Qimarox HR9 User manual

User manual
Palletiser HR9
(partly completed machine)
Assembly
Project number: QS21XXXX
Machine identification: Assembly
Version: 1.0 24 June 2021

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UM Assembly Palletiser HR7 (partly completed) QS203263 v1.0 EN
Qimarox B.V.
Nobelstraat 43
3846 CE Harderwijk,
The Netherlands
Tel: [phone]
Fax: [phone]
Email: [e-mail] Inter-
net: www.qimarox.com
Copyright © Qimarox
All rights reserved. No part of this publication may be reproduced, stored in a database or
an automated database, or made public in any form or by any means, electronic, mechani-
cal, by print, photocopy, microfilm or any other way, without prior written permission from
Qimarox.
“Original User manual”

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UM Assembly Palletiser HR7 (partly completed) QS203263 v1.0 EN
Introduction
Introduction
This manual informs the operator about the safe use and daily maintenance of the assembly
partly completed Palletiser HR9. This assembly will be referred to as ‘machine’ in the rest
of this manual.
The machine is intended to be assembled with a control system, safety devices and other ma-
chines. The machine comes with a working design for a control system, a working design for
software and a sample operating manual. The control cabinet, safety fencing with doors and
light curtains, control panels, emergency stops, etc. are not included in the scope of delivery.
Supply and discharge conveyors are also not supplied.
The machine is an assembly of separate modules. Due to the lack of a functional control sys-
tem, this assembly is delivered as a ‘partly completed machine’ according to Machinery Di-
rective 2006/42/EC.
The machine is supplied with a Declaration of Incorporation for partly completed machinery
according to Machinery Directive 2006/42/EC Annex II section 1B. This means that it is forbid-
den to put the machine into operation before all the requirements of the Machinery Directive
have been met and a CE mark has been affixed to the machine.
Dimensions and mirroring of the machine in this manual may differ from that supplied. For ac-
tual dimensions, see the accompanying other documentation further down and in in chapter
1.3
Tip
Make sure that this manual is always available with the machine.
Read this user manual carefully before using or working on the machine. Only then is optimal
safety guaranteed.
WARNING
Operation and daily maintenance of the machine must only be carried out by quali-
fied personnel.
Tip
The manuals of the various (main) components can be found in the Technical file.
Operation and software
The operation and control screens of the machine are described in a separate specific Oper-
ating manual.

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Introduction
Main components
The Palletiser HR9 consists of the following main components, which have their own manuals:
Metering belt conveyor BC1
UM Belt conveyor BC1 v1.1 EN.pdf
Turning unit (Twistrunner) TR6
UM Twistrunner TRr1_6 v1.0 EN.pdf
Product formation deck PFS7
UM Product formation v1.0 EN.pdf
Layer pusher LP1
UM Layer pusher HR9 v1.1 EN.pdf
Layer buffer LB1
UM Layer buffer v1.0 EN.pdf
Layer pusher LP3
UM Layer pusher HR9 v1.1 EN.pdf
Stacking plates LH7
UM Stacking plates HR9 v1.0 EN.pdf
Side and back restraints LH7
UM Side-back restraints HR9 v1.0 EN.pdf
Pallet lift Prorunner Prmk10
UM Prorunner mk10 v2.0 EN.pdf
Pallet chain conveyor loading position PCc3
UM Pallet chain conveyor v1.0 EN.pdf
These component manuals can be downloaded from www.qimarox.com.

