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User manual Interroll Pallet Roller Flow FIFO

1. WW FOL yid UE JUGI IOA Pod ae asq JOU WW SOL 058 73 TLOLGDELD SV JIC BIJDUIS WW 9S FOL 424 ww egg 57 ww ecg BF WW OCOL 058 is eS ee ZOLEOSOOLI SV 90LE0S00L4 S OC 0 S0EL9 S aes ee Te pol jjaq pow JUuBIY QOOLELEQ0LU SYV JIC B DUIS DON DUPWWO dojs sojeJedas E hee tI yn 4 4 SUS aE VLCOCLELO S LLSOSOFLO SV eae OD AAP WW 7QL Yrtic WU 9G Yt WW 090 058 14 WW OSOL 058 14 414 7 n4 ELZOOLELD SV OLS0SO7LO SV 7 eos ee IDUIS AAR SH 67 Appendix Version 3 0 June 2013 EN Translated from French 68 Pallet Flow Roller Flow FIFO Regular S3R separator AS G13092471 Full kit Paqular senara aor Rod AS F100503102 Left rod Lg 788 mm Ceman 850 1050 ma a LNA oo E on ao M o aR LN Y lt L 850 1050 mm Separator stop AS G11041151 Appendix Timer N D ce MA eJ Y lt L N O CO oS M EJ Y lt 110 mm 110 mm INTERROLL Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO al E E p Z Heavy S3R separator WW OLZ 14
2. Jedos g DUIS AAPA 69 Appendix Version 3 0 June 2013 EN Translated from French al E E pe z JOUS U0I4I JOJd U OEL J4 74190019 HM eJ IU 0E J4 pac TOLVA WU OE 73 ATA Pallet Flow Roller Flow FIFO STP tracks JOYS UOPIJOJId Version 3 0 June 2013 EN Translated from French JOYS YOILII OI4 4 Appendix 70 Pallet Flow Roller Flow FIFO INTERROLL List of spare parts Before placing your order have Interroll confirm the reference numbers by pro viding your order number Recommended inventory status A Keep in stock B Recommended stock C Optional stock Machine no No Name Reference Quantity Inventory status 1 Pallet guide AS F11113070 B 2 Loading plate AS F04013020 A 3 PL cross tie AS F04030221 C 4 Rollers Diam 60 1 5 mm thick A AS G11041523 Diam 60 2 mm thick A AS G11041522 5 Speed control roller EL 130 Basic AS 13091870 A Magnetic AS G12120710 A EL 230 Basic AS 13091872 A Magnetic AS G13052972 A Magnetic deep freeze AS G14042471 EL 850 1050 Basic AS 13052110 A Magnetic AS G11031452 A Magnetic deep freeze AS G14011771 6 Regular separator
3. Pressing on the separator flap locks the stop This stops the second pallet and creates a separation This separation enables the first pallet to be unloaded without hindrance from the accumulated pressure of the pallet line during unloading the flap remains in the low position thanks to the Time Plus function while the separator stop is in the up position Start up and operation 45 46 Checks before each start up Pallet Flow Roller Flow FIFO INTERROLL 5 30 sec With the Time Plus function the separator flap moves up after 5 to 30 seconds depending on the settings The separator stop is then unlocked and the next pallet is freed A space is created between the pallets The pallet activates the separator flap and slides over the separator stop When the pallet passes the separator stop the separator stop moves and locks in the vertical position to stop the next pallet Operation Close down a lane if you observe any of the following e Suspicious noise e A visibly worn component e A blocked or swerved container e A deteriorated rack e A defective attachment between the lane and the rack e A component which has failed or which is not operating correctly gt Check that everyone present is informed and trained on the use of the system and that no one is in a position of danger gt Check that there is no visible degradation to the lanes or the rack gt Check that there is no foreign
4. FOB062504 F13022524 F03100721 HM10x30 Nut M10 Screw 6 3x19 os x12 x2 5090 9000000000090 0 00900900 990000909 0000090000000 a z Attach without tightening Attach without tightening Version 3 0 June 2013 EN Translated from French Assembly and installation 21 22 Angle beam traverse roller loading module TR Pallet Flow Roller Flow FIFO INTERROLL The holes in the angle beam allow the loading module to be centred O automatically F03100721 HM10x30 Nut M10 HM10x30 Locknut M10 Washer 810 0000 000000000000000 00000000000000000000000F8 Y G 550 000000000000 oo ooo 00 0 0090000092900000000 Attach without tightening Attach without tightening Version 3 0 June 2013 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Notice The PLJ connecting plates are assembled as follows gt The PLJ connecting plates must not exceed the width of the modules The PLJ connecting plate excess is between the pro files under the rollers gt The mounting bracket for the PLJ connecting plate must be on the loading side gt The screw fixing the profile to the PLJ connecting plate is insert ed into the second hole of the profile with the screw head at the top recommended torque 45 Nm PLJ connecting plates overhang Ae 2nd hole to the interior of the module Mounting bracket for the PLJ connecting plate loading side A Remin
5. INTERROLLE What to do in case of an accident or failure gt Stop the lane gt Secure the area and set up appropriate signage gt In the event of an accident provide first aid and call the emergency services gt Inform qualified maintenance personnel gt Have the system repaired by qualified maintenance personnel gt Do not use the lane until authorised by qualified maintenance personnel Version 3 0 June 2013 EN Translated from French Start up and operation 53 54 Preparing an intervention Performing an intervention Pallet Flow Roller Flow FIFO INTERROLL Cleaning maintenance and repair Cleaning Notice Damage in case of improper cleaning gt Do not use abrasive products pressurised jets or products which may cause oxidisation or damage the equipment gt Clean the lane using dry cloths Remark in case of maintenance and repair Warning Risk of injury in case of improper intervention gt Maintenance must only be carried out by qualified and regularly trained personnel in compliance with safety and other instruc tions gt Wear Personal Protective Equipment PPE Before any intervention you must take into account e Safety instructions concerning the work area e g movements in the area weld ing grinding and the duration of maintenance operations for cold rooms e Specifications particular to the company where the installation is used e Technical data p
6. Lie 0 eZ A Na G KA Ke Example of maintenance paliet Attaching the maintenance lirs Pore ose aacn Saococa ono s S gt oe Fam Using a maintenance pallet Version 3 0 June 2013 EN Translated from French Cleaning maintenance and repair 55 Pallet Flow Roller Flow FIFO INTERROLLE Two people are required in order to use a maintenance pallet e one who works on the pallet e another who provides assistance while remaining in the boom lift To raise the operator to the lane use an appropriate lift such as a boom lift ac cording to the rules applicable in the country Warning Risk of falling due to the rotating rollers gt Never walk on the rollers nor on the profiles gt When working on the lane you must always be attached using a safety harness gt Check that the system for locking the pallet on the profiles is working correctly gt Check the operation of the system for attaching the hoist next to the pallet gt Check the operation of the system for attaching the hoist ahead of the lane to the rollers on the rack gt Using a lifting device or boom position yourself on the loading side in front of the lane located next to the lane requiring main tenance gt Use a forklift to position the maintenance pallet next to the load ing side of the lane where maintenance is required Position it in that lane gt Block the pallet when it is loaded using the locking syste
