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Qimarox Prorunner mk5 User Manual

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User Manual
Prorunner mk5
Version 3.0 - 31/08/2023

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  • Page 1 User Manual Prorunner mk5 Version 3.0 - 31/08/2023...
  • 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 B.V.

  • Page 3: Table Of Contents

    Connection unit ....................24 Motor ........................27 Control system ..................... 29 Guiding of the carriers ..................30 Machine in a system .................... 31 Specifications ....................... 33 Installation General ......................... 35 Delivery ........................ 35 Possible installations .................... 36 UM Prorunner mk5 3.0 EN...
  • Page 4 About this manual Unpacking ......................36 Location ........................ 36 On-site transport ....................37 Preparations for a Qimarox installation (optional) ..........39 Installing the machine ..................39 Installing conveyors ....................46 Maintenance General ......................... 48 Specific safety regulations ................... 48 Preventive maintenance schedule ............... 49 Cleaning .......................

  • Page 5: About This Manual

    About this manual About this manual 1.1 Introduction This manual provides information about the Prorunner mk5. From here on, the Prorunner mk5 is referred to as the 'machine'. Note Make sure this manual is always available with the machine. The function of the machine is vertical movement of products within a transport system.

  • Page 6: Machine Documentation

    Specifications [serial number] 1 or 2 Electrical drawings Electrical drawing [serial number] Machine test manual Test manual prorunner mk5 v2.1 EN Generic information Machine specific information Information on electrical, pneumatic or other components can be found on the websites of their manufacturers.

  • Page 7: Terminology List

    The outfeed conveyor moves products out of the machine. Outfeed conveyor The outfeed conveyor is part of the machine. 1.6 Further support and information Qimarox can supply additional expertise and support services, for: • Training • Global support •...

  • Page 8: General

    2.1 Machine identification The machine identification is given on the type plate. The type plate is located at the back of the machine. Refer to the specification sheet of this serial number, for specifications of this machine. UM Prorunner mk5 3.0 EN...

  • Page 9: Machine Layout Drawing And Specifications

    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.

  • Page 10: Ce Installation Instructions

    Qimarox. 2.5 Liability Qimarox believes to the best of its knowledge that the information in this user manual is accurate. In the event that technical or typographical errors exist, Qimarox reserves the right to make changes to subsequent editions of this user manual without prior notice to holders of this edition.

  • Page 11: Ukca

    2.8 Patents Patent protection applies to parts of the machine. Consequently, other parties are not permitted to build this machine in this form, unless Qimarox B.V. has explicitly given permission for this. For more information, refer to mk5patents.qimarox.com. UM Prorunner mk5 3.0 EN...

  • Page 12: Safety

    When operating the machine between 50Hz and 60Hz, the frequency from the specification sheet provided should be used. When exceeding 50Hz, torque loss may occur. It is mandatory to use the frequency which is provided in the delivered specification sheet. UM Prorunner mk5 3.0 EN...

  • Page 13: User Types And Qualifications

    Operating Manual. All maintenance work should be performed by qualified maintenance personnel Qimarox can also give advice about actions and tasks to be carried out on the machine. It is also possible to get training on maintenance and service of the machine.

  • Page 14: Safety Instructions

    3.3.4 During machine operation • Keep your hands and feet away from danger zones. • Make sure you do not wear loose clothing and secure long or loose hair. UM Prorunner mk5 3.0 EN...

  • Page 15: Safety Provisions

    • 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.
  • Page 16 No reaching in At single product infeed and outfeed openings (only when necessary). The following labels icons are present on the control cabinet: UM Prorunner mk5 3.0 EN...
  • Page 17 For specific requirements to the safety fencing, see the CE installation instructions in chapter 8. Make sure that the fenced area complies with local law and rules for protection against danger. If Qimarox supplies the safety fencing, the specifications will be included in the machine layout drawing. 3.4.4 Safety controls Performance level...