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UM Assembly Palletiser HR7 (partly completed) QS203263 v1.0 EN
Contents
Contents
Introduction......................................................................................................................................... 3
Contents............................................................................................................................................. 5
Document history................................................................................................................................ 6
1Introduction.................................................................................................................................. 7
1.1 Warning................................................................................................................................ 7
1.2 Manufacturer ........................................................................................................................7
1.3 Related documents............................................................................................................... 7
1.4 Machine identification / CE marking......................................................................................8
1.5 Warranty............................................................................................................................... 9
1.6 Liability ................................................................................................................................. 9
2Safety precautions..................................................................................................................... 10
2.1 Safety and warning symbols............................................................................................... 10
2.2 Hazard pictograms ............................................................................................................. 10
2.3 Operator............................................................................................................................. 13
2.4 Maintenance engineer........................................................................................................ 13
2.5 Safety................................................................................................................................. 14
2.5.1 General ....................................................................................................................... 14
2.5.2 Working at heights, under lifts and under loads ........................................................... 15
2.5.3 Hazardous areas......................................................................................................... 16
2.6 Safety devices.................................................................................................................... 17
2.6.1 Emergency stop buttons / Machine stop buttons:......................................................... 18
2.6.2 Security fencing with safety doors................................................................................ 19
2.6.3 Safety light curtains..................................................................................................... 20
2.6.4 Mechanical locking device lift..................................Fout! Bladwijzer niet gedefinieerd.
3Installation................................................................................................................................. 22
3.1 Safety regulations............................................................................................................... 22
3.2 Important installation topics ................................................................................................ 22
3.2.1 Placing the machine.................................................................................................... 22
3.2.2 Installing the machine.................................................................................................. 23
3.2.3 Commissioning the partly completed machine............................................................. 23
4Machine description................................................................................................................... 24
4.1 Function.............................................................................................................................. 24
Overview of the partly completed machine........................Fout! Bladwijzer niet gedefinieerd.
4.2 ................................................................................................................................................. 24
4.3 Process description............................................................................................................ 25
4.4 Controls.............................................................................................................................. 26
4.4.1 Main switch.................................................................................................................. 26
4.4.2 Emergency stop button................................................................................................ 26
4.4.3 Status lamps (signal post) ........................................................................................... 26

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Contents
4.4.4 Mute lamp light curtain at pallet outfeed ...................................................................... 26
4.4.5 Main control panel....................................................................................................... 26
5Maintenance.............................................................................................................................. 27
5.1 Safety precautions.............................................................................................................. 27
5.2 Maintenance schedule........................................................................................................ 28
5.2.1 Daily maintenance....................................................................................................... 28
6..................................................................................................Fout! Bladwijzer niet gedefinieerd.
Transport and storage ...................................................................................................................... 29
6.1 Safety precautions.............................................................................................................. 29
6.1 Transport and storage of the machine................................................................................ 29
7Removal...............................................................................Fout! Bladwijzer niet gedefinieerd.
7.1 Safety precautions.............................................................................................................. 30
7.2 Removal of the machine..................................................................................................... 30
7.3 Environmental aspects ....................................................................................................... 30
Appendix 1 –Specifications.............................................................................................................. 31
Appendix 2 –Decleration of incorporation......................................................................................... 32
Document history
The document has been issued according to the overview below.
Tabel 01: History
Version
Date
Author
Description
v1.0
2021-06-24
JHO
First released version

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UM Assembly Palletiser HR7 (partly completed) QS203263 v1.0 EN
Introduction
1 Introduction
1.1 Warning
WARNING
Operation and daily maintenance of the machine must only be carried out by
qualified personnel.
WARNING
Optimal safety is only guaranteed if you read this manual carefully before using or
working on the machine.
1.2 Manufacturer
Machine manufactured by:
Qimarox B.V.
Nobelstraat 43
3846 CE Hardewijk,
The Netherlands
Telephone: [phone]
Fax: [phone]
Internet: www.qimarox.com
Email: [e-mail]
1.3 Related documents
In addition to this manual, the following documents are supplied with the machine:
• The manuals of the different (main) components (PDF or URL).
• Operating manual: operation, control screens (for partly completed machine)
• Mechanical drawings and parts lists
• Pneumatic diagram (for partly completed machine)
• Electrical diagram (for partly completed machine)
• Declaration of Incorporation for partly completed machinery

