Qimarox Prmk10-PS User manual

User Manual
Pallet stacker Prmk10-PS
Version 2.0 - 17/06/2022
For serial number Prmk10-PS 2200000 and higher
(Always check Specification sheet of machine for applicable version)

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UM Pallet stacker Prmk10-PS v2.0 EN
Qimarox B.V.
Nobelstraat 43
3846 CE Harderwijk
The Netherlands
Tel: [phone]
E-mail: [e-mail]
Internet: www.qimarox.com
Copyright © Qimarox B.V.
All rights reserved. No part of this publication may be reproduced, stored in a computer database or
published in any form or in any way electronically, mechanically, by means of photocopying,
recordings or in any manner without prior written permission from Qimarox.

About this manual
UM Pallet stacker Prmk10-PS v2.0 EN
3
Table of contents
1About this manual 4
Introduction ......................................................................................................................... 4
Machine documentation...................................................................................................... 5
Source language................................................................................................................. 5
Symbols used in the manual............................................................................................... 5
Terminology list................................................................................................................... 6
Further support and information.......................................................................................... 6
2General 7
Pallet stacker identification ................................................................................................. 7
Machine layout drawing and specifications ........................................................................ 7
CE Installation instructions.................................................................................................. 8
Warranty.............................................................................................................................. 8
Liability ................................................................................................................................ 9
CE ....................................................................................................................................... 9
3Safety 9
Intended use of the pallet stacker....................................................................................... 9
User types and qualifications............................................................................................ 10
Safety instructions............................................................................................................. 12
Safety provisions............................................................................................................... 15
Electrical safety................................................................................................................. 19
Sound level ....................................................................................................................... 19
Personal safety ................................................................................................................. 19
Residual risks.................................................................................................................... 20
Machine end of life and disposal....................................................................................... 20
Overload test..................................................................................................................... 21
4Description 22
General overview.............................................................................................................. 22
Working principle............................................................................................................... 23
Connection units ............................................................................................................... 26
Machine set in a conveyor system.................................................................................... 26
Specifications.................................................................................................................... 27
5Installation 28
6Maintenance 28
General ............................................................................................................................. 28
Specific safety regulations ................................................................................................ 28
Preventive maintenance schedule.................................................................................... 28
Cleaning............................................................................................................................ 30
7Troubleshooting 31
8EC declaration of conformity 32
CE Installation instructions.......................................................................................................... 34
9Electrical drawings 35
10 Pneumatic diagram 35

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UM Pallet stacker Prmk10-PS v2.0 EN
1 About this manual
Introduction
This manual provides information about the pallet stacker Prmk10-PS machine that is used for
loaded pallets on top of each other in a distribution system. Henceforth the Prmk10-PS will be
referred to as the ‘machine’.
The machine is an assembly of two separate modules, the Qimarox vertical conveyor
Prorunner mk10 (without carrier or conveyor) and the stacking module. This manual deals only
with issues concerning the stacking module and the combination of the two machines. For
specific information about the Prorunner mk10, refer to its manual. See section 1.2
Note
Make sure this manual is always available with the machine.
This manual is intended for:
•Retailers/Original Equipment Manufacturers (OEM), project engineers and mechanics.
•Operators, installation and maintenance engineers and other users.
It is important to carefully read this manual as soon as possible after purchase of the machine.
Before operating the machine this manual should be read by all users.
System integrators/OEMs
This manual explains machine configurations that can be used to set up the machine. It also
provides mandatory installation instructions for the System integrator/OEM, necessary for the
machine to comply with EU regulations (CE) and instructions for installation of the machine on
site.
To integrate the pallet stacker within a system, refer to the documentation of the Prorunner
mk10
Note
The text of this manual was written assuming that the integrator followed the EC
Installation instructions completely.
Users
This manual gives safety and maintenance instructions and instructions for troubleshooting.
Operating instructions are found in the operating manual (OM) of the system, provided by the
System integrator/OEM.

