Qimarox PRORUNNER mk9 User Manual Download

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User Manual

PRORUNNER mk9

Version 2.0 / 03-02-2016

Summary of Contents for PRORUNNER mk9

Page 1: ...User Manual PRORUNNER mk9 Version 2 0 03 02 2016 ...

Page 2: ...ail info Qimarox com 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 ...

Page 3: ... 3 1 Intended use of the machine 11 3 2 User types and qualifications 11 3 3 Safety instructions 11 3 4 Safety equipment 12 3 5 Potential risks 14 3 6 Machine end of life and environment disposal 15 4 Description 4 1 Working principle 17 4 2 Sensors 19 4 3 Motor 20 4 4 Control 21 4 5 Machine in a system 21 4 6 Specifications 22 4 7 Application information 23 5 Installation 5 1 Location 24 5 2 Deli...

Page 4: ...hedule 35 6 3 Cleaning 37 7 Troubleshooting 7 1 Vertical conveyor 38 8 Exploded views 8 1 Frame parts 41 9 Electrical circuit diagrams 9 1 Drives 55 9 2 Installing 87Hz 55 10 Pneumatic circuit diagrams 10 1 Mechanical locking device 57 11 Appendix 11 1 Product registration form 58 ...

Page 5: ...stem integrators OEMs This manual explains machine configurations you can use to setup the machine It also provides instructions on how to add or change the machine technical components Users The machine may be supplied pre assembled if so some chapters in this manual will not be applicable To integrate the machine within a transport system Qimarox advises you to refer to documentation provided by...

Page 6: ...mage to the machine if the instructions are not accurately followed Note To provide additional information to the user about a task or issue Term Definition machine The PRORUNNER mk9 product Products transported by the machine carrier The component on which a conveyor can be mounted or which carries the product feeding conveyor The conveyor that delivers products to the machine The feeding conveyo...

Page 7: ... drive for product conveyor moveable E type of product conveyor fixed position F type of drive for product conveyor fixed position G type of E components Column type i Carrier type i Fixed position type i i KS Standard column DB Carrier with conveyor DZ Carrier without conveyor UV Fixed outfeed conveyor Made in Holland Designed by Manufacturing year T ype Serial number Mk9 Order number Power suppl...

Page 8: ...pe 000 None not supplied 000 F01 Fork M01 Roller conveyor M02 Roller chain conveyor 999 Special version D Conveyor in eleva tor drive 00 None not supplied 00 03 3 Phase 9 1 05 3 Phase TF 9 1 06 3 Phase BR 9 1 07 3 Phase BR TF 9 1 99 Special version E Fixed conveyor type 000 None not supplied 000 M01 Roller conveyor M02 Roller chain conveyor 999 Special version F Fixed conveyor drive 00 None not su...

Page 9: ...tructions 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 A A Surface roughness Ra Unless indicatedotherwise Roughness indications according to EN ISO 1302 NPR 3634 Weldsymbols according to NEN EN ISO...

Page 10: ...lting 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 acciden...

Page 11: ... operate install or maintain the machine A user is only qualified if the user has attended appropriate training and or attained appropriate industry standard recognized qualifications Qimarox can provide training if required Qimarox can also give advice about actions and tasks to be carried out on the machine 3 3 Safety instructions 3 3 1 General Comply with the safety regulations given in this ma...

Page 12: ...upply 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 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...

Page 13: ...3 4 2 If Qimarox supplies the safety fencing the specifications will be included in the machine layout drawing 3 4 2 Safety controls The provisions 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 control in compliance with EN ISO 13849 1 2008 To the machine a PL_d applies in which d indicates that...

Page 14: ... safety is at risk This device is installed for personnel safety and can not be used as fall protection during operation For detailed information about the safety valve that controls the release of the mechanical locking device refer to the manual of the supplier 3 5 Potential risks The machine is intended to be integrated into a transport system Qimarox has attempted to protect against as many ha...

Page 15: ...s 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 Observe all relevant legislation regulations instructions and precautions with regard to the disposal of products in the environment ...

Page 16: ...of a column a moveable carrier and a drive section The carrier is suspended by two flat belts which are wound up by a motor located in the drive section The carrier is guided by wheels running over guiding profiles in the column For safety reasons the machine is equipped with a mechanical lcoking device preventing any downward movement of the carrier when the safety circuit is triggered A C B ...