  • Page 18: Electrical Safety

    3.7 Personal safety For your own safety use personal protective equipment. Always wear proper personal protective equipment when working with, on or near the machine. The following table gives an overview of the required personal protective equipment. UM Prorunner mk5 3.0 EN...

  • Page 19: Residual Risks

    3.8 Residual risks The machine is intended to be integrated into an automated production line. Qimarox has attempted to protect against as many hazards as possible, either though inherent safe design or by shielding off the dangers. Machine users should be aware of the following residual risks before working with the machine: 3.8.1 Falling of products...

  • Page 20: Machine End Of Life And Disposal

    The overload test needs to be done by the integrator when the installation is installed and electrically connected. See chapter 11 for a sample overload test report. UM Prorunner mk5 3.0 EN...

  • Page 21: Description

    (un)loaded while moving. Discontinuous: the machine can be stopped for the loading and unloading of forks, this is not preferred. This reduces the capacity of the machine. Consult Qimarox before using a machine discontinuously. UM Prorunner mk5 3.0 EN...

  • Page 22: Working Principles

    This information is shown in the Specifications document. Caution The infeed of a product outside the infeed time frame can cause serious damage to the machine. UM Prorunner mk5 3.0 EN...
  • Page 23 (D) to reach the hatched area (C) depends on the spacing, speed of the forks and speed of the conveyor. Caution The outfeed of a product outside the outfeed time frame can cause serious damage to the machine. UM Prorunner mk5 3.0 EN...

  • Page 24: Connection Unit

    It is possible to install an encoder on the gearmotor. With an encoder, it is possible to track each fork, which is useful in sorter application. Consider to use an encoder and Qimarox software to find malfunctions easily. Refer to the documentation of the software for more detailed information.
  • Page 25 The Reverse infeed security sensor (B5) and the Reverse outfeed security sensor (B13) are used for rotation in the other direction. The Rotation detection sensor (B6) is used for both rotation directions. UM Prorunner mk5 3.0 EN...
  • Page 26 Monitor the time between each signal of the Reference position sensor (B1). Stop and check the machine if the interval is longer than expected. The Reference position sensor (B1) is located on the side where the infeed conveyor is attached. UM Prorunner mk5 3.0 EN...

  • Page 27: Motor

    EMC (Electromagnetic compatibility) directives must be observed and the device should be installed according to the manufacturer specifications. The motor safety relays must meet EN-IEC 60204-1 specifications. The setting range depends on the motor specifications. UM Prorunner mk5 3.0 EN...
  • Page 28 Description Refer to the Qimarox Specifications document for drive parameters. The following page (example) of the Specifications document shows the main drive specifications. The OEM gearmotor specifications are given in the 'gearmotor mk5(serial number)' document, which is part of the order documentation.

  • Page 29: Control System

    4.5.2 Control software The software of the machine is supplied by Qimarox and is described in the specification sheet. There are two software versions: • Drive without an encoder.

  • Page 30: Guiding Of The Carriers

    The leveller (B) can turn and is installed in the trolley (C). The leveller has 4 guide wheels (A) that follow the steel guides in the columns. Thus the fork is kept level at all times. UM Prorunner mk5 3.0 EN...

  • Page 31: Machine In A System

    Refer to the Specifications document for the correct settings for the machine and conveyors. A. Machine B. Discharge conveyor (optionally supplied by Qimarox) C. Outfeed conveyor (optionally supplied by Qimarox) D. Infeed conveyor (optionally supplied by Qimarox) E. Feeding conveyor (optionally supplied by Qimarox) UM Prorunner mk5 3.0 EN...
  • Page 32 Stop the machine if sensor B15 is still covered at the end of the timeframe. Validate that the correct settings and sensors positions are used. Do not start the infeed of the next product until the infeed conveyor is empty and the next infeed timeframe is started. UM Prorunner mk5 3.0 EN...

