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Qimarox Prorunner PR2 User Manual

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User Manual
Prorunner PR2
Version 1.0 / May 2024

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Summary of Contents for Qimarox Prorunner PR2

  • Page 1 User Manual Prorunner PR2 Version 1.0 / May 2024...
  • 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. UM Prorunner PR2 v1.0 EN...
  • Page 3 Machine in a system ......................... 28 Specifications ........................... 30 Installation ......................31 General ............................. 31 Delivery ............................. 31 Unpacking ..........................32 Location ............................ 32 Onsite transport ........................32 Preparations for a Qimarox installation (optional) ..............34 Installing the machine ....................... 35 UM Prorunner_PR2-1.0-EN...
  • Page 4 Specific safety regulations ......................41 Preventive maintenance schedule ................... 42 Cleaning............................ 44 Replace parts ........................... 44 Troubleshooting ....................50 EC declaration of conformity ................53 Electrical drawings ....................56 Standard electrical drawings ....................56 Drives ............................57 UM Prorunner PR2 v1.0 EN...
  • Page 5 About this manual Introduction This manual provides information about the Prorunner PR2, which is used for the vertical movement of products within a transport system. Henceforth in this manual, the Prorunner PR2 will be denoted as the "machine". Note Make sure this manual is always available with the machine.
  • Page 6 Machine documentation Document Reference Machine manual UM-Prorunner_PR2-1.0-EN. Electrical components Refer to the manufacturer. Refer to chapter 9. Electrical drawings Specification sheet Refer to section 2.2. 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 table below explains common terms used by Qimarox for the machine. Term Definition Machine The Prorunner PR2. Product Products transported by the machine. Carrier The component on which a conveyor can be mounted or which carries the product.
  • Page 8 General Machine identification Figure 1 The machine identification is given on the type plate as indicated on . The type plate is located on the side of the machine. Refer to the specification sheet of this serial number, for specifications of this machine. Figure 1 : Type plate UM Prorunner_PR2-1.0-EN...
  • Page 9 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.
  • Page 10 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.
  • Page 11 The 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 12 Safety Intended use of the machine The machine is exclusively intended for the vertical transportation of products, as described in this manual. Refer to chapter 4 for a detailed description of the specifications of use. The machine is always set up within a larger transport system in which products are automatically loaded on and off the machine.
  • Page 13 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 in maintenance and service of the machine.
  • Page 14 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 15 Replace labels on the machine if they become unreadable or damaged Qimarox requires a protection fenced area around the machine. Any access doors must be secured with (interlocked) door switches. These switches must be included in the emergency stop and safety circuit. Refer to section 3.4.3 for information about how to set up the fenced area.
  • Page 16 3.4.2 Safety labels WARNING Replace labels on the machine if they become unreadable or damaged. The following safety labels are present near apertures in the area fencing: Note These labels are supplied by System integrator/OEM. No entry. Authorized personnel only At safety light curtains that can be interrupted during operation.
  • Page 17 If the fenced area is fitted with a door, it must have a safety switch to shut down the system when opened. If Qimarox supplies the safety fencing, a layout drawing of the safety fencing will be provided. Figure 5 : Safety fencing 3.4.4...
  • Page 18 Electrical safety controls Set the gearmotor protection relay Gearmotor protection devices must be set to the nominal gearmotor current. A relay set too low prevents optimum use of the gearmotor. A relay set too high does not guarantee full thermal protection.
  • Page 19 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 Maintenance No loose clothing...
  • Page 20 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.
  • Page 21 Description General overview The machine consists of the following components: Figure 6 : General overview The machine is designed to vertically transport a product from one level to another. The machine consists of a column (A), a moveable carrier (B) and a gearmotor (C). The carrier is attached to a timing belt which is driven by the gearmotor.
  • Page 22 Working principle 4.2.1 Reference procedure Before starting the machine make sure the machine is empty. When starting the machine, a reference procedure is required. During this procedure the carrier moves up or down to the reference sensor (A). When this sensor detects the carrier, the resolver value is set, and the machine is ready to run.
  • Page 23 Sensors and connection units 4.3.1 Sensors The following sensors must be installed on the machine: Figure 9 : Sensor overview Bottom limit switch. Top limit switch. Reference sensor. Connection unit. UM Prorunner_PR2-1.0-EN...
  • Page 24 4.3.2 Limit switches The machine is fitted with limit switches to prevent the carrier from moving out of its allowed range. When one of these limit switches is triggered, the machine must stop. The figures show how to mount the bottom limit switch (BG1) and the top limit switch (BG2).