Page 17: ... carrier sideways adjust the position of the wheels D by adjusting the bolts E 4 1 2 Suspension of the carrier A Adjusting bolts B Detection block C Sensor belt on tension Both hoisting belts must be tensioned equally This can be achieved by loosening or tightening the adjustment bolts When one or both detection blocks are not detected by sensors an emergency stop must be triggered Possible causes...

Page 18: ...wer failure occurs the safety pressure valve allows the air to rapidly escape When one or both sensors do not detect the locking pin the pin is either extended or a malfunction had occured This must trigger an error Do not move the carrier downwards When the pin is extended the only movement that is allowed is a slow and manual operated upward movement of the carrier with a maximum lift of 125 mm ...

Page 19: ... two sensors M N per extra level are installed in the column i Sensor code Sensor name B1 Bottom level stop B2 Bottom level low speed B3 Top level stop B4 Top level low speed S10 Bottom limit switch S11 Top limit switch Sensor code Sensor name M Additional level upward stop downward low speed N Additional level downward stop upward low speed M N S10 B2 B1 S11 B3 B4 ...

Page 20: ...it B Additional connection unit The sensors in the column are wired through the cable tray in the column to the connection unit in the drive section When the machine is configured to stop at more than two levels an additional connection unit is installed B 4 3 Motor The motor drives the movement of the carrier It is necessary to control this motor with a frequency inverter for controlled start sto...

Page 21: ... from a feeding conveyor at the bottom level to a discharge conveyor to a single top level Infeed The product is fed into the machine and monitored by sensor P3 This sensor is located on the end of the feeding conveyor The product A will wait at sensor P3 until the carrier is in position The carrier can move after a product has been transported into the machine and both sensors P1 and P2 are not a...

Page 22: ...s for the surrounding area deviate from the table above the machine must be adjusted to this Such adjustments shall always be carried out by Qimarox or after permission from Qimarox 4 6 3 Electrical specifications See the type plate Refer to section 2 1 and the electrical circuit diagrams Motor The motor can be connected directly or through an operating switch in the main switch box The machine mu...

Page 23: ...t Connection type indicates how the drive needs to be connected Regenerative power gives the maximum power a braking resistor needs to dissipate when the machine lowers a full load at the speed stated in the specification sheet Minimal power frequency inverter indicates the maximum power that the drive uses 4 7 Application information The machine layout drawing and specification sheet give the spe...

Page 24: ...tion instructions Refer to chapter 8 for exploded views of the machine 5 1 Location Refer to the machine layout drawing for detailed information about the location of the machine The minimum distance between moving parts of the machine and other equipment or structures must be 100 mm X X ...

Page 25: ...ed pre assembled or in parts A pre assembled machine will be delivered in a horizontal position For a machine delivered in parts the column section is delivered in an upright position in a crate A Machine pre assembled B Machine in two parts C Machine in three or more parts B A C ...

Page 26: ...tification plates of the product conveyors 5 3 2 Vertical transport 1 Check the type plate for the exact weight of the machine 2 Use a suitable hoisting system that complies with local regulations 3 Attach a suitable hoisting belt or hoisting chain A to the hoisting eyes of the machine 4 If necessary put the machine in the vertical position Make sure that the machine does not tip over after it has...

Page 27: ...ferably a bridge crane minimum carrying capacity 1 5 x the weight of the machine or a fork lift truck combined with a hoist with a minimum capacity of 2 x the weight of the machine at a lifting height with a minimum height of the machine plus 2 meters 5 Provide electric power 230 V AC at a maximum of 5 metres from the place of assembly of the machine 6 Provide the correct safety provisions Moveabl...

Page 28: ...etracted from the locking Refer to section 4 1 3 5 Make sure that the cable carrier B is not damaged 6 Make sure that the flat belts C run correctly over the pulleys 7 Check if the carrier D can run freely 5 6 3 Installing a machine delivered in parts 1 Put the bottom section A with drive system and carrier on the correct location Note Use Fischer FBN II 12 100 bolts or equival These bolts are not...