7. F03100721 HM10x30 Nut M10 Screw 6 3x19 QO 2 Xo XZ gt Centre the module on the beam then attach the 2 short PLJ connecting plates with 2 drill screws Attach without tightening tightening Version 3 0 June 2013 28 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Floor unloading traverse roller unloading module TR 1307131 F13071130 F06050310 G06050315 HM10x30 Nut M10 Ht 75 mm F13071130 _ ia Pilih hed aaea PEE neccacaees ooooe oo ag agpo pegpagocdoocisn EL Ae Attach without tightening nantening The floor mounting feet must all be level to ensure correct system operations A Adjust the feet if necessary to maintain a slope of 4 Refer to the assembly diagrams provided in the appendix for details of lane assembly on floor mounting feet Version 3 0 June 2013 EN Translated from French Assembly and installation 29 Pallet Flow Roller Flow FIFO INTERROLL Tubular beam 3 track unloading 3TL module F03100721 HM10x30 Nut M10 Screw 6 3x19 oo x2 gt Centre the module on the frame then attach the fixing bracket at the end of the lane onto the unloading beam with 2 drill screws Attach without tightening Attach without tightening Version 3 0 June 2013 30 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Angle beam traverse
8. Visual inspection Check that the real operation time of the Time Plus corre sponds to the time of use Check the tightening Visual inspection Check the tightening Date Work required Free the mechanism if neces sary or replace it if required Inspection no impact no trace of the start of a fracture Time from the moment when the container is lifted to the locking of the separator stop Re tighten if necessary to 45 Nm Inspection no impact no trace of the start of a fracture Re tighten if necessary to 45 Nm Cleaning maintenance and repair INTERROLL Performed by 59 60 Blocked container O Content falls to the floor Pallet Flow Roller Flow FIFO INTERROLL Troubleshooting In the event of a failure gt Stop using the lane and any lane which may be damaged by the failure gt Secure the area and set up appropriate signage gt Only qualified maintenance personnel should repair the failure gt Never try to hold back a container freed during a manipulation gt Before restarting the system check the integrity of the lane the rack and its en vironment e g sprinklers Follow the maintenance procedures of the various products dynamic lanes racks environment There may be many reasons causing a container to be blocked and preventing it from starting this is not necessarily a defect in the installation Inserting a new con tainer usually corrects the problem
9. gt In the event of a container blocked in the middle of a lane and or against the rack remove the containers via the lanes located to either side by transferring them to another pallet gt If you cannot unload via the side lanes unload via the loading side Use a hoist to move the blocked container as well as the upstream containers gt In the event of unstable content first secure the area Then use a boom lift to access the content and either stabilise or unload it gt Check whether the lane or the rack were damaged by the blocked container gt If content has fallen to the floor you must secure the area before taking any further action Version 3 0 June 2013 Troubleshooting EN Translated from French Pallet Flow Roller Flow FIFO Troubleshooting INTERROLL O Technical data in the order confirmation is noted below by the abbreviation OCTD Failure Immobilised pallet Speed not controlled gt 0 3 m sec Version 3 0 June 2013 EN Translated from French Cause Damaged pallet e Nails sticking out under the pallet e Cracked broken or missing skid e Damaged block e Nails loose on skid Pallet characteristics not compliant with OCTD type dimensions mois ture content weight and stored load Foreign particles attached to the pal let or when the pallet is packed under plastic film Load unevenly distributed on pallets Damaged speed control roller see List of maintenance and i
10. Bb ZL90S071D SY WW op 93 OL6ZS0ELD SV WW OSOL 058 13 S7ecllcla SV IS WW QSOL JJ WwW OLZ Tepad 13 Ole QLSCGUELD SV WU OSOL 0S8 J WW QLL ePad 13 OLL OLSZ60ELD SY WW cg D7 OladsQela SV BOLET Ww cg b7 ekodsStklda Sy poJ 4ybiy 0l OLZO80E19 SV WW OLZ 49 OL Licor WW AL 7g OLL OLZO80EL9 S 2 JOU WW QSOL 14 BE g0 A Vag a WW 0z Jepad 73 WwW QL epad 73 ULL LLS ovelo sv WW YOL id WU 09014 SL9L60ELD SY dP ajgnoq WW 9S yla WW OSOL 4 ZLOELOZLI SV 392 3 qno0G WW YOL Hid WW OSOL 058 73 TLILOQELY SV 32E DUIS WW 9S 424a WW OSOL 058 73 00LEL600LD SY 32E DUIS o G v O a ee UU LSU WW OLZ jepad 77 WW OSOL 73 TLIC SY y gp a Hi WW Ol jepad 73 MN OSO0L 7 098 1a ELSCOUELD SYV WU OZ jJepad 47 WW 9S YI 4Id Ww SOL 13 GLSZ60EL9 S WW 9S 434d W OL jeped 73 0SOL 058 14 CLICCO ray
11. material preventing correct operation of the in stallation gt Check that all signage is in place load capacity and restrictions for use Version 3 0 June 2013 Start up and operation EN Translated from French Loading a container TR loading mode Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Warning Risk of injury in case of improper handling gt Insert the containers in the lane on the loading side only gt Do not insert containers in the lane if they do not enter com pletely into it gt Do not load a container if pressure is required to insert it gt In the event of a blocked container remove it and determine the cause of the blockage Notice Damage in case of improper handling gt Load carefully so as not to damage the lane or the products stored in it gt Never touch the rollers or the rack with the forks of the forklift gt Never insert or reinsert a container on the unloading side The time between two loadings must be e For a standard speed controller 30 loads per hour maximum e For a high performance speed controller rate of 60 loads per hour maximum The rate can be extended to 90 loads per hour for a 10 minute period every 2 hours gt Check the bottom of the container in order to detect any possible damage or breakage of the skids or the presence of nails or foreign materials gt Damaged containers should not be us
