Page 1 Operating manual HR9 QS21XXXX Version 1.0 - 13/07/2021...
Page 2 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. Operating manual HR9 – QS21XXXX...
Page 3: Table Of Contents
ONTROL PANEL LIGHT GRID PACKML ..............................24 .......................... 24 MODE OVERVIEW ......................... 25 STATUS OVERVIEW ..........................29 ALARM SYSTEM OPERATING SCREENS ..........................31 ..........................31 EMPLATE STATUS BAR ......................... 31 EMPLATE NAVIGATION BAR ............................... 32 ABS MENU Operating manual HR9 – QS203263...
Page 4 Manual mode pallet lift ......................... 79 Manual pallet handling ......................... 80 ..............................81 ETTINGS General settings ..........................81 Palletiser settings .......................... 82 Belt conveyor settings ........................83 Turn conveyor settings ........................84 Forming table settings ........................86 Operating manual HR9 – QS21XXXX...
Page 5 ATCH PROCESSING Manual batch loading ......................... 124 Manual batch removal ........................ 125 Manual refreshing ........................126 NOTIFICATIONS ............................ 127 ..........................127 LARM INFORMATION ............................. 128 LARM LIST ......................... 143 ARNINGS INFORMATION ........................... 144 IST OF WARNINGS Operating manual HR9 – QS203263...
Page 6: About This Manual
About this manual Introduction This manual provides information about the palletiser type HR9. This type of machine is used to automatically palletise products on a pallet. Henceforth the palletiser machine type HR9 will be referred to as the ‘machine’, ‘unit’ or ‘palletiser’.
Page 7: Symbols Used In The Manual
Downstream Previous module in line / network Upstream Next module in line / network Further support and information Qimarox can supply additional expertise and support services, for:  Training  Global support ...
Page 8: General
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.
Page 9: Machine Parts
The machine is divided into different modules; each module has its own function and operation. Overall view Palletlift Side restraints Rear restraint Stackingplates Palletconveyor loading position Layerpusher layerhandling Layerbuffer Layer restaints Product formation single infeed Layer pusher formation Turning converyor Indexing belt conveyor Operating manual HR9 – QS203263...
Page 10: Belt Conveyor
Valid target orientation are 90, 180 or 270 (-90) degrees Conveyor also checks the length when product enters the light grid. Operating manual HR9 – QS21XXXX...
Page 11: Product Formation
The product pusher ensures that columns (rows of products), which are finished with their operations on the product formation, are moved to the correct position. The position is determined from the set pattern. Products are also reversed by means of a reversing cam mounted on the pattern-formation pusher. Operating manual HR9 – QS203263...
Page 12: Layer Pusher Formation
Row/Layer is fed in via the roller conveyor and the row/layer is positioned on the roller conveyor by means of an encoder. When the (complete) layer is closed up, the layer can be transported to stacking plates by means of the layer pusher of the layer processing. Operating manual HR9 – QS21XXXX...
Page 13: Layer Pusher Layer Processing
During opening, the layer restraints can be sent to the second position to determine the final size/dimensions on the pallet load. Once the pallet lift is under the stacking plates again, they are closed again. Operating manual HR9 – QS203263...
Page 14: Rear Restraint
Side restraints The side restraints are used to square the left and right-hand side of the layer during the deposition cycle. The restraints work centrically so the layers are always in the middle of the pallet. Operating manual HR9 – QS21XXXX...
Page 15: Pallet Lift
As soon as a pallet is ready on the pallet conveyor of the loading position, it is loaded with layers. When the pallet is full, i.e. the desired number of layers has been reached, and the pallet lift is at outfeed height, the full pallet is transported to the next pallet conveyor position. Operating manual HR9 – QS203263...
Page 16: Operating Controls
At full pallet outfeed On the fencing at supply conveyors  Palletiser control buttons  Stack light palletiser  Control panel palletiser  Control panel ground floor  Control panel access safety doors  Control panel light grids Operating manual HR9 – QS21XXXX...
Page 17: Main Switch
The emergency stop circuit is reset using the RESET button of third-party control WARNING The emergency stop button should NEVER be used to stop a normal production process. INFO The emergency stop can be recognized by its red colour Operating manual HR9 – QS203263...
