Program settings layer buffer........................................................................................................ 54
Program settings layer processing ................................................................................................ 55
Program settings pallet lift............................................................................................................ 56
Program settings patterns / sheets ............................................................................................... 57
PATTERN SETTINGS ..................................................................................................................................... 58
Pattern settings, explanation of pattern structure........................................................................ 59
Pattern settings General ............................................................................................................... 61
Pattern settings formation ............................................................................................................ 62
Pattern settings layer buffer.......................................................................................................... 63
Pattern settings layer slide ............................................................................................................ 64
Pattern settings layer processing .................................................................................................. 65
STATISTICS ................................................................................................................................................ 66
Unit dashboard.............................................................................................................................. 66
Machine effectiveness................................................................................................................... 67
Machine speed .............................................................................................................................. 68
Mode / Status times ...................................................................................................................... 69
Machine counters.......................................................................................................................... 70
MACHINE NOTIFICATIONS ............................................................................................................................ 71
Alarm list ....................................................................................................................................... 71
Warning list ................................................................................................................................... 72
History ........................................................................................................................................... 73
MANUAL MODE ......................................................................................................................................... 74
Manual control supply conveyor ................................................................................................... 75
Manual mode pattern-formation conveyor .................................................................................. 76
Manual mode layer buffer............................................................................................................. 77
Manual mode layer processing ..................................................................................................... 78
Manual mode pallet lift................................................................................................................. 79
Manual pallet handling ................................................................................................................. 80
SETTINGS.................................................................................................................................................. 81
General settings ............................................................................................................................ 81
Palletiser settings .......................................................................................................................... 82
Belt conveyor settings ................................................................................................................... 83
Turn conveyor settings .................................................................................................................. 84
Forming table settings................................................................................................................... 86

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Operating manual HR9 –QS203263
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Layer pusher settings..................................................................................................................... 88
Layer buffer settings...................................................................................................................... 89
Layer processing settings .............................................................................................................. 91
Side and rear restraint settings ..................................................................................................... 93
Pallet lift settings....................................................................................................................... 94
Pallet loading position settings ................................................................................................. 95
DIAGNOSTICS ............................................................................................................................................ 97
Drives............................................................................................................................................. 97
Hardware....................................................................................................................................... 98
Communication ............................................................................................................................. 99
Documentation............................................................................................................................ 100
PackML Log ................................................................................................................................. 101
EXTERNAL APPLICATIONS ........................................................................................................................... 102
Camera surveillance software ..................................................................................................... 103
Qimarox pattern generator ......................................................................................................... 105
7OPERATING THE PALLETISER................................................................................................................. 107
STARTING THE PALLETISER.......................................................................................................................... 107
Checks before starting................................................................................................................. 107
Starting up the palletiser ............................................................................................................. 107
Starting or restarting the palletiser............................................................................................. 110
STOPPING THE PALLETISER.......................................................................................................................... 111
Pausing the machine ................................................................................................................... 111
Stopping the machine.................................................................................................................. 112
Emergency stop of the machine .................................................................................................. 112
COMPLETE THE MACHINE (EMPTYING).......................................................................................................... 113
SWITCHING OFF THE MACHINE .................................................................................................................... 114
RESTORING THE MACHINE .......................................................................................................................... 115
Restoring after problem with row / layer formation................................................................... 115
Restoring after problem with layer processing ........................................................................... 119
BATCH PROCESSING .................................................................................................................................. 123
Manual batch loading ................................................................................................................. 124
Manual batch removal ................................................................................................................ 125
Manual refreshing ....................................................................................................................... 126
8NOTIFICATIONS .................................................................................................................................... 127
ALARM INFORMATION............................................................................................................................... 127
ALARM LIST............................................................................................................................................. 128
WARNINGS INFORMATION ......................................................................................................................... 143
LIST OF WARNINGS ................................................................................................................................... 144

About this manual
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Operating manual HR9 –QS21XXXX
1 About this manual
Introduction
This manual provides information about the palletiser type HR9. This type of machine is used
to automatically palletise products on a pallet.
Henceforth the palletiser machine type HR9 will be referred to as the ‘machine’, ‘unit’ or
‘palletiser’.
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. This is necessary to
make sure that all new users are familiar with the content of this manual.
Version
Version
Author
Description
V1.0
JHO
First English version
Source language
This manual was originally written in the English language.