12. on each side of the roller Perform a visual inspection of the attachment of the speed controller roller to the BU80 profile Check that the insert is cor rectly tightened Visual inspection of the tube Check the tightening of the screws on the profiles Cleaning maintenance and repair INTERROLL Date Work required Performed by Check the tolerance Replace it if necessary Contact Inter roll for a quote for replace ment If the brake is blocked or if it rotates freely if only a slight effort is required to turn it or if it makes a Suspicious noise have it replaced When in doubt contact Interroll for a quote for replacement Perform a visual inspection of tightening Replace the speed controller if necessary Contact Interroll for a quote for replacement Perform a visual inspection Tighten it if required with a torque of 45 Nm Inspection no impact on the tube or the end Raise the roller and check that the screws are held prop erly Re tighten if necessary to 45 Nm Version 3 0 June 2013 EN Translated from French Pallet Roller Flow FIFO Component Separator flap and stop Components for attaching the modules to the rack or the floor Cross tie Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO Tasks Checks Check that nothing obstructs the movement of the separa tor see Operating principle of the separator page 45
13. stop AS G11041151 A Heavy separator stop Single front no rollers 130 156 A AS G100913100 Single front no rollers 104 A AS G13091674 Dual front no rollers 130 156 A AS G12073012 Dual front no rollers 104 A AS G13091675 these components should be replaced exclusively by qualified maintenance per sonnel trained and certified by Interroll Version 3 0 June 2013 EN Translated from French Appendix 71 Machine no No Name 7 Regular separator flap Heavy separator flap 8 Lane end stop 9 Connecting plate 72 Pallet Flow Roller Flow FIFO INTERROLL Reference Quantity Inventory status TR module AS G13091973 A S3R module AS G13092470 A TR module no rollers 130 156 A AS G13032510 TR module no rollers 104 A AS G13091373 S3R module no rollers 104 130 156 A AS G13092571 TR stop AS A06111621 S3R stop AS A03101520 Long AS F03100721 Short AS F03100722 O Oo amp gt these components should be replaced exclusively by qualified maintenance per sonnel trained and certified by Interroll This table provides an indication of requirements for most users Each user should determine the stock levels required according to their actual usage Version 3 0 June 2013 EN Translated from French Appendix North Europe Denmark Interroll Nordic A S Sales Office Dynamic Storage Hammerholmen 2 6 DK 2650 Hvidovre Tel 45 36 88 33 33 Fax 45 36 88 33 72 d
14. the Pallet Roller Flow e Give this manual to any operator or subsequent user of the Pallet Roller Flow Interroll shall not be held responsible for damages or failures which may result from ignoring the recommendations in this manual Contact Interroll Customer Service if you have any questions after reading this manual The last page lists the details of the person to contact in your country Version 3 0 June 2013 About this manual EN Translated from French Structure of warnings Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Warnings in this document The warnings in this document concern dangers which may arise while using the Pallet Roller Flow For relevant warnings see Safety page 6 and the warnings at the beginning of each chapter There are three categories of danger indicated by the following key words e Danger e Warning e Caution Key word Meaning Danger Indicates a hazardous situation which if not avoided may result in death or serious injury Warning Indicates a hazardous situation which if not avoided may result in death or serious injury Caution Indicates a hazardous situation which if not avoided may result in a minor or moderate injury Danger Nature and source of hazard Possible consequences of non observance gt Information about how to avoid the hazard Notice This symbol identifies possible material damage gt Infor
15. 0 Fax 48 22 741 741 1 pl sales ds interroll com South Eastern Europe Near East Turkey Interroll Lojistik Sistemleri Tic Ltd Sti Agaoglu My Prestige Ofis Merkezi Barbaros Mah Ihlamur Sok No 1 D 89 34746 Atasehir Istanbul Turkey Tel 90 216 688 4280 Fax 90 216 688 4282 tr sales interroll com Also responsible for Greece Egypt United Arab Emirates Israel ComTrans Tech Ltd P O B 17433 Tel Aviv 61174 Israel Tel 972 54 4 27 27 47 Fax 972 3 7 44 08 64 il sales interroll com Africa South Africa Interroll SA Pty Ltd P O Box 3 27 Isando 1600 ZA Gauteng Tel 27 11 281 9900 Fax 27 11 252 9083 za sales interroll com North America Canada Interroll Canada Ltd 1201 Gorham Street CDN Newmarket Ontario L3Y 8Y2 Tel 1 905 727 3399 Fax 1 905 727 3299 cdn sales interroll com South America Brazil Interroll Logistica Elementos para Sistemas Transportadores Ltda Av Alexandrina das Chagas Moreira 945 Bairro Distrito Industrial Pindamonhangaba SP CEP 12412 800 Brazil Tel 55 12 3648 8021 Fax 55 12 3648 8164 sa sales interroll com INTERROLL Asia China Interroll Suzhou Co Ltd Unit 10B Modern Industrial Square No 333 Xing Pu Road Suzhou Industrial Park Suzhou Jiangsu Province People s Republic of China Postal Code 215126 Tel 86 512 6256 0383 Fax 86 512 6256 0385 cn sales interroll com Japan Interroll Japan Co Ltd 302 1 Shimokuzawa Sagamihara sh
16. A Ea ia a 7 PIGS a E E E A E mance euou ucla E A A T Product information Product descripto nenian 8 COMPONGONO ER 8 Technical characteristics of the Pallet Roller Flow FIFO asasnssennnnannnennnnnns 9 Transportation and storage TEATS ON VAUIOIN PA AE E AT A IE E A EAA ET 11 E see E ee A eee ees 11 Assembly and installation Warnings concerning assembly ccccecccceececeeeeceeeeceeeeeeeeeeseeeeeeeeeseeeesees 12 PASSSMIONY TUNG Sesia caneiandanaeresaetateatcued 13 Lane ASS CINMIDIY ccein aa EEEE A 16 Step 1 Assembly of the test bay ccc ccccccescecseseeeceseeeceseeeseneeeseeeeees 16 Se eaa AGS WS o E E E E E ET A TE 36 Step 3 Lahe assembly scssi anA ARAE Eanan 42 Start up and operation Warnings concerning operations s sssssssreesrrnrrresrrsrrrsrresrrrrrrrrrreerennnee 43 Checks before the initial start up cccccccecccesecceseeeeeeeesseeesseeeeseeeeseeeees 44 Forklift requirements sociic ccavdeinseddueccnensusdcuudedawoncnandadiedesaawadaiavietansdeundeanncdens 44 Loading and unloading Methods ccceeeecseeeeeeeeceeeeeeeeeseeeeseeeeseeeeseeees 45 Bece OUD ceric E ee mre E earn nee neta etree E E E A E E E EE E 46 What to do in case of an accident or failUre cee ccceecceceeeeeeaeeeeeneeeeeeaes 53 Cleaning maintenance and repair AEA aeee E EA E wees AE E EEE A E ates dennaeeneaiees 54 Remark in case of maintenance and repair cccccceceeeceeeceeeeeeeeeeesee