Page 18: Palletiser Control Buttons
‘EXECUTE’ state. Emptying button With this button it is possible to empty the machine. This is only possible if the machine is in ‘EXECUTE’ state. Control of signalling in the buttons Blinking Steady Operating manual HR9 – QS21XXXX...
Page 19: Stack Light Palletiser
Only one lamp can be active with the exception of the blue flashing light. This allows the machine to ask the operator to come to the machine to take preventive actions. B = Blinking S = Steady YELLOW Outfeed blocked YELLOW No supply BLUE Operator action BLUE Internal error GREEN Operating manual HR9 – QS203263...
Page 20: Touch Panel Palletiser
Chapter 6 provides a detailed description of the screens. Starting and stopping is done by means of the control push buttons. The touch panel is used to provide the operator with additional information. Operating manual HR9 – QS21XXXX...
Page 21: Control Panel Ground Floor
Description Start button Issuing (re)start command at status: IDLE HELD SUSPENDED Stop button Stop command can always be given to stop the machine as soon as possible Control of signalling in the buttons Blinking Steady Operating manual HR9 – QS203263...
Page 22: Control Panel Access Safety Door
WARNING Resetting an access door may never be carried out if someone is still around or inside the machine. INFO The door is automatically locked again when the machine is restarted. Operating manual HR9 – QS21XXXX...
Page 23: Control Panel Light Grid
You can recognise the bridging because the muting lamp at the light grid will start to flash quickly WARNING Resetting or bridging a light grid may never be carried out if there is still someone around or inside the machine. Operating manual HR9 – QS203263...
Page 24: Packml
In this mode the unit runs production and works automatically depending on the Automatic settings / program choice INFO When switching mode, the machine is always stopped first. This is necessary because not every mode has the same states. Operating manual HR9 – QS21XXXX...
Page 25: Packml Status Overview
Machine can no longer or in production produce. (Green lamp) End of Production , machine stopped External problem, machine can no longer produce due to external influence Machine has stopped Serious (Red lamp) problem, machine is switched off Operating manual HR9 – QS203263...
Page 26 This takes approx. 3 sec. In this state it is checked whether the production settings are correct. If not, the machine will be stopped to give the operator a chance to correct this. Operating manual HR9 – QS21XXXX...
Page 27 Then the machine will restart automatically. The operator can also restart the machine by pressing start. External machine parts are ready for operation. SUSPENDING Machine will start up machine parts and go back to EXECUTE Operating manual HR9 – QS203263...
Page 28 ‘Produce layers’ is selected COMPLETE Machine is completely empty, operator must accept the complete via the reset button, then the machine will jump back to ‘IDLE’. After this, new production can be started via the production settings screen. Operating manual HR9 – QS21XXXX...
Page 29: Packml Alarm System
Machine will be stopped as soon as possible. Referencing (homing) the machine is now only possible in manual mode ALERT The blue light will blink to warn the operator. SHOW ONLY Alarm is only displayed in alarm overview Operating manual HR9 – QS203263...
Page 30 Modules Lowrunner 1 (Row processing) Layer processing Modules Lowrunner 3 (Layer processing) Layer processing Modules Highrunner 7 (Layer processing) Pallet lift Pallet lift modules Pallet handling Pallet handling modules Pallet dispenser Pallet dispenser modules Supply conveyor Supply conveyor modules Operating manual HR9 – QS21XXXX...
Page 31: Operating Screens
Go back to previous screen, this can be done until you get to the first screen. The alarm overview shows how many faults the unit has active. If a machine part is malfunctioning, this is indicated with the icon. Operating manual HR9 – QS203263...
Page 32: Tabs Menu
If more than 5 tabs are needed in the menu structure, a left and right button will be used to switch between the series of tabs using symbols < and >. INFO Up to 25 tabs can be present Operating manual HR9 – QS21XXXX...
Page 33: Keyboards
A full keyboard will appear for entering names. Full keyboard Numeric keypad After entering a number or character, the completed field can be accepted by pressing ‘ENTER’. Operating manual HR9 – QS203263...
Page 34: Main Menu
The status of all safety guides such as doors/emergency stops/light grids are also shown here. Press the module to get an extensive module overview. It shows which signals are active, which step is active and an overview of alarms and warnings. Operating manual HR9 – QS21XXXX...
Page 35: Recovering The Palletiser
Collecting layers on pallet to desired height Loading position INFO You cannot change anything in this step; step 1 provides information about the current situation. INFO The machine cannot be started as long as recover procedure is active Operating manual HR9 – QS203263...