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Introduction
1.4 Machine identification / CE marking
The machine is referred to as the ‘Palletiser HR9’. The year of construction of the machine is
2019. The machine identification plate is mounted on the machine according to figure 1-1.
Manufacturing year
: 2021
Type
: Assembly Palletiser HR9
Serial number
: QS21XXXX Assembly …
Order number
: QS21XXXX
Power supply
: 3x400 V - 50 Hz NPE
Nominal power
: 23 kW
Weight
: 4350 kg
Maximum load
: 25 / 180 / 1000 kg
Nominal capacity
: 1300 p/hour
Figure 1-1: Machine identification plate of the partly completed Palletiser HR9
Because the machine is delivered without a control system, it is a ‘partly completed machine’
and does not have a CE marking. This means that this machine does not fully meet the essen-
tial health and safety requirements of the European Union. The requirements that are met are
stated in the enclosed Declaration of Incorporation for partly completed machinery. It is forbid-
den to put the machine into operation before all the requirements have been met and a CE
mark has been affixed to the machine.

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UM Assembly Palletiser HR7 (partly completed) QS203263 v1.0 EN
Introduction
1.5 Warranty
Qimarox guarantees the machine from the delivery date.
Please refer to the provisions as mentioned in the order confirmation of this order for the spe-
cific warranty terms.
The warranty applies only if the machine is used in accordance with the specifications men-
tioned and if the operating and maintenance instructions are followed.
The warranty of the machinery is no longer valid in the event of:
• Improper use.
• Insufficient maintenance.
• Incompetent maintenance.
• Modifications to the machine without the prior permission of the manufacturer. The war-
ranty does not apply to machine parts that need to be replaced periodically.
1.6 Liability
The manufacturer of the machine is not liable for unsafe situations, accidents and damage re-
sulting from:
• Ignoring warnings or instructions as displayed on the machine or in this manual.
• Usage of the machine for other applications, or under different conditions than indicated
in this manual.
• Making changes to the machine of any kind. This also includes the use of other replace-
ment parts.
• Insufficient maintenance.
The manufacturer is not liable for consequential damages in case of failure of the machine,
such as product damage, business interruption, loss of production, and so on.

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Safety precautions
2 Safety precautions
2.1 Safety and warning symbols
Various safety and warning symbols are used in this manual. In order of severity, these are:
Tip
Additional information for the user.
WARNING
Indicates damage to the machine or product if the instructions are not followed care-
fully.
HAZARD
Indicates serious injury to the operator if instructions are not followed carefully.
2.2 Hazard pictograms
Hazard pictograms on the machine are not included. An example of affixing hazard picto-
grams to the machine is shown in the safety layout (figure 2.1). This layout gives an overview
of a number of situations that can occur with an example of the icons that can be used.
Before using the machine, the correct pictograms must be applied in accordance with the Ma-
chinery Directive.
The machine is equipped with a number of fixed surveillance cameras and recording equip-
ment for remote assistance in case of malfunctions. If necessary, icons can be placed for this
purpose.
Figure 2-1: Position warning icons

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Safety precautions
A full size safety layout is provided with the relating documents (see paragraph 1.3 for the complete list).
• Electrical hazard (not shown)
on electrical equipment where hazardous electrical voltage is present.
Figure 2-2: Pictogram ‘Electrical hazard’
• Warning: Read the Manual before use (not
shown)
at the main switch of the machine.
Figure 2-3: Pictogram ‘Warning: Read the Manual before use’
• No access
• at safety light curtains that can be interrupted during operation.
• at doors that can be opened during operation. in the safety fencing.
• at large throughput openings for empty pallets.
Figure 2-4: Pictogram ‘No access’
• Crushing hazard
on machine parts where there is a risk of crushing.
Figure 2-5: Pictogram ‘Crushing hazard’

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Safety precautions
• Safety helmet mandatory (not shown)
when working at heights, under lifts and under load.
Figure 2-6: Pictogram ‘Safety helmet mandatory’
•Camera surveillance (not shown)
at doors in safety fencing in the vicinity of CCTV cameras
Figure 2-7: Pictogram ‘Camera surveillance’