17. INTERROLL INSPIRED BY EFFICIENCY User manual Interroll Pallet Roller Flow FIFO PF 1100 Version 3 0 June 2013 EN Translated from French Manufacturer Interroll Dynamic Storage 310 rue du Clair Bocage Zone d Activit Beaupuy 2 85000 Mouilleron le Captif France Tel 33 251 37 12 32 Fax 33 157 67 99 71 www interroll com dynamicstorage interroll com Copyright for this manual Interroll Dynamic Storage holds the copyright on this manual The manual contains standards drawings and illustrations which may not be disclosed published or duplicated either fully or in part nor used for any other purpose than the installation referred to in this manual without the prior written consent of Interroll Version 3 0 June 2013 EN Translated from French Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLLE Contents About this manual Remarks concerning the use of this Manual ccccceseeeeeeeeeeeeaeeeeeaeeees 4 Warnings in this COCUMENL cccceeceeeeeeeeeeeeeeeeeseeeeseeeesaeeesaeeeseueesseeesaaees 5 Additi nal SymDOlS ss ecisssnsii kapein E i i ia 5 Safety General safety instructions cccceccceeseeeeeeeeeeeseeeeeeeeeeeeeeeeeeseeeeeseeeeesaeeeens 6 mended USG esre E A 6 Unintended USC s cgccie dade msciceiotdees eieniecensaiowiaicieandeeihaudunceiepuipdcemasebasiewadelsandidaseiancduanne 6 Qualified personnel serisinin e ea aA
18. J60x2 Zn AS GT0L1523 AS G11041522 FL EL 24 850 1050 Ele Ie 130 2 210 432 532 132 850 1050 mm Basic SC EL 130 Magnetic SC EL 130 AS G13052710 AS G17120 710 EL 130 mm FL 130 mm Dok Eke 230 MSC EL 230 Pio Vir ELS 2o0 AS BIZ0910 72 AS G13052972 AS G14042477 EL 230 m EL 230 mm EL 230 m Grey Yellow Black Yellow Black Black Version 3 0 June 2013 oF Appendix EN Translated from French Pallet Flow Roller Flow FIFO INTERROLLE Basic SC Magnetic SC Magnetic SC deep freeze AS G13032110 AS G11031452 AS G14011771 EL 850 1050 EL 850 1050 EL 850 1050 Black Black Grey Yellow Connecting plate long Connecting plate short AS F03100721 AS F03100722 Loading guide Loading plate Cross_tie PL AS F04030221 FL 110 130 210 850 1050 AS F04013020 FL 10 130 210 850 1050 mm Splicing plate AS F03102722 Version 3 0 June 2013 Appendix 65 EN T
19. OLL Installing the short intermediate modules F03100721 HM10x30 Nut M10 oe000000 9090900009000090 TTI IIEL LLLA 90 0000900000000000000 ooo0o00090000000000000 QES oooooococo ogpovo000Qo0 00 CO OOOO o ONS E Attach without A a iai tightening Reminder A e Do not attach with drill screws the PLJ connecting plates onto the beams for the moment e Do not tighten the screws between the profile and the PLJ connecting plate The oblong holes allow you to adjust the position of the modules when aligning the lanes Version 3 0 June 2013 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO i E E p a Z Unloading modules On the unloading side insert all the unloading modules for the test bay on the rack j l AAAI CUTE MBA UAU TAA amp vy MS Mins Na Vy 7 We f a Ls AN i eA Tim Wa 27 Assembly and installation Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL A Avoid impacts on the safety elements of the separator When inserting the unloading modules in the rack ensure that the parts located in the frame below Time Plus separator flap rod and separator stop do not hit the forks of the forklift or the rack beams Damage to these safety elements could cause operating problems in the lane Tubular beam traverse roller unloading module TR
20. a is half the distance 2a between the lanes Version 3 0 June 2013 EN Translated from French Assembly and installation 15 Identifying the components Checking the rack Pallet Flow Roller Flow FIFO INTERROLLE Lane assembly The attached diagrams show the composition of the Pallet Roller Flow lane The diagrams are included in an envelope inside the spare parts box gt Identify each component by referring to the diagrams This is especially impor tant when you must assemble different types of lanes gt Check that all the parts required and indicated for the assembly are available If anything is missing you must inform Interroll within 8 days gt Check that the rack is installed according to instructions see Rack assembly page 14 p gt Pay particular attention to the alignment and the slope of the beams Step 1 Assembly of the test bay Before proceeding with assembly of the complete installation a test bay must be assembled to ensure the correct operation of the system gt Start by defining the location of the dynamic storage block by referring to the master diagram gt If necessary remove the module pallets from the assembly area gt Sweep the zone and secure the work area gt Mark on the floor the grid which will enable you to position each of the frame uprights gt Using a laser or site laser level define the aligning heights for each frame up right The rack uprights must
21. all be level to ensure correct system operations In the event of incorrect rack installation Interroll shall not be held responsible for any operating malfunctions Version 3 0 June 2013 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Rack Start by installing the front row of frames on the loading side Align the rack according to the floor markings on the front and sides gt Use as many wedges as required to ensure the rack is level level height ob tained by laser or site laser level The beams must be horizontal and the up rights vertical Vertical 0 25 Horizontal 0 25 Version 3 0 June 2013 EN Translated from French Assembly and installation 17 18 Pallet Flow Roller Flow FIFO INTERROLLE gt Position the beams along the row of frames according to the master diagram provided by the rack manufacturer Ensure you use the correct beam type on the loading side tubular beam o a angle beam Tubular beam Angle beam The beams must be aligned and must have a constant slope from loading to un loading The slope matches the slope of the lane 4 rise of 50 mm every 1250 gt Drill then fasten the uprights to the floor Version 3 0 June 2013 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO yp INTERROLL ho d Loading modules For installation of the Pallet Roller Flow lanes see the a
22. bly wear appropriate Personal Protective Equip ment gloves safety shoes safety harness helmet etc Version 3 0 June 2013 Assembly and installation EN Translated from French i O Qualified personnel O General rules Pallet Flow Roller Flow FIFO INTERROLL Assembly rules There are several methods for assembling the Pallet Roller Flow Adapt the as sembly method provided by Interroll according to the national and local safety rules and requirements in the installation country Some companies may require the use of a boom lift for work at a height The dynamic storage lanes are subsystems of the overall installation They are delivered in compliance with the technical data indicated in the order confirma tion The delivery of Pallet Roller Flow lanes comprises pre assembled roller chassis and accessories These components must be assembled installed and posi tioned on a rack or on module risers If any changes are made to the components or their location in the lanes then Interroll is no longer responsible for the installation as this represents unintended use of the Pallet Roller Flow The racks must be assembled at the same time as roller modules are inserted on the beams The racks must be attached to the floor to provide rigidity to the entire system The assembly and installation must be carried out by qualified personnel in com pliance with the instructions concerning assembly and instal
