Qimarox PRORUNNER Mk5 User manual

User Manual
Prorunner mk5 Washdown
Version 1.0 - 06/11/2023

About this manual
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UM Prorunner mk5 WD 1.0 EN
Qimarox B.V.
Nobelstraat 43
3846 CE Harderwijk
The Netherlands
Tel: [phone]
E-mail: [email protected]
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
B.V.

About this manual
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Table of contents
1About this manual 5
1.1 Introduction..............................................................................................................5
1.2 Machine documentation..........................................................................................6
1.3 Source language.....................................................................................................6
1.4 Symbols used in the manual...................................................................................6
1.5 Terminology list.......................................................................................................7
1.6 Further support and information..............................................................................7
2General 8
2.1 Machine identification..............................................................................................8
2.2 Machine layout drawing and specifications.............................................................9
2.3 CE Installation instructions................................................................................... 10
2.4 Warranty............................................................................................................... 10
2.5 Liability ................................................................................................................. 10
2.6 CE ........................................................................................................................ 11
2.7 UKCA ................................................................................................................... 11
2.8 Patents................................................................................................................. 11
3Safety 12
3.1 Intended use of the machine................................................................................ 12
3.2 User types and qualifications............................................................................... 13
3.3 Safety instructions................................................................................................ 14
3.4 Safety provisions.................................................................................................. 15
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
3.10 Overload tests...................................................................................................... 20
4Description 21
Fout! Bladwijzer niet gedefinieerd.
4.1 General overview ................................................................................................. 21
22
4.2 Working principles................................................................................................ 22
4.3 Sensors................................................................................................................ 24
4.4 Motor.................................................................................................................... 25
4.5 Control system ..................................................................................................... 26
4.6 Guiding of the carriers.......................................................................................... 27
4.7 Machine in a system ............................................................................................ 28
4.8 Specifications....................................................................................................... 30
5Installation 32
5.1 General................................................................................................................. 32
5.2 Delivery ................................................................................................................ 32

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5.3 Possible installations............................................................................................ 32
5.4 Unpacking ............................................................................................................ 32
5.5 Location................................................................................................................ 33
5.6 On-site transport .................................................................................................. 34
5.7 Preparations for a Qimarox installation (optional)................................................ 36
5.8 Installing the machine .......................................................................................... 36
5.9 Installing conveyors.............................................................................................. 40
6Maintenance 41
6.1 General................................................................................................................. 41
6.2 Specific safety regulations ................................................................................... 41
6.3 Preventive maintenance schedule....................................................................... 42
6.4 Cleaning............................................................................................................... 46
6.5 Lubrication............................................................................................................ 47
6.6 Chain maintenance .............................................................................................. 47
6.7 Bottom sprocket plain bearing rejection dimension ............................................. 49
6.8 Plain bearing (between trolley and leveller) rejection dimension......................... 49
6.9 Replace parts....................................................................................................... 49
7Troubleshooting 67
8EC declaration of conformity 71
CE Installation instructions............................................................................................. 73
9Electrical circuit diagrams 74
9.1 Standard electric drawings................................................................................... 74
9.2 Drives................................................................................................................... 75
10 Overload test report 76

About this manual
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1 About this manual
1.1 Introduction
This manual provides information about the Prorunner mk5 Washdown (WD). From
here on, the Prorunner mk5 WD is referred to as the 'machine'.
Note
Make sure this manual is always available with the machine.
The function of the machine is vertical movement of products within a transport
system. This manual is intended for:
• Retailers/Original Equipment Manufacturers (OEM) project engineers and
mechanics.
• Operators, installation and maintenance engineers and other users.
As soon as possible after purchase of the machine, carefully read this manual. Before
you operate the machine, you must read this manual. Make sure that you are familiar
with the content of the manual and the machine.
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
The machine is supplied fully assembled.
To integrate the machine within a transport system, refer to the documentation
provided by the OEM of the transport system.

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1.2 Machine documentation
Document
Reference
Machine manual (this document)1
UM Prorunner mk5 WD 1.0 EN
Machine layout drawing2
Layout drawing [serial number]
Specification sheet2
Specifications [serial number]
Electrical drawings1or 2
Electrical drawing [serial number]
Machine test manual1
Test manual prorunner mk5 v2.1 EN
1Generic information 2Machine specific information
Information on electrical, pneumatic or other components can be found on the
websites of their manufacturers.
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.

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1.5 Terminology list
The table below explains common terms used in this manual.
Term
Definition
Machine
Prorunner mk5 WD
Product
Products transported by the machine.
Fork
The component which carries the product.
Feeding conveyor
The conveyor that delivers products to the machine. The
feeding conveyor is not part of the machine.
Discharge conveyor
The conveyor that discharges products from the machine.
The discharge conveyor is not part of the machine.
Fenced area
Area around the machine that unauthorized personnel
cannot enter for safety reasons.
Infeed conveyor
The feeding conveyor puts products on the infeed
conveyor. The infeed conveyor is part of the machine and
positions the products right above the fork.
Outfeed conveyor
The outfeed conveyor moves products out of the machine.
The outfeed conveyor is part of the machine.
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. Refer to the specification sheet of this serial number, for
specifications of this machine.