  • Page 25 The power of the frequency inverter. • The size of the breaking resistor. Refer to the Qimarox specification sheet for drive parameters. The figure below is an example of a drive that is used at a higher frequency. DRIVE Motor type...
  • Page 26 CAUTION The Prorunner PR2 should always be controlled by a frequency inverter for acceleration/deceleration. A breaking resistor is required to dispense the energy generated by the gearmotor when travelling down. If there is no braking resistor the energy causes too high voltage inside the frequency inverter.
  • Page 27 • A configuration with a cross transfer involves special control requirements. An example of the software is supplied by Qimarox. For information refer to the applicable software blocks and functional description. UM Prorunner_PR2-1.0-EN...
  • Page 28 Figure 15 : Machine in a system A Feeding conveyor (not supplied by Qimarox). B Machine. C Discharge conveyor (not supplied by Qimarox).
  • Page 29 4.6.1 Product infeed After the carrier is positioned, the product is fed in onto the conveyor and monitored by sensor S1. The sensor is located on the end of the feeding conveyor. The product (A) will wait at sensor S1 until the carrier is in position.
  • Page 30 Qimarox or after written permission from Qimarox has been obtained. If Qimarox does not supply the product conveyor, the weight of the applied conveyor needs to be checked by Qimarox to determine the correct drive on the vertical movement.
  • Page 31 Installation General This chapter describes installation instructions. Refer to the assembly manual for machine assembly instructions Delivery The machine can be delivered fully assembled or in parts. • A fully assembled machine (A) will be delivered in a horizontal position. •...
  • Page 32 Unpacking • Check the packing list when unpacking the machine. • Immediately report damage or missing parts to Qimarox Location Refer to the machine layout drawing for detailed information about the location of the machine. The minimum distance (X) between the moving parts...
  • Page 33 Refer to sections 5.6. It is necessary to mount a special lifting tool on the column to prevent it from buckling during lifting. This tool or drawings of how to make it can be provided by Qimarox. A manual is provided with the tool. UM Prorunner_PR2-1.0-EN...
  • Page 34 All equipment listed below must be present before and during assembly. 1. Indicate the contact person to whom the mechanic of Qimarox must report when arriving or leaving before and after the assembly. This only applies when Qimarox takes care of the assembly.
  • Page 35 Installing the machine WARNING • The machine may only be set up by qualified personnel. Refer to chapter • Machines higher than 4 m must be laterally supported to get sufficient stability in the column. Refer to the machine layout drawing. 5.7.1 Preparation •...
  • Page 36 Figure 24 : Anchor the machine Note Use Fischer FBN II 12/100 bolts or equivalent. These bolts are not delivered by Qimarox. For the specifications of the bolts, see the information of the supplier. 1. Disconnect the hoisting belt, the hoisting chain and the lifting eye.
  • Page 37 5.7.3 Installing a machine delivered in parts 1. Mount the parts. Use the delivered coupling pieces. Refer to the assembly instructions for mounting. The machine can be installed from top to bottom (see section 5.7.4 or from bottom to top (see section 5.7.5).
  • Page 38 5.7.4 Installing a machine from top to bottom Figure 28 : Installation from top to bottom CAUTION Do not work directly under the load. 1. Hoist up the top section. 2. Mount the next section below the top section. 3. Hoist up and mount the next section. 4.
  • Page 39 5.7.5 Installing a machine from bottom to top Figure 29 : Installation from bottom to top CAUTION Not removing the lifting eye from a stainless-steel machine will cause corrosion of the machine. 1. Place the bottom section with the carrier. 2.
  • Page 40 5.7.6 Installing the earth cables The system must be grounded to prevent electric shock in case of a fault in the electrical system. 1. Attach the earth cable (A) to the carrier (B). 2. Attach the earth cable (A) to the column (C). Figure 30 : Earth cables 5.7.7 Tensioning the belt...
  • Page 41 Adjust the maintenance frequency to the actual number of running hours per year. • If required, Qimarox can carry out the maintenance activities. Specific safety regulations For the proper functioning of the machine the various machine parts must be regularly maintained.
  • Page 42 Preventive maintenance schedule Note Machine is excluding the conveyor. 6.3.1 Daily maintenance Item Task Action when required by the check Guards Check for visible damage. Replace damaged guards. Check if the mounting materials Place the mounting materials or are present and have been correct the way in which they correctly placed.