23. checks and maintenance performed on the installation Fail ing which the operator shall be held responsible in case of an incident or an ac cident on the installation and cannot claim any guarantee nor indemnity from Interroll The safety mechanisms speed controller separator and end of lane stop should be replaced exclusively by trained personnel certified by Interroll Tasks Checks Visual inspection Check the tightening Visual inspection Check that the roller rotates freely Check the tightening of the in serts on the profiles Check the condition and tight ening of the roller ends Gap tolerance max 3 mm of axial clearance Date Work required Inspection no impact no trace of the start of a fracture Re tighten if necessary to 45 Nm Inspection no impact on the tube or the ends Turn the roller Free the roller if necessary or replace it if re quired Raise the roller and check that the insert is held proper ly Re tighten if necessary to 45 Nm Slide the roller from side to side to check the axial clear ance Replace the roller if necessary Cleaning maintenance and repair Performed by 57 Pallet Roller Flow FIFO Component Speed controllers 58 Pallet Flow Roller Flow FIFO Tasks Checks Check the condition and tight ening of the speed controller roller ends Gap tolerance max 3 mm of axial clearance The brake may project past the rollers by 1 6 mm
24. der e Do not attach with drill screws the PLJ connecting plates onto the beams for the moment e Do not tighten the screws between the profile and the PLJ connecting plate The oblong holes allow you to adjust the position of the modules when aligning the lanes Version 3 0 June 2013 EN Translated from French Assembly and installation 23 2 E pe a Z 3 0 June 2013 EN Translated from French Version rding to the floor markings AS RALERALEA 29 FESR FRPP ESP Pee Pe FEE PPE S PSY SPS oa Fay P iH i ff 7 nloading side Install the modules from bottom to top WNE NE AN 7A WA y gt Next insert the intermediate modules to all levels of the test bay Load the mod ules from the front u Pallet Flow Roller Flow FIFO gt Attach the following frames acco Intermediate modules Assembly and installation Installing the long intermediate modules a Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL F03100721 HM10x30 Nut M10 Attach without Attach with tightening tightening Reminder e Do not attach with drill screws the PLJ connecting plates onto the beams for the moment e Do not tighten the screws between the profile and the PLJ connecting plate The oblong holes allow you to adjust the position of the modules when aligning the lanes Assembly and installation 25 Pallet Flow Roller Flow FIFO INTERR
25. ed in a dynamic lane they should be re moved from the storage zone Make sure that the container to be loaded is one of those described in the order confirmation gt Insert the forks of the forklift under the container gt Raise the container gently gt Slowly approach the installation on the loading side gt Align and centre the container correctly in the lane cise zx Bea siina TEV LT I CN TT SESS ot hi a accu ane anne aa gt Position the container at the correct height The container must be aligned and centred in the lane The entry guides are used only for guiding they should not be used as support points to position the container p gt Tilt the forks at 1 towards the forklift Start up and operation 47 48 Pallet Flow Roller Flow FIFO INTERROLL gt Slowly move the forklift forward in the axis of the lane on the loading side until the container is fully engaged in the lane gt In the event of an angle beam it is important to position the container behind the angle beam in order to avoid any damage or blocking gt Carefully place the container in the lane without jarring the container The con tainer must not be placed abruptly The maximum speed of descent of the forks is 0 1 m sec Version 3 0 June 2013 EN Translated from French Start up and operation Pallet Flow Roller Flow FIFO INTERROLL gt As soon as the forks no longer hold the container it star
26. ediately stop all levels of the bay and the neighbouring bays Set up appropriate signage gt In the event of a blocked container remove it and determine the cause of the blockage If the container appears to be defective set it aside from the storage zone gt If the container is blocked repeatedly at a given point inform the company s Maintenance Department so they can take appro priate action gt In order to prevent loads from tipping over provide safety equipment such as grates or nets Before starting up the installation all operations staff must be informed about e The specific use of a dynamic storage installation All the risks inherent in a dynamic storage system such as falling loads moving loads cut offs Version 3 0 June 2013 EN Translated from French Start up and operation 43 Pallet Flow Roller Flow FIFO INTERROLL Checks before the initial start up gt When connecting the storage lanes and other equipment in the warehouse perform a risk analysis of the entire installation gt In order to use the installation in a safe configuration verify the suitability of the width of the rows the height of the installation and the characteristics of the forklifts e g original manufacturer s protections turning radius stability and maximum load compared to the height gt Check that the racks and lanes do not have any visible damage gt Check that there is no foreign material in the worki
27. ees 54 Using a maintenance pallet ccccccccceeccseeeeeeeeeeeeeeseeeeeeeeeeaeeeeseeeeseeeesees 55 List of maintenance and inspection OPEratiONS ccccccccseeceeeeeeeeeeeeeees 56 Troubleshooting In the event of a failure cece cecceceeeeceeeeceeeeseeeeeeee esse eeseeeeseeeessaeeseas 60 THOUIDISSMOO UNG ssent aar E E E 61 Decommissioning and scrapping Waste diSpoSal seeriaid ai aaa T a ia ai D 63 Appendix Identification of kits and spare parts on the Modules cceeceeeeeeeees 64 3 Manual contents Validity of this manual O This manual is an integral part of the product Pallet Flow Roller Flow FIFO INTERROLL About this manual Remarks concerning the use of this manual This manual provides remarks and important information about the various oper ating phases of the Pallet Roller Flow e Transport assembly and start up e Safe operation maintenance troubleshooting waste disposal This manual describes the Pallet Roller Flow as it is delivered by Interroll In the event of an installation involving non standard containers or contents specif ic recommendations specific operations modes and all contractual documents are provided along with this manual e To ensure safe reliable operation and to benefit from the guarantee before us ing the Pallet Roller Flow you must follow the recommendations in this manual and the data in the order confirmation e Keep this manual near