  • Page 33: Specifications

    The specifications in this section, together with the Machine layout drawing and the Specifications document, give guidelines for the transportation of products. 4.8.2 Product transport specifications Refer to the Specifications document for the product specifications that apply to the relevant machine configuration. UM Prorunner mk5 3.0 EN...
  • Page 34 If you want to use the machine outside the recommended 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.

  • Page 35: Installation

    • For a machine delivered in modules, the column section is delivered in an upright position in a crate. Refer to the assembly manual for information on how to assemble the modules. A. Machine fully assembled B. Machine in two or more modules UM Prorunner mk5 3.0 EN...

  • Page 36: Possible Installations

    - It is possible to start with the bottom section. 5.4 Unpacking 1. Check the packing list when unpacking the machine. 2. Immediately report damaged or missing parts to Qimarox. 5.5 Location Refer to the machine layout drawing for detailed information about the location of the machine.

  • Page 37: On-Site Transport

    5.6.2 General preparation Calculate the total weight before moving the machine. 1. The weight of the machine delivered by Qimarox is given on the type plate. Refer to section 2.1. - Add to the weight of the machine the weights of any attachments to the machine, for example, product conveyors.
  • Page 38 6. Make sure that the machine does not tip over after it has been put in the vertical position. 7. Attach the machine to the floor before removing the hoisting belt or the hoisting chain. Refer to section 5.8.2. UM Prorunner mk5 3.0 EN...

  • Page 39: Preparations For A Qimarox Installation (Optional)

    1. Indicate the contact person to whom the mechanic of Qimarox must report when arriving or leaving before and after the installation. 2. Make sure that the mechanic of Qimarox is assisted by qualified mechanics of the client. Refer to section 3.
  • Page 40 Keep the rear side of the machine, especially the top of the drive, accessible for service. Maintain a free space of approximately 500 mm. • Machines higher than 4 meters (13 ft) must be laterally supported as highlighted in the illustration. ø11(4x) UM Prorunner mk5 3.0 EN...
  • Page 41 Use the bolts (A) to level the machine. 5. Measure the diagonals distances (A, B) between the supports of the machine and make sure that they are equal. 6. Use the bolts (A) to attach the machine to the floor. UM Prorunner mk5 3.0 EN...
  • Page 42 8. Remove the hoisting belt or the hoisting chain from the machine. 9. Remove the transport support (A & B). 10. Check the tension of the chain. Refer to section 6.6. Note Keep the transport supports for any future transport. UM Prorunner mk5 3.0 EN...
  • Page 43 Refer to section 5.6.3 or 5.8.2. 4. Attach the machine to the floor. Refer to section 5.8.2. 5. To install and connect the electrical components, refer to the electrical and layout drawings. 5.8.4 Installing a machine from top to bottom UM Prorunner mk5 3.0 EN...
  • Page 44 Fix the bottom section to the floor if the machine is installed in the final position 15. Tension the chain. Refer to section 6.6. 16. Attach infeed and outfeed conveyors (D). Refer to section 5.9. UM Prorunner mk5 3.0 EN...
  • Page 45 4. Make sure that the trolleys are installed in the bottom section (A). 5. Attach the chains to the trolleys. 6. Attach a middle section (B) on top of the bottom section. 7. Attach the trolleys on the left side and right side of the column. UM Prorunner mk5 3.0 EN...

  • Page 46: Installing Conveyors

    Make sure that a hoisting system is available above the conveyor. • If Qimarox supplied the support to the floor: Make sure that the surface is level and meets the requirements for carrying the weight of the conveyor. Refer to the layout drawing.
  • Page 47 3. Attach both conveyor support (A) to the console with the bolts (B). 4. Make sure that the conveyor supports (A) are level. 5. Disconnect the hoisting system. Note For information on the conveyors, refer to the related manuals. UM Prorunner mk5 3.0 EN...