  • Page 43 6.3.3 Monthly maintenance Item Task Action when required by the check Motor reductor: Follow the Check the seals for leakage. Replace the seals. instructions in the manual of Check for visible damage. Replace the damaged parts. the manufacturer of the Check for running sounds.
  • Page 44 3. Secure the main power supply switch with a padlock. 4. Remove deposit and dirt by hand. 5. Report any damage to the technically responsible person or to Qimarox and make sure that any damage is remedied before restarting the machine.
  • Page 45 6.5.1 Carrier Remove the carrier 1. Before switching off the machine, make sure that the carrier (A) is placed at the bottom of the column. 2. Loosening the belt (refer to section 5.7.7, in reverse order) Remove the timing belt Figure 32 : Bottom position carrier To remove the carrier from the belt 1.
  • Page 46 Remove the carrier 1. Remove the bottom cover (A). Figure 35 : Remove bottom cover 2. Remove the carrier (A) from the column in the direction shown. Replace the carrier 1. Mount the new carrier in the machine. 2. Reassemble the parts in reverse order. 6.5.2 Carrier wheel Figure 36 : Remove carrier...
  • Page 47 6.5.3 Timing belt CAUTION • Make sure there are no products on the product conveyor. • Place the safety locking pin and ensure that the carrier is resting on the pin to prevent the carrier from falling. Remove the timing belt 1.
  • Page 48 6.5.5 Timing belt pulley Remove the top timing belt pulley 1. Remove the timing belt as described in section 6.5.2. 2. Remove the gearmotor as described in section 6.5.4 3. Loosen the locking collars from the bearing unit, remove the circlips and move the drive shaft timing belt toward the gearmotor side.
  • Page 49 6.5.6 Cable carrier Remove the cable carrier 1. Remove cable carrier (A) from the carrier (B). CAUTION • Make sure that there are no products on the product conveyor. • Place the safety locking pin and ensure that the carrier is resting on the pin to prevent the carrier from falling.
  • Page 50 Troubleshooting Problem Possible cause Solution The gearmotor does Electrical failure. Remedy the electrical failure. not run. The operation or main switch Set the operation/main switch is on "OFF". to "ON". The door switch or emergency Release the emergency stop stop is active. switch after having checked if the situation is safe.
  • Page 51 Problem Possible cause Solution The gearmotor is The gearmotor was designed Change the connection from overheated. for a star connection but has triangle into star. been connected in a triangle. Voltage and/or frequency Connect the gearmotor deviates from the nominal according to the data on the value when switching on.
  • Page 52 Problem Possible cause Solution The gearmotor does Check and/or adjust the not run. The Incorrect setting of the gearmotor protection to the gearmotor protection gearmotor protection. correct value. is triggered The mechanical drive is Remove the blockage. Clean immediately. blocked. the machine.
  • Page 53 EC declaration of conformity The EC/UKCA declaration in this user manual is unsigned. The specific declaration for the machine can be found either in the specification sheet or in the separate document supplied with the documentation of the machine. Note Additional installation instructions may apply to the machine.
  • Page 54 Technical Dossier for this machine, and also declares that the machine: Designation Vertical transfer device Function Vertical transport of products Model/Type Prorunner PR2 Method of construction according to layout drawing Date of construction 202x Serial number PR2 2xxxxxx...
  • Page 55 Page 2 CE Installation instructions Prorunner PR2 Before the CE Installation instructions have been met completely, the machine must not be used. 1) Area safety fencing The machine must be placed within a safety fencing. This safety fencing has to comply with standards EN-ISO 14120, EN 619 and EN-ISO 13857 and the minimum required safety distances must be met.
  • Page 56 If the standard electrical drawings apply, the overview of all electrical components is listed on the specification sheet as shown in the figure below. ELECTRICAL COMPONENTS Positions correspond with standard electrical drawings of PRORUNNER PR2 Component Position Included Cable position Length Item no.
  • Page 57 Drives 9.2.1 Drive type: SEW 3PH Connection main power Connection TF Connection BR Other connection diagrams DR Drive - SEW DRN with EI8R encoder 9.2.2 Drive type: Movimot Connections Movimot The specification sheet indicates if the standard electrical drawings apply to the machine and if so, gives a web link to the drawings in the section “Documentation”.
  • Page 58 Nobelstraat 43 3846 CE Harderwijk Tel: +31 341 436 700 Fax: +31 341 436 701 E-mail: info@Qimarox.com Internet: www.Qimarox.com UM Prorunner_PR2-1.0-EN...