About this manual
UM Pallet stacker Prmk10-PS v2.0 EN
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Machine documentation
Document
Reference
Pallet stacker manual (this document) 1
UM Pallet stacker Prmk10-PS v2.0 EN
Prorunner mk10 manual 1
UM Prorunner mk10 v1.0 EN
Machine layout drawing 2
Layout drawing [serial number]
Specification sheet 2
Specifications [serial number]
Electrical drawings mk10-PS 1
Electrical drawing mk10 [serial number]
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.
Source language
This manual was originally written in the English language.
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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Terminology list
The table below explains common terms used in this manual.
Term
Definition
Pallet stacker
The pallet stacker module Prmk10-PS
Machine
The Prorunner mk10 including the pallet stacker Prmk10-PS
Conveyor
The conveyor that delivers and discharges pallets to and from the
machine. The conveyor is not part of the machine
Transportation
surface
A surface intended for transportation of products. For example a roller
conveyor
Transport
system
Combination of machines that is used for transporting products or pallets
Fenced area
Area around the machine that unauthorized personnel cannot enter for
safety reasons.
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
The pallet stacker module is an accessory of the vertical conveyor Prmk10 and has to be
identified by the Prmk10 on which it is installed. The layout drawing and specification of the
pallet stacker are bundled in the documentation of the Prmk10.
Pallet stacker identification
The machine identification is given on the type plate of the Prmk10. The type plate is located
on the drive section of the Prmk10. Refer to the specification sheet of this serial number for
specifications of this machine
Machine layout drawing and specifications
After a machine order is placed, a machine drawing and specification sheet is sent for
approval. After approval the machine drawing and specification sheet are sent as a reference
for this manual. The machine drawing and specification sheet include:
•Machine serial number
•Product dimensions and mass
•Machine dimensions and mass
•Machine configuration
•Machine capacity
•Maximum load
The machine can only be used according to the specifications given in this manual, 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.

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Machine maximum load (WLL) is the maximum pallet weight the machine can handle. The
type plate and a warning sticker indicate WLL. The warning sticker must be easily visible. See
the picture below.
CE Installation instructions
The machine is intended to be integrated into a pallet transport 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 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.
Warranty
The scope and duration of the warranty is agreed upon 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.

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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
Qimarox has determined the design of the machine and therefore supplies the EC declaration
of conformity of the machine. The declaration is only valid after the CE Installation instructions
on the EC declaration of conformity have been met completely.
An example of the declaration is given in chapter 8.
For the specific declaration of the machine, refer either to the Specifications sheet or to the
separate document supplied with the documentation of the machine.
3 Safety
Intended use of the pallet stacker
The pallet stacker is exclusively intended to stack loaded pallets on top of each other. The
loaded pallets have to meet the following requirements:
Pallet load must be suitable for stacking,
Top of the bottom pallet load must be flat and level.
The bottom pallet must wide enough, so the top pallet is stable and fully supported
when placed on top.

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Note
Within limits, pallet load may exceed pallet dimensions. You must contact
Qimarox to check if this is possible.
Refer to chapter 4 for a detailed description of the specifications of use.
The machine and pallet stacker must always be set up within a larger transport system in
which products are automatically loaded on and off the pallet stacker.
WARNING
Any other use of the machine is strictly forbidden.
WARNING
It is strictly forbidden to load or unload the machine by hand. The
machine must be part of transport system and the use of an infeed and
outfeed conveyor is mandatory.
WARNING
It is strictly forbidden to lift persons with the machine or to stand on
the pallets or lifting frame.
WARNING
It is strictly forbidden to overload the machine with too much weight.
See specification sheet or type plate and sticker “Max load” on the
machine.
WARNING
It is strictly forbidden to use the machine with pallets out of spec or of
insufficient quality. See specification sheet.
WARNING
It is strictly forbidden to use the machine with pallets loads out of spec or of
insufficient quality. See the first part of this section and the specification sheet.
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

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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.