28. ent of the modules is essential for correct lane operations Reference line Version 3 0 June 2013 EN Translated from French Assembly and installation 33 34 gt Pallet Flow Roller Flow FIFO INTERROLL Example of re alignment gt Attach all the PLJ connecting plates linking the modules with drill screws rec ommended torque 8 Nm maximum Stop screwing when the mounting bracket of the PLJ connecting plate is in contact with the beam We recommend the use of an extender to facilitate the passage of the socket un der the screws 10x30 gt Leave 6 mm between modules and tighten the modules to the PLJ connecting plates recommended torque 45 Nm Version 3 0 June 2013 EN Translated from French Assembly and installation Pallet Flow Roller Flow FIFO INTERROLL gt Then attach the other PLJ connecting plates without a splicing function using drill screws gt Tighten the modules to the PLJ connecting plates recommended torque 45 Nm a O 00020009000 00000000 00 oom Version 3 0 June 2013 EN Translated from French Assembly and installation 35 Pallet descent speed Loads do not swerve Pallet Flow Roller Flow FIFO INTERROLL Step 2 Lane test Tests of the lanes in the test bay must be carried out in the presence of the as sembly manager and the operator Comply with the technical data described in the order confirmation The order confirma
29. i JPN Kanagawa 229 1134 Tel 81 42 764 2677 Fax 81 42 764 2678 jpn sales interroll com Korea Interroll Korea Corporation Room 301 Dongsan Bldg 333 60 Shindang Dong Choong Ku Seoul Tel 822 22 31 19 00 Fax 822 22 54 36 83 kr sales interroll com Thailand Interroll DS Asia Pacific Co Ltd Amata Nakorn Industrial Estate 700 685 Moo 1 Tambol Phanthong Aumphur Phanthong Chonburi Thailand 20160 Tel 66 38 447 448 52 Fax 66 38 447 453 54 th sales ds interroll com Australia amp New Zealand Australia Interroll Australia Pty Ltd 8 Villas Road Dandenong South Victoria 3175 Australia Tel 613 9706 44 95 Fax 613 9706 4485 aus sales ds interroll com Also responsible for New Zealand Interoll reserves the right to modify the technical characteristics of all its products at any time Technical in formation dimensions data and characteristics are indicative only
30. ised containers Any other use is considered inappropriate The installation configurations must be applied They are defined in the order con firmation and in this manual All other changes concerning the components and their location in the lane are not authorised To load and unload containers in the lanes a suitable forklift must be used This forklift must meet all the following functions e inclinable upright or forks or not according to the provisions in the order confir mation e upright height adapted to the rack height Comply with the maximum loads recommended by the rack manufacturer and indi cated on the load plate The content must not exceed the maximum load specified by the container supplier or by the standards Unintended use The Pallet Roller Flow may not be used to transport people bulk products or small parts Applications which do not comply with the planned use of the Pallet Roller Flow require prior written approval from Interroll Version 3 0 June 2013 EN Translated from French Safety A Personal injury h Rotating parts Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLE Qualified personnel Qualified personnel are persons who read and understand this manual and tak ing national regulations into account can completely execute incidental work Only qualified and trained personnel may work with the Pallet Roller Flow taking the f
31. k sales ds interroll com Also responsible for Finland Iceland Norway Sweden Western Southern Europe France Interroll SAS Z de Kerannou B P 34 F 29250 Saint Pol de L on Tel 33 2 98 24 41 00 Fax 33 2 98 24 41 02 fr sales interroll com Italy Interroll Italia S R L Viale della Repubblica 28 20010 Cornaredo Mi Tel 39 229 3560442 Fax 39 229 356017 it sales interroll com Spain amp Portugal Interroll Espa a S A Parc Tecnologic del Valles C Dels Argenters 5 Edificio 1 m dulos Bp y Cp E 08290 Cerdanyola del Vall s Tel 34 90 210 2587 Fax 34 93 586 4895 e sales interroll com United Kingdom Interroll Ltd Sales Office Dynamic Storage Brunel Road Earlstrees Industrial Estate GB Corby Northants NN17 4UX Tel 44 1536 74 85 65 Fax 44 1536 74 85 74 gb sales ds interroll com Version 3 0 June 2013 EN Translated from French Central Europe Germany Interroll Fordertechnik GmbH Hoferhof 16 D 42929 Wermelskirchen Tel 49 2193 2 31 36 Fax 49 2193 2 31 22 d sales interroll com Also responsible for Austria Belgium Luxembourg Netherlands Switzerland Eastern Europe Germany Interroll Fordertechnik GmbH Hoferhof 16 D 42929 Wermelskirchen Tel 49 2193 2 31 81 Fax 49 2193 2 31 22 d sales interroll com Also responsible for Hungary Slovakia Czech Republic Russia Poland Interroll Polska Sp z 0 0 ul Plochocinska 8503 044 Warszawa Tel 48 22 741 741
32. lation and with safety instructions The manager of the team responsible for assembling the lanes must be techni cally competent and trained concerning the following e The products and their use e The dangers inherent in the assembly of heavy or cumbersome components in high places e The risks related to incorrect assembly e Uncontrolled speeds or propulsion of loads stored on the lane may may cause serious accidents e The adjustments required for correct operation of the lanes Interroll can provide dedicated training on the Pallet Roller Flow We will send a quote on request gt Comply with the rack specifications gt If other systems interface with the Pallet Roller Flow use the same reference point as the other systems to level the frames gt Check the stability of the modules on the containers before cutting the bands gt Recommended torque for modules on connecting plates 45 Nm gt Always start assembly from the loading site p gt Make sure you do not damage the modules nor the other components during assembly Pay particular attention to the speed controllers the separator and the end stop gt It is recommended to install a floor stop in front of both the loading and unload ing sides The stop is used to halt the forklift and thus prevent any contact with the rack gt Contact Interroll before attaching or hanging any equipment such as sprin klers in the area surrounding the dynamic storage in