Page 36 Send everything to starting position (no more layer may be present) Unload the layer; this allows all restraints (stacking plates do not move!) to a position to distance themselves from the layer on stacking plates Operating manual HR9 – QS21XXXX...
Page 37 When you press this button a check will be performed on the entered changes; if problems arise you will see a pop-up. You need to resolve these problems before you can complete the restoration procedure. Operating manual HR9 – QS203263...
Page 38 You will be taken to the initial step and screen (Step 1). As you can see, the new information has been loaded. Check this again before restarting the machine. The machine can now be restarted. Operating manual HR9 – QS21XXXX...
Page 39: Production Selection
Infinite: The machine produces pallets until the operator empties the machine by a manual action. Generator: The machine produces pallets using the help of the Qimarox Pattern Generator. This is a partly automated process, if a product is introduced with attributes matching in the database it automatically starts production.
Page 40 Top sheet, intermediate sheet and/or bottom sheet (if sheet-laying unit is present) Production counters At the production counters you can see how much has been produced during this production run. These are set to ‘0’ when the machine is run empty. Operating manual HR9 – QS21XXXX...
Page 41: Database
As soon as a match is found you can activate this program and it is then loaded and actively placed on the palletizer. You can also see on this screen the result of the program number in which database number. The description of the program is also shown. Operating manual HR9 – QS203263...
Page 42 Generate program Generating patterns starts. After confirming the product properties, the Qimarox Pattern Generator will generate different patterns. NOTE Generating programs is only possible when the machine is not in production. It has to be stopped first;...
Page 43: Generate
1. After pressing the "Generate program" button, a pop-up emerges 2. By pressing Start, the Qimarox Pattern Generator starts up, you can read back the status in the pop-up. The status now stands on "Waiting." If the notification turns red, something went wrong.
Page 44 Operating screens Once the Qimarox Pattern Generator has collected its data, this can take 2-30 seconds, the screen with the suggested patterns becomes active! 4. Select 1 of the patterns you see above. Top left is the most stable pattern and has the best filling rate on the pallet.
Page 45 7. When you press “FINISH” you will see the machine has loaded the generated program NOTE You can recognize a generated pattern by the -1 decimal number that is in front of the program description. Operating manual HR9 – QS203263...
Page 46: Packml Model
The control buttons are always visible, so that the machine can also be operated from this menu. In this menu the supply conveyor can also be started & reset. INFO For the OEM it is possible to enable the software buttons, which overrides the selection switch. Operating manual HR9 – QS21XXXX...
Page 47: Program Settings
On the next page, this will be discussed in detail. Modify the program to be changed. When pressed, a pop-up with a drop down list will appear in which you can choose a program Save program. Go to next screen of Program settings Operating manual HR9 – QS203263...
Page 48: Program Database
Also all result are shown, like program description If no match is found, you’ll be able to start with a default program. This program uses the same default speed as the generated programs, but no patterns are available. Operating manual HR9 – QS21XXXX...
Page 49: Program Settings - General
Pallet type  Standard: Euro, Chep, DDP. The number of types varies per end user. Length  Between 700 and 1300mm Width  Between 700 and 1300mm Height  Between 100 and 350mm Product data: Length100Between 600 and 100mm Width100Between 600 and 100mm Height  Between 50 and 600mm Operating manual HR9 – QS203263...
Page 50: Program Settings Infeed
Outfeed belt Speed while feeding product out to next module speed This consists of a high and a low speed. The low speed is used for the last bit of positioning, the length is set below Operating manual HR9 – QS21XXXX...
Page 51: Program Settings Turning
Finish speed Finishing speed when product approaches its end state. Window product Extra marge to register when rotation is ready. rotation ready Time limit Time limit on how long the process takes to turn the product. Operating manual HR9 – QS203263...
Page 52: Program Settings Formation
This makes it possible to reduce the impact of the moving pusher on the stationary product/column. Enter the starting position and the length of the area to which a different speed profile applies. 0=not active Operating manual HR9 – QS21XXXX...
Page 53: Program Settings Layer Pusher
This makes it possible to reduce the impact of the moving pusher on the stationary layer. Enter the starting position and the length of the area to which a different speed profile applies. 0=not active Operating manual HR9 – QS203263...