  • Page 48: Maintenance

    WARNING The maintenance schedule is based on 2000 running hours or annuallly. Adjust the maintenance frequency to the actual number of running hours per year. If required, Qimarox can carry out maintenance activities. 6.2 Specific safety regulations For optimum functioning of the machine the various machine parts must be regularly maintained.

  • Page 49: Preventive Maintenance Schedule

    Make sure that the Replace the bolt which is fastening bolt on the visible in section 6.9.2. carrying shaft is there and Make sure the bolt is attached correctly. tightened. Examine for dirt. Clean. Refer to section 6.4. UM Prorunner mk5 3.0 EN...
  • Page 50 Attach loose parts. Examine for dirt. Clean. Refer to section 6.4. Inductive sensors Examine for visible Replace the sensor if damage. necessary. Examine for loose parts. Attach loose parts. Examine for dirt Clean. Refer to section 6.4. UM Prorunner mk5 3.0 EN...
  • Page 51 Examine if the trolleys run Inspect individual parts of through the curves the trolley. Refer to smoothly sections 6.9.2 and 6.9.3 Collar bearing on trolleys Examine for slack. Refer Replace the part. Refer to to section 6.8. section 6.9.5 UM Prorunner mk5 3.0 EN...
  • Page 52 Examine if the sprocket is Refer to section 6.9.12. aligned with the vertical running surface. The following parts needs replacement every year due to wear: A. Rubber profile carriage B. Plain bearing C. Shim ring sprocket D. Plain bearing UM Prorunner mk5 3.0 EN...

  • Page 53: Cleaning

    2. Lock the main switch with a personal lock. 3. Remove deposit and dirt by hand. 4. Report any damage to the technically responsible person or to Qimarox. 5. Make sure that any damage is repaired before a start of the machine.

  • Page 54: Lubrication

    6.6.3. If the chain elongation is 2-3%, the chain must be replaced soon. Replace the chain within 4 weeks. If the chain elongation is 3% or more, replace the chain immediately. Refer to section 6.9.10. UM Prorunner mk5 3.0 EN...
  • Page 55 4. Loosen the two bolts (C) on the front that attach the turning plate to the main frame. UM Prorunner mk5 3.0 EN...