33. ly maintenance personnel is authorised to enter the lanes and only in com pliance with current safety standards Safety 7 Pallet Flow Roller Flow FIFO INTERROLL Product information Product description The Pallet Roller Flow is a dynamic storage system for heavy loads It ensures the controlled descent of pallets Speed controllers control the descent of loads at a constant speed On the unloading site the separator isolates the pallet from the pressure of the accumulated line of pallets Components Separator flap Side profile Handling rollers Separator stop Speed controller Cross tie Pallet guide Loading plate Loading module 10 Module riser 11 Intermediate module 12 Unloading module 13 Lane end stop 14 Time plus retarder Version 3 0 June 2013 Product information EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Technical characteristics of the Pallet Roller Flow FIFO Gravity based system Load 60 to 1250 kg per pallet Regulated speed 0 3 m sec from 60 to 1250 kg Maximum instantaneous speed 0 6m sec from loading to separation Maximum deceleration 1 m sec Slope Specified in the order confirmation Generally recommended slope 4 Types of pallets handled by the Standardised EUR EPAL pallet 800 Interroll system mm x 1200 mm W X D see Intended use page 6 Standardised EUR EPAL pallet 1000 mm x 1200 mm W X D Standardised GKN CHEP pallet 1000 mm x 1200
34. m gt Position yourself opposite the lane using a boom or lifting de vice p gt Attach yourself to the rack using the safety harness gt Climb onto the maintenance pallet and sit down in it gt With the assistance from the second operator in the boom in stall the system for attaching the hoist ahead of the lane to the rollers on the rack gt Install the attachment system on the side of the pallet gt Unlock the pallet and control its descent to the location requir ing maintenance Readjust the safety harness gt When you reach the location requiring maintenance lock the pallet to the profile and attach yourself to the rack using the safety harness gt Perform the maintenance gt When finished unlock the pallet and let it descend gt Position the boom lift opposite gt Remove the safety harness from the rack gt Move out of the maintenance pallet and into the boom lift gt Use a forklift to remove the maintenance pallet like any other pallet List of maintenance and inspection operations Version 3 0 June 2013 Cleaning maintenance and repair Eni caine laiearerena sah Pallet Roller Flow FIFO Component Loading plate Roller Version 3 0 June 2013 EN Translated from French O Pallet Flow Roller Flow FIFO INTERROLL In order to keep the installation in perfect operational condition you must system atically replace any damaged components Maintain a log of the
35. mation about how to avoid damage Additional symbols This symbol displays safety instructions This symbol marks useful and important information This symbol marks the steps that have to be carried out About this manual 5 Pallet Flow Roller Flow FIFO INTERROLLE Safety General safety instructions The Pallet Roller Flow is designed according to the technical state of the art However certain risks may still arise e Risks of physical injury or death to the user or bystanders e Damage caused to the Pallet Roller Flow or to other material Disregarding the warnings in this manual may lead to serious injury or even death gt Always read this manual carefully and make sure you follow the safety instruc tions gt Only qualified and specially trained personnel may work with the Pallet Roller Flow gt Always keep this manual at hand and make it accessible to all personnel gt Always comply with the relevant national safety regulations in your company gt Contact Interroll Customer Service if you have any questions after reading this manual The last page lists the details of the person to contact in your country Intended use The Pallet Roller Flow is reserved exclusively for industrial use in suitable envi ronments The installed lanes are intended for dynamic gravity based storage only of foreseen and previously approved isolated loads They are reserved ex clusively for storing referenced or standard
36. mm W X D Other containers please contact Interroll EUR EPAL EUR EPAL GKN CHEP 800x1200 MM I000x1200 MM I000x1200 MM EL 850 EL 1050 EL 1050 Forklifts Specified in the order confirmation Atmospheric conditions Ambient tem during 30 C to 40 C perature operation during assembly 30 C to 40 C for transportation 30 C to 80 C and storage Humidity Up to max 90 without condensation Version 3 0 June 2013 EN Translated from French Product information 9 Pallet Flow Roller Flow FIFO INTERROLL Environment The Pallet Roller Flow is not suitable for use in an environment presenting the following risks Oxidisation either atmospheric or via chemical attacks Projection Decomposition Vibration Explosion Radioactive radiation Electromagnetic radiation Exceptions are possible please contact Interroll Load contents The contents of the loads and their containers must not e Oxidise e Corrode e Decompose e Block the lane s components e Pollute steel or plastic components e Prevent correct operation of any mechanisms The Pallet Roller Flow must not be used in direct contact with food products 10 Product information Version 3 0 June 2013 EN Translated from French Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Transportation and storage Transportation gt Only qualified and authorised personnel should transp
37. mpliant with the OCTD Replace it if necessary Comply with the unloading proce dures see Unloading a container page 50 Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLLE Decommissioning and scrapping Waste disposal Recommendation for As far as possible the packaging should be disposed of in an environmentally protecting the environment friendly way Interroll can provide the component contents type and quantity upon request The speed control rollers contain lead The rollers and speed controllers contain plastic gt For all maintenance work and when disposing of equipment please comply with environmental standards and use appropriate disposal methods gt In the event of cleaning with substances which may harm the environment store those substances in suitable containers which may be handled Close and dispose of them using appropriate methods Comply with the warnings on the packaging of harmful substances Version 3 0 June 2013 D ae ee d 63 EN Translated from French ee ta a ial Pallet Flow Roller Flow FIFO y INTERROLL Appendix Identification of kits and spare parts on the modules Spare parts ere ols ie EMG SlOD E AS AQ6111621 AS A03101520 FL 850 10 FL 110 130 7 210 mm 50 mm Roller J60x15 Zn amp Ac Roller
38. ng area gt Check that all signage is in place load capacity plate restrictions for use Forklift requirements The forklifts are described in the order confirmation The forks The forks must be suitable for the depth of the container Recommended length from 1150 mm to 1200 mm e The fork spacing changes according to the type of pallet used so as to carry the loads in a stable manner without damaging the container Lifting height The maximum lifting height of the forklift should enable risk free loading and un loading at all levels of the installation Technical characteristics The forklift s technical characteristics must be suitable for the containers to be stored as well as for the height of the loading and unloading zones Version 3 0 June 2013 44 Start up and operation EN Translated from French Recommended equipment Operating principle of the separator Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Loading and unloading methods It is recommended to use forklifts with the following equipment e A angle measuring system in order to accurately adjust the forks e A vertical or dual vertical and horizontal indexing system if two pallets must be front loaded at the same time e An embedded camera system for the forks e Visual markers The separator comprises two components 1 Separator flap 2 Separator stop regular heavy or double front