Page 29: ... the previous section 4 Connect both sections with bolts and tighten the bolts correctly 5 Connect the strips C for the mechanical locking device and tighten the bolts correctly 6 Repeat steps 5 to 8 for all mid sections 7 Put the top section D on top of the previous section 8 Connect both sections with bolts and tighten the bolts correctly B C D ...

Page 30: ...9 2 0 EN 9 Connect the strips E for the mechanical locking device and tighten the bolts correctly 10 Install the running surfaces F and G in the bottom section 11 Install the running surfaces H and I in the mid sections E F F G H H I ...

Page 31: ...UM PRORUNNER_mk9 2 0 EN 31 Installation 12 Install the running surfaces J and K in the top section 13 Unwind the flat belts L 14 Guide the flat belts over the idler pulleys M J J K L M ...

Page 32: ...sition 17 Connect the cable carrier to end piece Q 18 Connect the electrical parts in accordance with the electrical diagrams Use the cable tray in the column to guide the cables to the drive section Refer to chapter 9 for more information about the electrical set up 5 7 Installing the moveable conveyor N O P Q Note If a moveable conveyor is included in the delivery it is pre installed on the carr...

Page 33: ...UM PRORUNNER_mk9 2 0 EN 33 Installation If a moveable conveyor is not included you can install another conveyor Only drill holes in parts A of the carrier for installation of the conveyor A A ...

Page 34: ... 2 Turn off the power supply to the machine with the main switch before starting any maintenance or repair activities Secure the main switch with a padlock Make sure that the locking pins of the mechanical locking device are extended Do not use any corrosive and inflammable solvents or cleaning agents on the machine that contain TRI PER TETRA or FCHC When you use chemical substances cleaning agent...

Page 35: ... to section 6 3 Check for running sounds Replace the wheels Flat belt Check for wear and tear Replace the flat belt Check for running sounds Lubricate the flange of the pul leys with silicone spray or teflon spray Check the connection to the carrier Tighten the bolts and locking screw Cable carrier Check for damaged links Replace the damaged links Cabling Check the cables for visible damage Replac...

Page 36: ...Replace the bearings Check for visible damaged parts Replace the parts Idlers Check the bearings for play and running sounds Replace the bearings Check the fasteners Tighten the fasteners Item Task Action when required by the check Item Task Action when required by the check Motor reductor Follow the instructions in the manual of the manufacturer of the motor reductor Follow the instructions in th...

Page 37: ...ox and make sure that any damage is remedied before restarting the machine WARNING Do not use any corrosive and inflammable solvents or cleaning agents on the machine that contain TRI PER TETRA or FCHC Read the instructions on the packaging when use is made of chemical sub stances cleaning agents Electrical components should not make contact with water or other liquids Do not clean the machine wit...

Page 38: ...se Replace the fuse Thermal safeguard triggered Investigate and remedy the cause of the heating Motor protection triggered by short circuit or overload Investigate and remedy the cause Then reset the motor protection Defective power controller Investigate and remedy the cause Replace the power con troller The motor starts with difficulty Electrical faults such as The motor does not run and makes a...

Page 39: ... motor protection to the nominal motor current Short circuit in the winding or with respect to the earth Dismount the motor for repair The motor does not run The motor protection is triggered immediately Incorrect setting of the motor protection Check and or adjust the motor protection to the correct value The mechanical drive chains belts rollers or guides are blocked Remove the blockage Clean th...

Page 40: ...k guides chains and return wheels for damage or dirt Replace or clean them as necessary Increased temperature of the bearings or bearing blocks The idlers turn with difficulty Damaged bearings bearing blocks or idlers Investigate and remedy the cause Reset the motor protec tion Loose bolt connections Investigate and remedy the cause Reset the motor protec tion Other machine parts run loose Investi...

Page 41: ...UM PRORUNNER_mk9 2 0 EN 41 Exploded views 8 Exploded views 8 1 Frame parts The following pages show exploded views of the frame parts and include part list and attachment materials information ...

Page 42: ... M10 8x M10x20 8x M10 8x M8 8x M8x16 8x M8 8x M10 4x M10x30 4x M10 4x M10 8x M10 8x M10x30 8x M10 8x M10 10x M10 10x M10x30 10x M10 10x M12 4x M12 4x M12x90 4x M12 4x M10 4x M10x20 4x M10 4x M8 4x M8x16 4x M8 4x M12x60 4x M12 4x M10x20 4x M10 4x M6x16 4x M6 4x M16x35 8x M16 8x M5x45 2x M5 2x A O D B C E L G H I N M K P O Q R F J ...