Page 54: Program Settings Layer Buffer
Percentage of Nominal speed. 100% = Nominal speed Acceleration is in seconds, from standstill to desired speed. Deceleration is in seconds, from actual speed to standstill. Operating manual HR9 – QS21XXXX...
Page 55: Program Settings Layer Processing
Enter the starting position and the length of the area to which a different speed profile applies. 0=not active Layer receiving Here you can set per movement at which position it waits until a layer is present position on the stacking plates. Operating manual HR9 – QS203263...
Page 56: Program Settings Pallet Lift
With this value the distance between stacking plate and pallet load can be corrected if necessary. WARNING At a high value, the pallet load can lift the stacking plates. If smaller drop height is desired, increase the value by small steps. Operating manual HR9 – QS21XXXX...
Page 57: Program Settings Patterns / Sheets
You can choose from the pattern number tabs you see at the top. Choose from A, B, C or D. It is also possible to set, per layer, whether a sheet should be placed on it. This only applies if the intermediate sheets option is enabled. Operating manual HR9 – QS203263...
Page 58: Pattern Settings
If not, all changes will be reset. Save program & pattern settings Go to next screen of pattern settings Operating manual HR9 – QS21XXXX...
Page 59: Pattern Settings, Explanation Of Pattern Structure
Rule 3: The last product in the column must be set to be the last of the column When numbering, the number of products per column must be taken into account. See the example below. Operating manual HR9 – QS203263...
Page 60 Product 2 Product 2 Product 2 From column 4 From column 3 From column 2 From column 1 Rule 4: The last column in the row must be set to be the last of the row. Operating manual HR9 – QS21XXXX...
Page 61: Pattern Settings General
Operating screens Pattern settings General Setting Description Total products Number of products in pattern (total) in pattern Number of rows Number of rows in pattern in pattern Operating manual HR9 – QS203263...
Page 62: Pattern Settings Formation
Position of column on pallet, Note the orange frame, this is the pallet 1200 width. position on pallet Here you can set the position of the column on the pallet. Last of row Yes = Last column of row Operating manual HR9 – QS21XXXX...
Page 63: Pattern Settings Layer Buffer
If the width is not accurate, the row/layer will not run in far enough onto the layer buffer and a malfunction will occur. This is checked with a sensor Extra infeed This makes it possible to feed the row/layer into the layer buffer an extra distance distance Operating manual HR9 – QS203263...
Page 64: Pattern Settings Layer Slide
It is possible to shift a layer on the shuttle plates before the layer is squared. With patterns with special spaces, this allows you to ensure that the product is in the correct position on the shuttle plates so that the spaces are guaranteed. Operating manual HR9 – QS21XXXX...
Page 65: Pattern Settings Layer Processing
With the shift you can set whether the layer should be squared from the centre. When switching dimensions you set at which position (when stacking plates open) the dimensions are changed (From situation 1 to 2). Operating manual HR9 – QS203263...
Page 66: Statistics
Overview of machine statistics You see here: Production history, with program, production data and with timestamps Production statistics (Quality) Palletiser availability Machine speed (past 5 minutes) More detailed information can be found in the other tabs. Operating manual HR9 – QS21XXXX...
Page 67: Machine Effectiveness
100% is considered unfeasible. INFO Machine effectiveness is a derivative of Overall Equipment Effectiveness (OEE). More information can be found at: https://en.wikipedia.org/wiki/Overall_equipment_effectiveness. INFO The machine can best be judged on its availability. Operating manual HR9 – QS203263...
Page 68: Machine Speed
The exact number can be found with the ruler buttons on the right side. You can switch between ‘CURRENT’  The last 15 minutes; this will be updated. By selecting ‘LOG’ you can see the speed of the past 24 hours. Operating manual HR9 – QS21XXXX...
Page 69: Mode / Status Times
The times of the last mode and state switch is tracked. Time since reset represents the time the machine has been in production. It is reset when another program is selected or when the machine is run empty. Operating manual HR9 – QS203263...
Page 70: Machine Counters
Operating screens Machine counters Total counters are: Processed products Working hours (machine in effective production) Switched on hours (Voltage on installation) Operating manual HR9 – QS21XXXX...
Page 71: Machine Notifications
A total of 48 alarms can be active at the same time; you can switch between the different pages By pressing the button you will see a pop-up window with a cause and solution for this fault: Operating manual HR9 – QS203263...