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2.2 Machine layout drawing and specifications
After a machine order is placed, a machine drawing and specification sheet are 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
•Product dimensions and mass
•Machine dimensions and mass
•Machine configuration
•Machine capacity
•Maximum load
•Motor specifications
•Number of forks
•Electrical components
The machine can only be used according to the specifications given in this manual, in
the machine layout drawing and in 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.
The maximum load on the fork is displayed on the sticker “Max load” and the type
plate. The load needs to be distributed in the middle of the fork.

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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 lifting 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 at order placement of 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 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.
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

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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
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 a 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.
2.7
UKCA
Qimarox has determined the design of the machine and therefore supplies the VK
declaration of conformity of the machine. The declaration is only valid after the UKCA
Installation instructions on the VK declaration of conformity have been met completely.
An example of a 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.
2.8 Patents
Patent protection applies to parts of the machine. Consequently, other parties are not
permitted to build this machine in this form, unless Qimarox B.V. has explicitly given
permission for this. For more information, refer to mk5 WDpatents.qimarox.com.

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3 Safety
3.1 Intended use of the machine
The machine is exclusively intended for the vertical transportation of goods, as
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 products are
automatically loaded on and off the machine.
WARNING
Any other use of the machine is strictly forbidden.
WARNING
It is strictly forbidden to manually place products on the carrier.
WARNING
It is strictly forbidden to lift persons with the machine or to stand on
moving parts of the machine.
WARNING
It is strictly forbidden to overload the machine with too much weight or
with too many products. See specification sheet or type plate and
sticker “Max load” on the machine.
WARNING
When operating the machine between 50Hz and 60Hz, the frequency
from the specification sheet provided should be used. When exceeding
50Hz, torque loss may occur. It is mandatory to use the frequency which
is provided in the delivered specification sheet.

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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
Qimarox can also give advice about actions and tasks to be carried out on the
machine. It is also possible to get training on maintenance and service of the machine.

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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) of 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, when applicable, 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, when applicable, to vent all cylinders in order to
create a safe environment to work in.
•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.
•When applicable, 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.

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•Make sure that no persons or objects are within the range of any moving parts of
the machine.
•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 chapter 6.
•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.
•When applicable, 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.
•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.
3.4 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)

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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.
The following safety labels are applied on the machine:
Caution rotating parts
oat machine with rotating parts.
The following safety labels are present near apertures in the area fencing:
Note
These labels are supplied by System integrator/OEM.
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 product infeed and outfeed openings (only when necessary).
The following labels icons are present on the control cabinet:

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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.
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.
For specific requirements to the safety fencing, see the CE installation instructions 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 chapter 8.

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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 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.
3.5 Electrical safety
Set the motor protection relay
Motor protection devices must be set to the nominal motor current. A relay set too low
prevents optimum use of the motor. A relay set too high does not guarantee full
thermal protection.
Thermistor protection (TF contact)
For motors that are frequently started and stopped, intermittently operated, use a high
switching frequency or power controller, it is essential to use a motor protection relay
and thermistor protection. This is to avoid prematurely switching the motor protection
relay or overheating of the motor winding in these operational conditions.
3.6 Sound level
The A-weighted emission sound pressure level LpA at workstations does not exceed
70dB(A). To measure and calculate the sound level, refer to the standards ISO 3740
and ISO 3744
Note
The sound pressure level applies to standard products, “loud products”
can increase the LpA and in that case the LpA must be measured on site.
Note
Factors like the state of the machine, state of the bearings, geometry
and surface of the building, external noise sources also influence the
noise level. The user should carry out additional measurements for
workplace noise assessments after the machine is in full operation.
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 loose
long hair.
Maintenance
Cleaning
Foot protection
Production
Maintenance
Cleaning
Eye protection
Maintenance
Cleaning
Ear protection
During production
Protective gloves
Maintenance
Cleaning
Safety harness
During work at
height
3.8 Residual risks
The machine is intended to be integrated into an automated production line.
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 products
When the machine is integrated into a production line, there will be a chance of falling
products. This can occur during maintenance or when misused. Be aware of falling
products when performing maintenance and whenever a person is inside the safety
fencing.
3.8.2 Machine connection to other parts of the production line
Hazards might occur at places where the machine connects to other parts of the
production line, such as supply and discharge conveyors. When performing
maintenance, be aware of moving parts and potential risks.

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3.8.3 Potential gravitational energy
When applicable, cylinders are vented of trapped air for repair and maintenance,
cylinders and machine parts may start moving, thus creating crushing and other
hazards.
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.
WARNING
Observe all relevant legislation, regulations, instructions and
precautions with regard to the disposal of products in the environment.
3.10 Overload tests
The overload test needs to be done by the integrator when the installation is installed
and electrically connected. A new static and dynamic overload test may be necessary
after complete disassembly of the machine or after replacing critical parts.
See chapter 10 for a sample overload test report.