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Operating manual HR9 –QS203263
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Symbols used in the manual
The following symbols are used in this manual.
WARNING
Risk of serious injury to the user if the instructions are not accurately followed.
CAUTION
Risk of damage to the machine if the instructions are not accurately followed.
NOTE
To provide additional information to the user about a task or issue.
INSTRUCTION
To provide additional instructions to the user to complete a task or issue.
Terminology list
The table below explains common terms used in this manual.
Term
Definition
HMI
Human Machine Interface, commonly a touch panel
PLC
Programmable Logic Controller
NC
Normally Closed: normally closed contact without enabling / switching
the component
NO
Normally Open: normally opened contact without enabling / switching
the component
PROFINET
Profinet (usually styled as PROFINET,
as a portmanteau for Process Field Net) is an industry technical
standard for data communication over Industrial Ethernet, designed for
collecting data from, and controlling equipment in industrial systems,
with a particular strength in delivering data under tight time constraints.
Downstream
Previous module in line / network
Upstream
Next module in line / network
Further support and information
Qimarox can supply additional expertise and support services, for:
Training
Global support
Service contracts
For more information please contact Qimarox.

General
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Operating manual HR9 –QS21XXXX
2 General
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 wear of
the parts.
The machine warranty is null and void in cases of:
Unskilled use.
Inadequate maintenance.
Unskilled maintenance.
Modifications made to the Machine without prior written permission From Qimarox.
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.
CE Declaration of Conformity
The CE declaration can be found in the User manual of the complete system. This manual is
provided by the system integrator.

Machine parts
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3 Machine parts
The machine is divided into different modules; each module has its own function and
operation.
Overall view
Palletconveyor
loading position
Product
formation
single infeed
Layerbuffer
+
Layer restaints
Turning converyor
Palletlift
Side restraints
Layer
pusher
formation
Rear restraint
Stackingplates
Indexing belt
conveyor
Layerpusher
layerhandling

Machine parts
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Operating manual HR9 –QS21XXXX
Belt conveyor
The belt conveyor ensures controlled infeed of products into the palletiser. This belt has a
special grip belt that ensures that products that are not yet allowed to run into the machine
stay nicely in place.
As soon as the machine is ready for a new product, the belt will start.
Spaces must be created between products in order to be able to count products. These
spaces are created by speed differences.
The photocell at the end of the belt ensures counting and is also the start/stop point of the
infeed cycle.
Turning conveyor
The Turning conveyor is used to change product orientation.
On this module we use a light grid to measure product orientation, while scanning 2D to
measure length of the box, the speed of conveyors is adjusted until target orientation is
reached.
Valid target orientation are 90, 180 or 270 (-90) degrees
Conveyor also checks the length when product enters the light grid.

Machine parts
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Product formation
The product formation ensures that products that approach the position stop according to the
set pattern.
This is done with an encoder mounted on the back of the motor. At the beginning of the
product formation, a photocell is located; as soon as it gets covered, during the running-in of
the product, the encoder begins measuring. Once the correct position has been reached, the
motor stops running.
Subsequently, it is from the set pattern whether the product is the last of a column and
possibly requires further processing.
Product pusher
The product pusher ensures that columns (rows of products), which are finished with their
operations on the product formation, are moved to the correct position.
The position is determined from the set pattern.
Products are also reversed by means of a reversing cam mounted on the pattern-formation
pusher.

Machine parts
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Operating manual HR9 –QS21XXXX
Layer pusher formation
The layer pusher is used for sliding rows/layers from the formation deck to the next module/
machine part.
During receipt of a row and/or layer, the beams are used as the end position of the pattern-
formation conveyor.
Layer buffer
The layer buffer is added to receive layer or rows, to buffer and then (optionally) to square the
complete layer in preparation for layer processing.
Row/Layer is fed in via the roller conveyor and the row/layer is positioned on the roller
conveyor by means of an encoder.
When the (complete) layer is closed up, the layer can be transported to stacking plates by
means of the layer pusher of the layer processing.

Machine parts
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Layer pusher layer processing
The layer pusher is used to slide rows/layers from the formation to the stacking plate.
When depositing a layer on the stacking plates, the layer pusher is also used as a front
restraint of the layer on the stacking plates
Stacking plates
The stacking plates consist of 2 plates that move independently of each other.
As soon as the pallet lift, with pallet load, is underneath the stacking plates, the stacking plates
are opened to place the layer on the pallet load that is on the pallet lift.
The layer is first closed up with the 3 restraints that are located on the stacking plates
•Layer pusher (restraining front layer)
•Side restraints (restraining left and right-hand side layer)
•Rear restraint (restraining rear layer)
During opening, the layer restraints can be sent to the second position to determine the final
size/dimensions on the pallet load.
Once the pallet lift is under the stacking plates again, they are closed again.

Machine parts
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Operating manual HR9 –QS21XXXX
Rear restraint
The rear restraint is used to square the back of the layer during the deposition cycle of the
stacking plates.
Side restraints
The side restraints are used to square the left and right-hand side of the layer during the
deposition cycle.
The restraints work centrically so the layers are always in the middle of the pallet.