Page 72: Warning List
 Description of warning  Start time warning  Category  PackML action on warning By pressing the button you will see a pop-up window with a cause and solution for this warning: Operating manual HR9 – QS21XXXX...
Page 73: History
Type: Alarm or warning  Notification number / ID  Description of notification  Notification start time  Confirmed notification time A total of 240 events can be buffered; you can switch between the different pages. Operating manual HR9 – QS203263...
Page 74: Manual Mode
If you are in one of the manual control screens, you can always return to the overview above by pressing the button. Press the part of the installation where you want to perform the manual operation. Or use the tabs to go to the correct machine part!! Operating manual HR9 – QS21XXXX...
Page 75: Manual Control Supply Conveyor
Align the lightgrids until the first, last and weakest beam are 100% Press enable again.(Disable beam alignment) The button start will appear in the lightgrid teach-in windows. Press start to perform the teach-in. Operating manual HR9 – QS203263...
Page 76: Manual Mode Pattern-Formation Conveyor
Roller conveyors product formation  Product pusher  Layer pusher formation All relevant sensors are shown with a picture of the relevant sensor and a short description. When it turns green, the sensor enters the PLC Operating manual HR9 – QS21XXXX...
Page 77: Manual Mode Layer Buffer
The following can be operated in this screen:  Roller conveyor layer buffer  Layer restraints All relevant sensors are shown with a picture of the relevant sensor and a short description. When it turns green, the sensor enters the PLC Operating manual HR9 – QS203263...
Page 78: Manual Mode Layer Processing
Layer pusher layer processing (Front restraint)  Side restraints  Rear restraint  Stacking plates All relevant sensors are shown with a picture of the relevant sensor and a short description. When it turns green, the sensor enters the PLC Operating manual HR9 – QS21XXXX...
Page 79: Manual Mode Pallet Lift
All relevant sensors are shown with a picture of the relevant sensor and a short description. When it turns green, the sensor enters the PLC INFO Before the lift can move, the stacking restraints must be in the safe (base) position. Operating manual HR9 – QS203263...
Page 80: Manual Pallet Handling
If the pallet lift is not in the lowest position, not all manual operations can be performed. INFO When a transport from section A to section B is carried out, the pallet automatically stops in the photocell of section B. Operating manual HR9 – QS21XXXX...
Page 81: Settings
The rest of the buttons are for technical purposes. Under user management it is possible to change your own password and create new users. You can also choose to enable another language here. Standard = NL-NL or EN-US. Operating manual HR9 – QS203263...
Page 82: Palletiser Settings
In the case of upstream, the settings are communication signal release for product supply. In the case of downstream, it is time monitoring that gives an indication that communication signals are not coming in as expected. Operating manual HR9 – QS21XXXX...
Page 83: Belt Conveyor Settings
In that case, the sensor must be covered longer before the machine actually receives the signal (ON delay); it is also possible to keep the signal high while the sensor is already uncovered (OFF delay). Operating manual HR9 – QS203263...
Page 84: Turn Conveyor Settings
Minimum process quality Minimum process quality before alarm & teach required Minimum alignment Minimum alignment quality during the teach in process. quality Operating manual HR9 – QS21XXXX...
Page 85 Operating screens Timer Setting Description Stabilize Time the twistrunner has to stabilize after rotation Operating manual HR9 – QS203263...
Page 86: Forming Table Settings
This is the minimum passage distance, even if nothing is set in the pattern settings Motion configuration for product pusher Setting Description Nominal speed Speed in meters per second at 50Hz Operating manual HR9 – QS21XXXX...
Page 87 Used to create an offset on program settings. Position that the drive can reach without encountering mechanical Maximum obstacles. Options product pusher Setting Description Yes = Present, use stopper to keep product on pattern-formation Turn ridge conveyor. Operating manual HR9 – QS203263...
Page 88: Layer Pusher Settings
In that case, the sensor must be covered longer before the machine actually receives the signal (ON delay); it is also possible to keep the signal high while the sensor is already uncovered (OFF delay). Operating manual HR9 – QS21XXXX...
Page 89: Layer Buffer Settings
This value is determined by the smallest row that the machine processes. After completion of infeed additional positioning is started, this is the Minimum row Y offset minimum offset, even when ‘0’ is entered in pattern settings. Operating manual HR9 – QS203263...