Page 43: ... Circlip ring A40 1 75 I 2 1000932 Sensor IME 18 08BPSZC0K J 1 AE0008223 Top section H 1475 1 AE0008226 Top section H 1725 1 AE0008220 Top section H 1975 K 1 AE0007201 Threaded plate 2 x M4 L 1 AE0005534 Limit switch head M 1 AE0005524 Limit switch body N 1 AE0005537 Limit switch lever O 2 AE000067901 Running surface top H 1475 2 AE000067902 Running surface top H 1725 2 AE000067903 Running surface...

Page 44: ...view M10 4x M10 4x M10x20 4x M10 4x M10 7x M10x20 7x M10 7x M10 7x M10x20 7x M10 7x M8 7x M8x16 7x M8 7x M10 4x M10x30 4x M10 4x M10 8x M10 8x M10x30 8x M10 8x M12 4x M12 4x M12x90 4x M12 4x M10 4x M10x20 4x M10 4x M8 4x M8x16 4x M8 4x O P O Q R M6x16 4x M6 4x A B C J I ...

Page 45: ...00069303 Back shielding H 698 I 2 1000932 Sensor IME 18 08BPSZC0K J 1 AE0000520 Mid section H 1250 1 AE0000529 Mid section H 1750 O 2 AE000068201 Running surface mid H 1250 2 AE000068202 Running surface mid H 1750 P 2 AE000067001 Strip fall protection H 1250 2 AE000067002 Strip fall protection H 1750 Q 2 AE0000690 Plate fall protection R 2 AE000067701 Running surface mid H 1250 2 AE000067702 Runni...

Page 46: ...4x M10 4x M8 4x M8x16 4x M8 4x M10 4x M10x20 4x M10 4x M10x20 6x M10 6x M6x16 3x M6 3x M10 5x M10x20 5x M10 5x M8 5x M8x16 5x M8 5x M10 4x M10 4x M10x30 4x M10 4x M12 4x M12x100 4x M12 4x M10 5x M10x20 5x M10 5x M10 4x M10x30 4x M10 4x A O B C I P O Q R J M5x45 2x M5 2x L N M K S B1 4x10 4x T ...

Page 47: ...n H 1475 1 AE0000541 Bottom section H 1725 1 AE0000542 Bottom section H 1975 K 1 AE0000713 Threaded plate 2 x M5 L 1 1001532 Limit switch head M 1 1001531 Limit switch body N 1 1001533 Limit switch lever O 2 AE000068301 Running surface bottom H 1475 2 AE000068302 Running surface bottom H 1725 2 AE000068303 Running surface bottom H 1975 P 2 AE000067101 Strip fall protection H 1475 2 AE000067102 Str...

Page 48: ... 2x M12x3D 2x M12x20 2x M12 2x M12x35 4x M12 4x M12x35 4x M12 4x M16x100 4x M16 4x M10x12 4x M6x20 16x M6 16x M4 3x M4x16 3x M4 3x M12x3D 2x M12x20 2x M12 2x M10 16 M10x20 16 M10 16 M5x12 8x M5 8x M12x45 4x M12 4x M12x45 4x M12 4x M12x35 4x M12 4x M8x30 4x M8 4x A O K W K X D N G V F E I B M C B M Y H R S U T P L J M6 2x M6x12 8x M6 8x Z A H ...

Page 49: ...03981 Push in fitting QS 1 8 10 J 4 1005551 Wheel 80 x 40 bearing 20 x 45 K 4 1005552 Bearing Iglidur G 30 34 x 9 L 4 AE0000548 Mounting bracket wheel M 4 AE0000549 Mounting bracket wheel N 2 AE0000552 Hinge fall protection O 2 AE0000722 Bracket detection P 2 AE0000736 Detection bar R 2 AE0000737 Linking shaft S 2 AE0000738 Clampingplate belt front T 2 AE0000739 Clampingplate belt back U 2 AE00007...

Page 50: ...Exploded views 50 UM PRORUNNER_mk9 2 0 EN 8 1 5 Support exploded view M20 8x M10x20 8x M20 8x M20 8x M10x20 8x M20 8x M10x20 12x M20 12x M10x20 12x M20 12x M16x40 4x M16 4x M16x40 4x M16 4x B C A A ...

