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
6
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.

About this manual
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
Operating manual HR9 –QS203263
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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.