Page 90 Speed of movements of restraints with no layer processing Percentage of Nominal speed. 100% = Nominal speed Acceleration is in seconds, from standstill to desired speed. Deceleration is in seconds, from actual speed to standstill. Operating manual HR9 – QS21XXXX...
Page 91: Layer Processing Settings
Within reach of side Position where the layer pusher is within reach of arms of side restraints restraints Position with respect to positioning where the outside of the pallet starts Offset outside pallet at the loading position. Operating manual HR9 – QS203263...
Page 92 In that case, the sensor must be covered longer before the machine actually receives the signal (ON delay); it is also possible to keep the signal high while the sensor is already uncovered (OFF delay). Operating manual HR9 – QS21XXXX...
Page 93: Side And Rear Restraint Settings
Position of pusher on starting point of the pallet at the loading position. Offset pallet format Used to create an offset on program settings. Position that the drive can reach without encountering mechanical Maximum obstacles. Operating manual HR9 – QS203263...
Page 94: Pallet Lift Settings
Up with empty pallet Down with layers Down with full pallet Speed is in meters per second Acceleration is in seconds, from standstill to desired speed. Deceleration is in seconds, from actual speed to standstill. Operating manual HR9 – QS21XXXX...
Page 95: Pallet Loading Position Settings
When the pallet has started to be fed out, pallet infeeding can be Delay infeed pallet during started, if an empty pallet is present. Depending on the distances outfeed pallet between the pallets, this process can be delayed. Operating manual HR9 – QS203263...
Page 96 Yes = Present and use empty pallet centring Duration of centring empty pallet before centring returns to basic Centring duration position Maximum time that it may take before the cylinder reaches the desired Blocked position. Operating manual HR9 – QS21XXXX...
Page 97: Diagnostics
This usually gives a clearer picture of how a fault occurred. The faults list has 5 spots. 1 to 5. 1 is the most recent fault. With the buttons < and > you can switch between the indexes. Operating manual HR9 – QS203263...
Page 98: Hardware
Overview of hardware and its status, with the buttons  and  you can jump through the various menus; each menu provides information about hardware of the PLC It is also possible to read the diagnostics buffer from the PLC. Operating manual HR9 – QS21XXXX...
Page 99: Communication
Communication Overview of signals sent between palletiser and other installations. Red = Not active Green = Active For a clear sequence diagram of the signals, you can request documentation from the OEM or system integrator Operating manual HR9 – QS203263...
Page 100: Documentation
A PDF reader will appear by clicking on the item. INFO You may need to wait a few seconds for the PDF to load. This depends on the size of the PDF file PDF reader: Operating manual HR9 – QS21XXXX...
Page 101: Packml Log
Operating screens PackML Log Above, the operator can see all of the commands which have been given to the PackML state / mode model. Time and date are linked to it. A description is also given Operating manual HR9 – QS203263...
Page 102: External Applications
Applications that are supported;  Camera surveillance software (Axis companion)  Qimarox Pattern Generator By pressing the "Start" button, application is started and opened, with "Open" the application is brought to the front Operating manual HR9 – QS21XXXX...
Page 103: Camera Surveillance Software
The cameras are fixed and not moveable by software or externally NOTICE To preserve the privacy of the persons working around the palletizer we add privacy masks to the area’s that are not relevant for machine diagnostics Operating manual HR9 – QS203263...
Page 104 NOTICE Camera’s only record on motion detection NOTICE Recordings are stored as long a possible by default, if you want to set a maximum limit please contact the OEM Operating manual HR9 – QS21XXXX...
Page 105: Qimarox Pattern Generator
Operating screens Qimarox pattern generator You can use the application menu to open the software of the pattern generator. Last send Last send Generator pallet product status attributes attributes commands Last generated patterns Operating manual HR9 – QS203263...
Page 106 Operating screens Operating manual HR9 – QS21XXXX...
Page 107: Operating The Palletiser
Wait until the stacking light lamps are lit. Most likely it is the red lamp Check all safety circuits of the machine and reset if necessary. If light blue reset buttons except for the palletiser control panel are flashing, first press them Operating manual HR9 – QS203263...
Page 108 ‘AUTO’. Enter the desired production details; Choose the desired production selection Infinite Pallets Batch First choose the right program Check: Number of layers on pallet is correct Pallet type Choice of sheets (if available) Operating manual HR9 – QS21XXXX...