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Safety instructions
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 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.
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.
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.
Starting the machine
Do not switch the main power supply on when persons are in contact with the machine.
Do not switch the air service unit on when persons are in contact with the machine.
Do not start the machine when persons are in contact with the machine.
Do not start the machine when persons are present in the fenced area of the machine.
Before the machine is put into operation, all machine parts must comply with all relevant
health and safety directives and regulations.
During operation
Keep your hands and feet away from danger zones.
Make sure you do not wear loose clothing and secure long or loose hair.
Make sure that no persons or objects are within the range of any moving parts of the
machine.
Make sure that users know and observe all safety rules with regard to the machine and
the environment in which it operates.
Maintenance and repair
See also the specific safety regulations for maintenance and repair in section Fout!
Verwijzingsbron niet gevonden.
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.

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Switch off air service unit before starting any maintenance or repair tasks.
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.
Pallet quality
A good quality of pallet is essential for the efficiency and safety of the machine. Pallets should
be suitable for automated handling and stacking. No missing parts, no nails, screws or
splinters sticking out that might disrupt the handling or stacking of the pallet.
WARNING
Danger of products or pallet falling. Unsuitable pallets might cause the
loaded pallet to fall down or sideways or might cause products to fall
from the pallet.
WARNING
Danger of products or pallet falling. Because of their size, the forks may
apply big forces on relatively small parts of the pallet. One should
always check is the pallet type is strong enough for these forces.
Pallet load quality
A good and stable pallet load is essential for the efficiency and safety of the machine. The
products on the pallet should be suitable for automated handling and stacking. The load must
be able to carry the weight of a pallet stacked on top of it.
Also the top of the pallet load must be level and have enough carrying surface for the
underside of the pallet on top.
WARNING
Danger of products or pallet falling. Unsuitable products or pallet load
might cause the loaded pallet to fall down or sideways or might cause
products to fall from the pallet.
Pallet clamp position
To ensure that the pallets are stacked safely, the distance between the pallet clamps must be
inserted according to the size of the pallet. There must be approximately 10mm distance
between forks and the side of the pallet.

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For a correct insertion, it is necessary to position the pallet correctly on transportation surface
before inserting the clamps... Qimarox advises to use a mechanical pallet stopper and to
center the pallet.
WARNING
Danger of products or pallet falling. Incorrectly inserted pallet clamps
might cause the stack to fall forward or sideways or might cause
products to fall from the top of the stack.
Special attention to the insertion of the fork is need when the pallet load
is wider than the pallet.
WARNING
Danger of products or pallet falling. Always position the pallet on the
transportation surface.
Fork adjustment
To ensure that the pallets are stacked and de-stacked safely, the forks must be adjusted
according to the size of the pallet. See figure and table below for the right fork position.
Pallet width
Position lift fingers
800mm
1
1000mm
2

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1200mm
3
WARNING
Danger of products or pallet falling. Incorrectly adjusted forks might cause a
pallet to fall from the top of the stack.
Contact Qimarox with any deviation of pallet sizes for the required lift finger position to match
that specific pallet size!
Safety provisions
Safety equipment
Check the correct operation of the safety devices monthly.
You must not disassemble, bypass or disable any safety equipment on the machine.
The machine must not be started and must be immediately taken out of operation if even
a single item of machine safety equipment is defective.
After maintenance tasks are completed, always replace all safety equipment that has
been removed from the machine.
The following safety equipment is part of the machine:
Covers
Safety labels
Emergency stops
Area safety fencing
Safety circuits
Interlocking door switches (and possibly safety light screens)
Safety quick exhaust valve
Some part of the safety equipment may be supplied by the System integrator/OEM. See the
CE installation instructions in in chapter 8. Before the CE Installation instructions have been
met completely, the machine must not be used.
In case of non-compliance with the required safety measures, the EC Declaration of
Conformity will become null and void.
Safety labels
Note
See also the sections about safety labels in the user manuals of the separate
modules.
WARNING
Replace labels on the machine if they become unreadable or damaged.
The following safety labels are present near apertures in the area fencing:

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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.
Wear head protection
oat doors that can be opened during operation.
The following labels icons are present on the control cabinet:
Note
The labels on the control cabinet are supplied by System integrator/OEM.
Electrical hazard
oif hazardous electrical voltage is present.
Read the Manual before use
oat the main switch of the machine