  • Page 56: Bottom Sprocket Plain Bearing Rejection Dimension

    WARNING Always replace parts with parts supplied or recommended by Qimarox. If parts are not replaced with supplied or recommended Qimarox parts, the machine warranty becomes null and void. Refer to section 2.3. UM Prorunner mk5 3.0 EN...
  • Page 57 Refer to section 6.6.3. 6. Remove the bolt (A). 7. Remove the fork (B). 8. Remove the adjusting ring (C) and the shim ring (D). Note Pay attention to the wear of the shim ring (B) UM Prorunner mk5 3.0 EN...
  • Page 58 Maintenance 9. Carefully remove the leveller (A) from the machine and the shim ring (B). Remove the trolley 1. Remove the front cover (A). 2. Remove the curve plate (A). UM Prorunner mk5 3.0 EN...
  • Page 59 4. Remove the trolley (A). Replace the trolley 1. Check the parts for wear. 2. Replace worn parts by new ones. Refer to section 6.9.3. 3. Reassemble the parts in reverse order. UM Prorunner mk5 3.0 EN...
  • Page 60 2. Replace worn parts by new ones. 3. Reassemble the parts in reverse order. 6.9.4 Rubber profile of the trolley Remove the rubber profile 1. Remove the bolts (A). 2. Remove the carrier and chain (B). UM Prorunner mk5 3.0 EN...
  • Page 61 2. Remove the adjusting ring (A). 3. Remove the shim ring (B). Note Pay attention to wear of the shim ring (B) 4. Carefully remove the leveller (A) from the machine. 5. Remove the shim ring (B). UM Prorunner mk5 3.0 EN...
  • Page 62 (B) or another position where you can level the fork (A). 2. Switch the main switch to “OFF”. 3. Lock the main switch with a personal lock. 4. Remove the bolt (B). 5. Remove the fork (A). UM Prorunner mk5 3.0 EN...
  • Page 63 6.9.8 Curve plate – bottom section Remove the curve plate 1. Move the fork (A) away from the bottom curve plate (B). 2. Switch the main switch to “OFF”. 3. Lock the main switch with a personal lock. UM Prorunner mk5 3.0 EN...
  • Page 64 4. Remove the side covers (A). 5. Remove the curve plate (A). Replace the curve plate – bottom side 1. Check the parts for wear. 2. Replace worn parts by new ones. 3. Reassemble the parts in reverse order. UM Prorunner mk5 3.0 EN...
  • Page 65 4. Remove the side covers (A). 5. Remove the curve plate (A). Installing the curve plate 1. Check the parts for wear. 2. Replace worn parts by new ones. 3. Reassemble the parts in reverse order. UM Prorunner mk5 3.0 EN...
  • Page 66 1. Move the fork (A) to the bottom sprocket (B). 2. Switch the main switch to “OFF”. 3. Lock the main switch with a personal lock. 4. Remove the fork (A). 5. Remove the covers (A). UM Prorunner mk5 3.0 EN...
  • Page 67 3. If the chain is fully replaced: adjust the chain tension. Refer to section 6.6.3. 4. Reassemble the parts in reverse order. UM Prorunner mk5 3.0 EN...
  • Page 68 (Prmk5 XL) (A) for wear. Refer to section 6.7. 2. Replace worn parts by new ones. 3. Reassemble the parts in reverse order. Warning Align the sprocket correctly to prevent damage to the chain. UM Prorunner mk5 3.0 EN...
  • Page 69 Maintenance UM Prorunner mk5 3.0 EN...
  • Page 70 Align the sprocket. 5. To align the sprocket with the side guides (B) of the chain, use a ruler (A). 6. Install the chain. Refer to 6.9.10. 7. Install the cover. Refer to 6.9.2. UM Prorunner mk5 3.0 EN...
  • Page 71 4. To align the upper sprocket with the guide strips (B) of the trolley, use a ruler (A). Caution Align the sprocket correctly to prevent damage to the white wheels on the trolley. UM Prorunner mk5 3.0 EN...
  • Page 72 ≤ 40 mm: 17 Nm Shaft diameter ≤ 65 mm: 41 Nm Shaft diameter ≤ 95 mm: 83 Nm Shaft diameter 6. Install the chain. Refer to section 6.9.9. 7. Reassemble the parts in reverse order. UM Prorunner mk5 3.0 EN...
  • Page 73 3. Remove the front cover (A) at the upper sprocket. 4. Put the auxiliary tools (A) into position. 5. Install the two M16x40 bolts (B) (2x). 6. Tighten the bolts to attach the upper sprocket (C) to the frame (D). UM Prorunner mk5 3.0 EN...
  • Page 74 Attach the sprocket correctly to prevent injury and to easily remove and replace the drive or shaft. 1. Switch the main switch to “OFF”. 2. Lock the main switch with a personal lock. 3. Remove the front cover (A) at the upper sprocket. UM Prorunner mk5 3.0 EN...
  • Page 75 4. Remove the bolt (A). 5. Disconnect the gearmotor (B) from the reactor bar brackets (C). Note Make sure that the spline (A) does not fall 6. Remove the gearmotor (B) carefully from the shaft (C). UM Prorunner mk5 3.0 EN...
  • Page 76 1. Remove the clamping bush (A) from the shaft. 2. Remove the main shaft (A) from the bearing. Uninstall the bearings 1. Remove the bolts (A) to remove bearings (B) and bearing block spacers (C). UM Prorunner mk5 3.0 EN...
  • Page 77 Maintenance Install the gearmotor 1. Check the parts for wear. 2. Replace worn parts by new ones. 3. Reassemble the parts in reverse order. UM Prorunner mk5 3.0 EN...