Page 109 13. Check if the machine remains in status ‘EXECUTE’. Wait about 30 seconds before walking away from the machine INFO If the machine goes to ‘SUSPENDED’ status, it is probably because there is no supply of products. Operating manual HR9 – QS203263...
Page 110: Starting Or Restarting The Palletiser
Check if the machine remains in status ‘EXECUTE’. Wait about 30 seconds before walking away from the machine INFO If the machine goes to ‘SUSPENDED’ status, it is probably because there is no supply of products. Operating manual HR9 – QS21XXXX...
Page 111: Stopping The Palletiser
‘SUSPENDING’ state Check if the machine is in the ‘SUSPENDED’ state. INFO If the machine is paused by the operator, the operator must also restart it. Pause mode can be cancelled by pressing the start button Operating manual HR9 – QS203263...
Page 112: Stopping The Machine
Wait for the machine to stop. INFO The machine will switch to the ‘ABORTING’ state Check if the machine is in the ‘ABORTED’ state. Operating manual HR9 – QS21XXXX...
Page 113: Complete The Machine (Emptying)
As soon as the pallet is out of the system, the state will switch to ‘COMPLETE’ Press the reset button to return the machine state to ‘IDLE’ You can now switch programs or start a new command. Operating manual HR9 – QS203263...
Page 114: Switching Off The Machine
‘IDLE’ if no notifications are active. Switch off the machine by turning the main switch to the ‘OFF’ or ‘0’ position. WARNING When working in or around the machine, lock the master switch with a lock Operating manual HR9 – QS21XXXX...
Page 115: Restoring The Machine
Check if the machine is in the ‘STOPPED’ state. INFO If the machine is paused by the operator, the operator must also restart it. INFO It is possible that the state will switch to ‘IDLE’ if no notifications are active. Operating manual HR9 – QS203263...
Page 116 You can see which layer belongs to which batch; you can see this by the colour of the circle at the top right of each window The related information can be found in the batch legend Operating manual HR9 – QS21XXXX...
Page 117 If the machine is running in batch mode, you must also enter which batch this layer belongs to. You can do that by pressing the batch button, it changes colour, select the correct one from the batch overview. Operating manual HR9 – QS203263...
Page 118 13. When software has been checked you will see all fields turn orange. Check this again Press ACCEPT to load new situation and complete the recovery procedure. 14. Then restart the machine as indicated in section ‘Starting or restarting the machine’ Operating manual HR9 – QS21XXXX...
Page 119: Restoring After Problem With Layer Processing
You can see which layer belongs to which batch; you can see this by the colour of the circle at the top right of each window The related information can be found in the batch legend Operating manual HR9 – QS203263...
Page 120 For this you need to know the pattern that the machine is running INFO Option 1 has the advantage that you don’t have to count and start with an empty situation. Press Next step. Operating manual HR9 – QS21XXXX...
Page 121 If the machine is running in batch mode, you must also enter which batch this layer belongs to. You can do that by pressing the batch button, it changes colour, select the correct one from the batch overview. Operating manual HR9 – QS203263...
Page 122 Press ACCEPT to load new situation and complete the recovery procedure. 17. Then restart the machine as indicated in section ‘Starting or restarting the machine’ Operating manual HR9 – QS21XXXX...
Page 123: Batch Processing
You can find it in MAIN MENU  PRODUCTION By pressing the button you will see all other information associated with it The above window may differ from what you see, because additional information may differ per end user Operating manual HR9 – QS203263...
Page 124: Manual Batch Loading
You should now be able to load the batch if all information is correct. WARNING Check the information carefully before pressing ‘LOAD’ INFO You do need the operator password to do this! Press ‘LOAD’ Operating manual HR9 – QS21XXXX...
Page 125: Manual Batch Removal
Skip to main menu And press Tab ‘PRODUCTION SELECTION’ You can now delete the batch on the machine by pressing the ‘DELETE’ button INFO You do need the operator password to do this! Operating manual HR9 – QS203263...
Page 126: Manual Refreshing
Manual refreshing You can always request a refresh of the batch controller by pressing the ‘REFRESH’ button Here the status of the batch is set to ‘REFRESH’ and the batch controller will send new information Operating manual HR9 – QS21XXXX...