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Safety fencing
Qimarox requires a protection fenced area around the machine. Any access doors must be
secured with (interlock) door switches. These switches must be included in the emergency
stop and safety circuit. The fenced area must comply with EN ISO 13857 and EN 619
standards.
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
light curtain.
Interlocking door switches and (if present) safety light curtains must be included in the safety
circuits. Unsafe access must stop the machine immediately.
The safety fencing must be strong enough against the force of a product falling down.
For specific requirements to the safety fencing, see the CE installation instructions in in
chapter 8.
Make sure that the fenced area complies with local law and rules for protection against
danger.
If Qimarox supplies the safety fencing, the specifications will be included in the machine layout
drawing.
Safety controls
Performance level
Emergency stops and safety circuits must be designed according to a so-called Performance
Level (PL) corresponding with the current standard for safety functions of a machine or a
machine. For required PL of this machine see the CE installation instructions in in chapter 8.
Emergency stops
The machine must have one or more emergency stops included in the safety circuits. When
one of the emergency stop buttons is pressed, the main power and air supply and the control
current of the machine are switched off immediately. For specific requirements, see the CE
installation instructions in in chapter 8.
Safety circuit
The machine must have safety circuits. Unsafe access must stop the machine immediately.
For specific requirements, see the CE installation instructions in in chapter 8.
Mechanical locking device
The pallet lift of the machine is equipped with a mechanical protection against the un-
controlled lowering of the carrier. The protection is a lock (4 safety pins) which is activated
automatically when entering the hazardous zone of the lift.
The safety pins are operated by a supplied safety start valve with safety category PL d. The
safety valve must be integrated into the safety circuit of the machine.
A description of the operation of the mechanical locking device can be found in the manual of
the main component Pallet elevator Prmk10 section 4 and in the Pneumatic diagram.
To protect the operator from the dangers of uncontrolled lowering of the lift.

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WARNING
Always switch off the machine when working under the carrier.
WARNING
When working in the hazardous area under the carrier, ALWAYS lower the lift to
its lowest position manually or let it rest on its fall protection.

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Electrical safety
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.
Sound level
The A-weighted emission sound pressure level LpA at workstations does not exceed 70dB(A).
Note
The sound pressure level applies to typical pallets made of wood or plastic.
Pallets made of other materials might increase the sound level.
Note
Factors like the state of the machine, filling degrees of products, 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.
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
Safety sign
Description
When required
Protective clothing. No
loose clothing or long
hair.
Maintenance
Cleaning
Foot protection
Production
Maintenance
Cleaning

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Residual risks
The machine is intended to be integrated into an automated pallet conveyor system.
Qimarox has attempted to protect against as many hazards as possible, either though inherent
safe design or by shielding off the dangers. Machine users should be aware of the following
residual risks before working with the machine:
Falling of pallet and products
Pallets or pallet loads/products can fall from the vertical conveyor's carrier. The risk of this
happening is determined by the combination of product, pallet load and pallet (nature and
quality) and the setup and settings of the machine.
In spite of the mandatory area fencing, products can fall outside the fences. The can also be
deflected and change direction by other product or machine parts during their fall. The danger
is also present during the correction of faults, when the area fencing is accessed by an
operator.
The system integrator and operator must determine, before putting the machine into operation,
whether the risk of falling products acceptable.
The following influences ensure that the risk of falling product remains small:
A good quality pallet of the correct dimensions. See section 3.3.6.
A stable, good quality product and pallet load of the good dimensions. See section 3.3.7.
A well set up machine (horizontal transportation surfaces, no height differences).
A machine properly set up for the product.
A correct load clamp insertion and position.
Low speeds and accelerations.
The following influences increase the risk of a falling pallet or pallet load:
Product outside the machine's specifications. See specification sheet.
Products or pallet load unstable or of poor quality.
Stacking different sizes of pallets at the same time.
High speeds and accelerations. An abrupt stop due to motor brake application.
One can reduce the risk of injury with the following measures:
Stacking one size of pallet at the same time.
Area fencing (mandatory) of sufficient height and strength.
Area fencing (mandatory) at a sufficient distance of the falling products. Entering the
fencing must block the machine.
Wearing a safety helmet when entering the fenced area at floor level, near the pallet
stacker (mandatory).
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