  • Page 78: Troubleshooting

    Overheating or wiring triggered. fault. Find and repair the cause. Motor protection triggered 1. Find and repair the by short circuit or cause. overload. 2. Reset the motor protection Defective power 1. Reset the motor controller. protection UM Prorunner mk5 3.0 EN...
  • Page 79 Short circuit in the power. Repair the short circuit. Wrong fuse (too low Adjust the fuse to the value). nominal motor current. Motor protection poorly Adjust the motor set. protection to the nominal motor current. UM Prorunner mk5 3.0 EN...
  • Page 80 2. Examine the movement of the chain. 3. Shorten the cleaning interval. Chains or drive belts are Examine if the drive not running parallel. shafts are parallel to the frame. Repair if necessary. UM Prorunner mk5 3.0 EN...
  • Page 81 The Transport speed to high. Decrease the transport sprockets do not turn speed according to the easily. Specifications document. Loose bolt connections. Tighten the loose bolts. Other machine parts run Attach the loose parts. loose. UM Prorunner mk5 3.0 EN...

  • Page 82: Ec/Uk Declaration Of Conformity

    Note Additional installation instructions may apply to the machine. Refer to the specific EC/UK declaration supplied with the machine for additional installation instructions. UM Prorunner mk5 3.0 EN...
  • Page 83 EN 13854 :2019 (Minimum gaps to avoid crushing of parts of the human body) EN-ISO 13857:2019 (Safety distances upper and lower limbs) EN-ISO 14120: 2015 (Fixed and movable guards) Harderwijk, 18 January 2022 (Signature: see separate EC declaration document) P.G.Hannessen (director) UM Prorunner mk5 3.0 EN...

  • Page 84: Ce Installation Instructions

    Machinery Directive, the system integrator must have these tests performed by a competent person before initial commissioning. A test report must be signed by the integrator and added to the documentation. A copy must be sent to Qimarox. See the “Testing Qimarox vertical conveyors manual”.

  • Page 85: Electrical Circuit Diagrams

    Electrical circuit diagrams Electrical circuit diagrams 9.1 Standard electric drawings Download the electrical drawings of the machine from: https://www.qimarox.com. If the electrical drawings apply, the overview of all electrical components is listed on the Specifications document. Note The specifications document shown is an example If the standard electrical drawings do NOT apply, the electrical drawings are included with the machine.

  • Page 86: Drives

    Danger potential energy and moving parts. The use of a Safety quick- exhaust valve (soft-start and quick exhaust valve) PL(d) is mandatory but may not be in scope of supply of Qimarox. CAUTION Safety icons regarding switching off air pressure and venting cylinders need to be present and clearly visible on all cylinders.

  • Page 87: Pneumatic Diagram For Tilting Roller Conveyor Rdc3

    Pneumatic circuit diagram 10.2 Pneumatic diagram for Tilting roller conveyor RDC3 10.3 Pneumatic diagram for shuttle conveyor RDC5 UM Prorunner mk5 3.0 EN...

  • Page 88: Pneumatic Diagram For Pneumatic Stopper

    Pneumatic circuit diagram 10.4 Pneumatic diagram for pneumatic stopper neuma tic d ia g ra m A E0035603 Cilind e r DSN 16 0 1001342 10352 RE 1/ 4 UM Prorunner mk5 3.0 EN...

  • Page 89: Overload Test Report

    Overload test report 11 Overload test report The overload test report in this user manual is unsigned. The specific report for the machine is a separate document supplied with the documentation of the machine. UM Prorunner mk5 3.0 EN...
  • Page 90 Overload test report Nobelstraat 43 3846 CE Harderwijk Tel: +31 341 436 700 E-mail: info@qimarox.com Internet: www.qimarox.com UM Prorunner mk5 3.0 EN...

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Prorunner mk5-xl

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