Machine parts
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Pallet lift
With the pallet lift, the pallet load is brought to the position, to below the stacking plates, to
place layers on the pallet. This is detected by sensors.
As soon as the pallet is full, the pallet lift will move to the outfeed height to discharge the
pallet.
The pallet lift will also move to the infeed height during/before the feeding in of a new (empty)
pallet.
Depending on the pallet lift configuration, infeed and outfeed height may be the same.
Pallet handling
The pallet handling ensures that new (empty) pallets are available for stacking. The empty
pallet is fed in as soon as the pallet lift is at the correct height.
As soon as a pallet is ready on the pallet conveyor of the loading position, it is loaded with
layers.
When the pallet is full, i.e. the desired number of layers has been reached, and the pallet lift is
at outfeed height, the full pallet is transported to the next pallet conveyor position.

Operating controls
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Operating manual HR9 –QS21XXXX
4 Operating controls
Overview of palletiser controls
Main switch (black with lock).
- On the control cabinet
Emergency stops (red punch buttons).
- On the control cabinet / at the control panel
- At full pallet outfeed
- On the fencing at supply conveyors
Palletiser control buttons
Stack light palletiser
Control panel palletiser
Control panel ground floor
Control panel access safety doors
Control panel light grids

Operating controls
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Main switch
The main switch has 2 positions
Position
Description
I –ON
The main power supply (400V) is switched on
O –OFF
The main power supply (400V) is switched off
In the O –OFF position it is possible to lock the switch with a lock. This allows you to prevent
the machine from unexpectedly turning on during maintenance or service.
WARNING
The main switch is located on the main control cabinet and should only be
switched off for authorised technical personnel
Emergency stop
In order to be able to stop the ENTIRE palletising installation quickly in case of emergency (or
possible damage to the installation), the installation is equipped with emergency stop buttons.
When an emergency stop button is pressed the entire system will go into emergency stop
mode. The emergency stop circuit is reset using the RESET button of third-party control
WARNING
The emergency stop button should NEVER be used to stop a normal production
process.
INFO
The emergency stop can be recognized by its red colour

Operating controls
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Operating manual HR9 –QS21XXXX
Palletiser control buttons
Each machine is equipped with a series of push buttons to start and stop the machine.
The mode of the machine can also be influenced with this
Position
Description
Mode selection
Mode options
- AUTO (Automatic production)
- MANUAL (Manual mode)
Reset button
Issuing reset command in case of state:
- ABORTED
- STOPPED
- COMPLETE
Start button
Issuing (re)start command at status:
- IDLE
- HELD
- SUSPENDED
Stop button
Stop command can always be given to stop the machine as soon as
possible
Pause button
With this button it is possible to pause the machine. This is only possible
if the machine is in ‘EXECUTE’ state.
Emptying button
With this button it is possible to empty the machine. This is only possible
if the machine is in ‘EXECUTE’ state.
Control of signalling in the buttons
B =
Blinking
S =
Steady
Aborting
Aborted
Clearing
Stopping
Stopped
Resetting
Idle
Starting
Execute
Holding
Held
Unholding
Suspending
Suspended
Unsuspending
Completing
Completed
B
B
B
B
S
S
B
S
B
S
S

Operating controls
Operating manual HR9 –QS203263
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Stack light palletiser
The status of the machine is displayed through a stack light.
Colour
Frequency
Description
Red
Continuous
Machine has stopped or is in the process of stopping
(STOPPING/STOPPED). This could be due to malfunction or
the machine has been stopped by the operator
Red
Pulsing 0,5
Hz
Machine is blocked (ABORTING/ABORTED). Safety circuit
faulty or hardware problems
Yellow
Continuous
Machine has been stopped because no pallet removal is
possible. (SUSPENDED)
Yellow
Pulsing 0,5
Hz
Machine has stopped because there is no supply of products.
(SUSPENDED)
Blue
Continuous
Machine is paused by the operator / or due to certain
malfunctions (HOLD)
Blue
Pulsing 0,5
Hz
Machine needs material, depots are running low (Pallets &
Sheets) or any other operator action is required
Green
Continuous
Machine mode started or (re)starting (in EXECUTIVE state)
Green
Pulsing 0,5
Hz
Machine Standby (IDLE) or completed (COMPLETE)
Below is an overview of which lamp is lit for which status of the machine.
Only one lamp can be active with the exception of the blue flashing light. This allows the
machine to ask the operator to come to the machine to take preventive actions.
B = Blinking
S = Steady
Aborting
Aborted
Clearing
Stopping
Stopped
Resetting
Idle
Starting
Execute
Holding
Held
Unholding
Suspending
Suspended
Unsuspending
Completing
Completed
RED
B
B
B
S
S
S
S
YELLOW
Outfeed blocked
S
S
YELLOW
No supply
B
B
BLUE
Operator action
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
BLUE
Internal error
S
S
GREEN
S
B
B
B
B
B

Operating controls
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Operating manual HR9 –QS21XXXX
Touch panel palletiser
The control panel of each palletiser is equipped with a touch panel. The software can be
operated using the touch panel.
Chapter 6 provides a detailed description of the screens.
Starting and stopping is done by means of the control push buttons.
The touch panel is used to provide the operator with additional information.