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Safety precautions
2.3 Operator
Only qualified personnel may operate the machine. A qualified operator has experience with
operating machinery and is informed about the contents of this manual.
WARNING
The safety precautions in this manual must be observed. Non-compliance with
these precautions can result in unacceptable risk.
The operator must be familiar with the contents of Chapters 1, 2 and 4 of this user manual,
the operating manual and operating screens before the machine may be operated.
The following personal protective equipment must be worn when operating the machine:
• Protective clothing.
• Safety shoes.
Figure 2-8: Personal protective equipment to be worn
2.4 Maintenance engineer
All maintenance work should be performed by qualified maintenance personnel.
WARNING
The safety precautions in this manual must be observed. Non-compliance with
these precautions can result in unacceptable risk.
The maintenance engineer must be familiar with the entire contents of this user manual, the
manuals of the different main components and the operating manual and operating screens,
before any maintenance work is carried out on the machine.
During maintenance or installation of the machine the following personal protective equip-
ment must be worn:
• Protective clothing.
• Safety shoes.
• Protective gloves
Figure 2-9: Personal protective equipment to be worn

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Safety precautions
2.5 Safety
2.5.1 General
At the time of delivery, the machine only complies with the essential health and safety requirements of
the European Union stated on the enclosed Declaration of Incorporation for Machinery. Before the
machine can be put into operation, the other requirements must be met. This means that the machine
then complies fully with the Machinery Directive and can be safely operated and maintained if all
safety measures are observed. However, dangerous situations can arise due to improper use or negli-
gence. WARNING
Remain alert to anything that may be dangerous.
Observe the following general safety precautions:
• Be careful with loose clothing and hair.
• Keep your hands away from any hazardous areas.
• Always wear the prescribed personal protective equipment when working on the ma-
chine.
• Never walk on roller conveyors, chain conveyors or belts of a running machine. Roller
conveyors, chain conveyors or belts can start unexpectedly.
• Be aware that unexpected movements in automatic mode of the machine can occur.
• Check the correct operation of the safety devices daily.
• Do not switch the main switch to the ON position when people are in contact with the ma-
chine.
• Never start the machine if persons are in contact with the machine or are inside the se-
curity fencing.
• Always switch off the machine and lock the main switch (with a padlock on the main
switch) before performing any maintenance work.
• Always replace any damaged or defective parts before returning the machine to service.
• Replace all removed covers before using the machine.
• It is not permitted to make modifications to the machine without prior approval from the
manufacturer. Safety devices should never be bypassed or removed.
• Remove any tools or objects left on or in the machine before starting the machine.
• Before working on the different devices, the manuals of the relevant parts must be stud-
ied. Read these manuals before you start work!
• Only skilled and trained personnel may work on the electrical installation.
• Any other general safety measures required by CE conformity must be added to the ma-
chine.

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UM Assembly Palletiser HR7 (partly completed) QS203263 v1.0 EN
Safety precautions
2.5.2 Working at heights, under lifts and under loads
Wear a safety helmet when working at heights, under lifts and under loads.
Wearing a safety helmet is mandatory if the risks entailed by the work necessitate this. This
is highly recommended when working under loads, for instance, where there is a risk of prod-
ucts falling.
When working in the hazardous area of a hoist or lifting gear, it must be placed in a safe po-
sition. This position is either all the way down or resting on the detent pin. When working, it is
advisable to first dispose of the products, so that the device is empty.
Wear fall protection when working at height.
It is obligatory to use approved safety equipment for working at height in situations and cir-
cumstances in which individuals are at risk of falling from heights above two metres.
Approved fall protection consists of an approved, well-anchored safety harness, an approved
safety net or a combination of both.
Figure 2-10: Additional personal protective equipment

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Safety precautions
2.5.3 Hazardous areas
The completed machine can be divided into multiple hazardous areas
For example:
• Zone 1: Supply conveyor.
• Zone 2: Palletiser and PRmk10 lift (partly completed machine).
• Zone 3: Pallet supply.
• Zone 4: Pallet output.
An example of these hazardous zones is shown in the following figure.
Hazardous areas must be secured with emergency stop buttons and/or machine stop buttons.
Emergency stop buttons (red mushroom push button with yellow back plate) put all zones in-
side the machine into safe stop.
Machine stop buttons (black mushroom push button) only switch a corresponding zone into
safe stop.
Figure 2-11: Zone layout