Page 127: Notifications
Machine will be stopped as soon as possible. Referencing (homing) the machine is now only possible in manual mode ALERT The blue light will blink to warn the operator. SHOW ONLY Alarm is only shown on display Operating manual HR9 – QS203263...
Page 128: Alarm List
ABORT Safety relay feedback error zone Safety relay feedback contact Reset the fault, make sure palletizer does not switch correctly relay functionality is correct or within maximum timelimits and feedback contact functionality is correct Operating manual HR9 – QS21XXXX...
Page 129 None or to high program chosen None or to high program Choose a correct program chosen. Selection must be between 1 and ?? between 1 and ?? in the program selection menu (Home) Restart machine after resetting the alarm. Operating manual HR9 – QS203263...
Page 130 Make sure the hardware slave has power supply ABORT PLC detected a programming PLC detected a programming Clear the alarm. error in the software blocks error in the software blocks If this problem returns frequently contact OEM Operating manual HR9 – QS21XXXX...
Page 131 Make sure the inverter & drive have power available STOP Twistrunner; Invalid configuration Configuration is incorrect or Check configuration in settings of lightgrid invalid menu Ask help from OEM Operating manual HR9 – QS203263...
Page 132 Recover machine Adjust turning settings of actual program HOLD Twistrunner; Product incorrect Product dimension of product Remove product from dimensions conveyor within settings of actual Recover machine program Check product dimensions and orientation Operating manual HR9 – QS21XXXX...
Page 133 Warn technicians and OEM rollerconveyor infeed offline PLC and inverter / drive. Use diagnostics and No connection established. documentation to detect the problem and how to solve it Make sure the inverter & drive have power available Operating manual HR9 – QS203263...
Page 134 Photocell on beginning of Check why photocell is object detected on begin of conveyor is triggered while; blocked conveyor no transfer is active or data is Check alignment and proper present operation Remove any objects, and acknowlegde alarm Operating manual HR9 – QS21XXXX...
Page 135 This is because the product formation already has products on it and the layer pusher needs to return over the product formation Operating manual HR9 – QS203263...
Page 136 Recover the machine and This is because the product confirm alarm. formation already has Restart the unit. products on it and the layer pusher needs to return over the product formation Operating manual HR9 – QS21XXXX...
Page 137 From this error code a short this code in the manufacturer’s description of the error is given. documentation Example: Fault code 8: Speed monitoring Operating manual HR9 – QS203263...
Page 138 Unit is aborted and quick stop Place unit in manual mode is generated to prevent any Move palletlift down, and reset damage alarm. Validate top stop position sensor for alignment and proper operation Operating manual HR9 – QS21XXXX...
Page 139 Pallet still present on pallet Check why photocell is still still present during completion conveyor during completion of covered pallet outfeed pallet outfeed. Confirm if pallet really reached Photocell is detecting an next pallet conveyor (unknown) object Operating manual HR9 – QS203263...
Page 140 Reset alarm to restart pallet This is normally monitored by transport a photocell If you remove the pallet, Probably the pallet is stuck or please use machine recovery its slipping update the new situation Operating manual HR9 – QS21XXXX...
Page 141 Generator: Invalid product height Product height incorrect See Alarm 2000 Value does not meet machine limits or configuration 2103 ALERT Generator: Invalid product weight Product height incorrect See Alarm 2000 Value does not meet machine limits or configuration Operating manual HR9 – QS203263...
Page 142 If alarm repeats then contact manufacturer or integrator 2116 ALERT Generator: Error while saving in Error saving program in Retry process database database If alarm repeats then contact manufacturer or integrator Operating manual HR9 – QS21XXXX...
Page 143: Warnings Information
Machine will be stopped as soon as possible. Referencing (homing) the machine is now only possible in manual mode ALERT The blue light will blink to warn the operator. SHOW ONLY Alarm is only shown on display Operating manual HR9 – QS203263...
Page 144: List Of Warnings
See warning 600 SUSPEND Pallet depot: Empty See warning 601 See warning 601 MATERIAL Sheet depot: Low on material See warning 600 See warning 600 SUSPEND Sheet depot: Empty See warning 601 See warning 601 Operating manual HR9 – QS21XXXX...
Page 145 Pallet depot empty See warning 601 See warning 601 1152 MATERIAL Pallet depot wrong Wrong pallet type in depot Please fill the depot with the pallet/material Not matching production right material settings Validate with production settings Operating manual HR9 – QS203263...

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