Page 51: ...9 2 0 EN 51 Exploded views Support parts list i Support parts list Pos Quantity Item number Description parts Notes A 8 1000164 Adjustment foot H 156 B 1 AE0002182 Support right PRmk9 C 1 AE0002178 Support left PRmk9 ...

Page 52: ...16 3 M4 3x M6x16 9x N M20 2x M20 2x M20x65 2x M20 2x M16x35 4x M16 4x M6 4x M6x16 4x M6 4x M6x16 3x M12x25 4x M12 4x M8x16 4x M8 4x M20 2x M20 2x M20x65 2x M20 2x G F J K M J A O 16x10x160 D H C C I L B E M12x25 4x M12 4x M8x16 4x M8 4x M6x16 3x M8x12 2x M8x12 2x 16x10x160 18x11x200 A55 A55 A40 A40 K J M J A L ...

Page 53: ...Ball bearing 6008 2RS D 2 1003982 Push in fitting QSL 1 2 10 E 1 1003983 Soft start quick exhaust valve F 1 1004038 Multi pin plug socket G 1 AE0000558 Drive frame H 2 AE0000582 Idler belt I 2 AE0000583 Shaft idler belt J 4 AE0008161 Flange winding pulley K 2 AE0008146 Winding pulley large L 4 AE0000590 Threaded plate 2 x M10 M 2 AE0008159 Plate winding pulley N 1 AE0000612 Shield plate drive O 1 ...

Page 54: ... 1 7 Belts exploded view Belts parts list i A B B C C D Belts parts list Pos Quantity Item number Description parts Notes A 1 AE0001390 Cable crossing strip B 2 1004947 Belt C 1 1003532 Cable carrier connection set D 1 1003531 Cable carrier link ...

Page 55: ...ction diagrams DR http www productliften nl media text 240 247 9pd0058us pdf 9 2 Installing 87Hz 9 2 1 Wiring the drive In a traditional wiring diagram the drive is connected in a so called star connection To make sure that the drive does not lose any torque above 60Hz it needs to be connected in a delta configuration The next figure shows how this can be done To reverse the configuration intercha...

Page 56: ...leads given that the torque remains the same to increased power The minimal power for the frequency inverter can be found in the Qimarox specification sheet at the technical data tab The frequency at which the drive needs to run to reach the specified capacity is also indicated on the sheet WARNING A braking resistor is necessary to make sure that the drive can dissipate any power when the load is...

Page 57: ...ng device compressed air goes to the cylinders and the locking pin retracts This will be applied until the emergency stop circuit is triggered or a power failure occurs When this happens air will rapidly flow out of the cylinders and the locking pin will hook into the column hence holding the carrier into its position 2 12 MS6 SV 1 2 E 10v24 SO AG ESNU 25 25 PA ESNU 25 25 PA 1 3 ...

Page 58: ...E ON THE EQUIPMENT THE CONTACT BETWEEN USER AND QIMAROX WILL BE THROUGH THE SUPPLIER INTEGRATOR Machine type mk 1 mk 5 mk 9 mk 10 Order number Qimarox Serial number Integrated by Order number integrator Installation date Start production date Your reference line machine number Contact details user Company name Address Zip code Town city Country Phone number Fax number e mail Website Technical cont...

Page 59: ...Nobelstraat 43 3846 CE Harderwijk Tel 31 341 436 700 Fax 31 341 436 701 E mail info qimarox com Internet www qimarox com ...

Page 60: ...ng range of the sensor If the carrier is obstructed while moving down both belts loose tension The extension spring pulls the seesaw out of balance which removes the seesaw out of the sensing range of the sensor Both events must trigger an emergency stop If the seesaw is not horizontal during normal use it is out of the sensing range of the sensor Use the adjustment bolts to level the seesaw Adjus...

Page 61: ...ge to the machine and surroundings the machine is equipped with a sensor to detect this tilting The distance between the sensor and the centre guide must be 4 mm When the centre guide is out of sensing range the carrier is tilting and an emergency stop must be triggered Tilting sensor D D B2 Centre guide Seesaw sensor D D B1 Seesaw ...

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