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Safety precautions
2.6 Safety devices
The machine is equipped with a mechanical locking device of the lift as a safety device. In order to fully
comply with the Machinery Directive, a number of additional safety devices must be added before the
machine can be put into service. An example of this is given in the following figure.
The performance level of the safety components used must be PL d cat.3.
Figure 2-12: Safety devices
1. Emergency stop buttons / Machine stop buttons (not delivered, not sketched in):
- On the control cabinet.
- On the main control panel.
- On the control panels.
2. Safety fencing with doors, equipped with safety switches and locks: (not supplied):
- Around the machine.
3. Safety light curtains (not supplied):
- At the pallet infeed conveyor.
- At the pallet outfeed conveyor.
- At the pallet dispenser.
4. Mechanical locking mechanism lift:
- At the pallet lift.
These safety provisions are explained in more detail in the following sections.

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Safety precautions
2.6.1 Emergency stop buttons / Machine stop buttons:
Partly completed machines must be fitted with emergency stop buttons and/or
machine stop buttons.
The emergency stop buttons or machine stop buttons can be placed in the following positions:
• On the control cabinet.
• On the main control panel.
• On other control panels.
• Locally in the field.
Emergency stop buttons (red mushroom push button with yellow back plate) put all zones in-
side the machine off. Except for the PLC/HMI, all hazardous moving parts in all zones are
switched off.
Machine stop buttons (black mushroom push button), safety switches and safety light curtains
cause a safe stop of the respective hazardous area of the machine when operated.
During a safe stop, the dangerous moving parts of the respective hazardous zone are immedi-
ately stopped. The other zones remain active.
For a description of the hazardous areas, see Chapter 2.5.3
In case of danger of personal injury (or damage to the machine):
• Always press one of the emergency stop buttons (red button with yellow back plate) to
stop the entire machine.
WARNING
Only use the emergency stop buttons in dangerous situations.
An emergency stop causes all dangerous moving parts to switch off immediately.

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Safety precautions
2.6.2 Security fencing with safety doors
Figure 2-13: Security fencing with safety doors
The machine must be fitted with all-round safety fencing. This fencing shall comply with stand-
ards EN-ISO 13857 and EN 619.
• To protect the operator from the dangers behind these fences. The safety fencing must
always be placed around the machine.
• The safety barriers around the machine may only be removed by authorised personnel if
necessary (e.g. when carrying out maintenance work). After such maintenance work, the
safety fencing must always be replaced before production is restarted.
HAZARD
The safety fencing may only be removed temporarily and only by authorised per-
sonnel for maintenance work. The machine may only be put back into operation
after all the fences have been reinstalled.
The same applies to the safety doors in the fencing. The safety doors provide access to the
hazardous zone and since they are equipped with door switches, the doors must be closed
before production can start. However, if these safety doors are opened by the operator dur-
ing normal production, a safe stop of the zone concerned (see section 2.5.3) takes place.
The door must be closed and the Reset button at the relevant door pressed to restore the
safety circuit, after which the zone can be restarted.
WARNING
If the safety doors are opened during production, a safe stop of the affected zone
takes place.
The doors must be equipped with an escape release device on the inside to prevent entrap-
ment in the machinery. Revolving doors must always hinge open outwards.
Emergency release

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Safety precautions
2.6.3 Safety light curtains
Figure 2-14: Safety light curtains (example)
The completed machine can be equipped with safety light curtains:
• In the opening of the fence for the pallet dispenser (1).
• In the opening of the fence above the pallet outfeed (2).
If a safety light curtain is triggered, the zone in question stops.
• To protect the operator from the dangers behind these fences.
WARNING
If the safety light curtain is triggered during production, a safe stop of the relevant
zone of the machine takes place.
WARNING
The safety light curtains may only be bridged by designated personnel. The key
must always be removed and stored again.
2
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1