39. nspection operations page 56 Damaged roller see List of mainte nance and inspection operations page 56 Lane alignment incorrect if the pallet is in contact with the rack see Rack assembly page 14 Damaged rack see the rack mainte nance procedure Damaged speed control roller see List of maintenance and inspection operations page 56 Pallet load greater than the OCTD Pallet characteristics not compliant with OCTD type dimensions mois ture content weight and stored load Troubleshooting Correction Remove the pallet from operation Remove the pallet from operation Remove the foreign particles Recondition the pallet Replace it if necessary Replace the roller if necessary Correct the alignment if necessary Replace the rack if necessary Replace the speed controller if neces sary Ensure the load is compliant with the OCTD Remove the pallet from operation 61 Failure No separation between pallets 62 Pallet Flow Roller Flow FIFO Cause Damaged speed control rollers before and or after the separator stop see List of maintenance and inspection operations page 56 Weight ratio between the lightest and heaviest pallet non complaint with the OCTD Damaged separator see List of maintenance and inspection opera tions page 56 Incorrect handling Troubleshooting INTERROLL Correction Replace them if necessary Ensure the load ratio is co
40. ollowing into account e The relevant manuals and diagrams e The warnings and safety instructions in this manual e The system specific regulations and requirements see Assembly and installa tion page 12 e National or local regulations and requirements for safety and accident preven tion Risks The following list informs you about the various types of dangers or damage that may occur when installing or working with the Pallet Roller Flow gt The equipment may be used by qualified personnel only in any of its operations modes gt Comply with the technical data provided in the order confirmation gt Follow the assembly and operating instructions gt Use suitable forklifts only gt Check the installation and perform maintenance on a regular basis gt Make sure that no one walks or stands underneath loads or in the loading or unloading zones of the dynamic storage lane Take all necessary precautions to prevent the presence of personnel within the lanes gt Make sure that the loading unloading rows include sufficient lighting so as not to hinder handling operations Risk of injury do not walk on the side profiles of the modules or on the rollers with out using a safety harness gt Wear suitable work clothes and Personal Protection Equipment safety shoes gloves etc gt Tie up long hair or wear a cap gt Remove jewellery such as necklaces or bracelets gt Do not walk on the rollers gt On
41. orks must not hit the rollers Closed beam ae cso0eOsc0cceG000 e098 coooooooooo0c 0000008 yoo000000 Version 3 0 June 2013 Start up and operation EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Angle beam TR unloading mode Lift the container Thanks to the Time Plus function the separator flap remains in the low position for 5 to 30 seconds depending on the settings In case of a picking error the Time Plus function even enables the container to be replaced in the lane as long as the separator stop is not locked gt If the top of the container touches the bottom of the upper beam reposition the forks horizontally or adjust their height Version 3 0 June 2013 EN Translated from French Start up and operation 51 Pallet Flow Roller Flow FIFO STL unloading mode Unloading uses the same method as for TR unloading but without inclining the forks as these descend between the tracks STP unloading mode Enter the forklift between the protections Lift the container Thanks to the Time Plus function the separator flap remains in the low position for 5 to 30 seconds depending on the settings J In case of a picking error the Time Plus function even enables the container to be replaced in the lane as long as the separator stop is not locked Version 3 0 June 2013 EN Translated from French 52 Start up and operation Pallet Flow Roller Flow FIFO
42. ort the equipment gt Use slings or appropriate lifting equipment to transport the equipment gt If the content is unstable unload the container unit by unit and not by truck gt The weight of each pallet is indicated on it If using a forklift with a different lifting capacity handle the module pallets one by one Storage gt Store equipment indoors gt Never store the equipment outdoors or in a dusty or humid environment gt Respect the ambient conditions see Technical characteristics of the Pallet Roller Flow FIFO page 9 gt Do not add additional loads to the pallets and boxes containing the Pallet Roller Flow and its components Transportation and storage 11 Pallet Flow Roller Flow FIFO INTERROLLE Assembly and installation Warnings concerning assembly Warning Risk of injury in case of incorrect assembly gt As the Pallet Roller Flow is the subsystem of the overall instal lation you need to perform a risk analysis of the entire installa tion gt Identify the protective measures required concerning risks re lated to the local conditions at the site and to usage gt Define a safety zone in the working area gt Secure the zone and set up proper signalling and appropriate protection gt For assembling modules on the rack refer to the safety rules concerning working at height gt Never climb on the rollers nor on the lane profiles without a safety harness gt During assem
43. r the test As the rack is perpendicular you do not need to align the frames with the floor markings It is recommended to assemble the modules from bottom to top gt Insert the unloading modules on all levels Step 3 Version 3 0 June 2013 EN Translated from French gt Align the modules and attach the lanes to the rack Assembly and installation 42 Pallet Flow Roller Flow FIFO INTERROLL Start up and operation Warnings concerning operations Warning Risk of injury in case of improper handling gt Insert the containers in the lane on the loading side only gt Do not insert containers in the lane if they do not enter com pletely into it gt If a container sticks out of the lane remove it immediately gt Do not load a container if pressure is required to insert it Notice Damage in case of improper handling Note the following remarks gt Load carefully so as not to damage the lane or the products stored in it gt Never touch the rollers tracks or the rack with the forks of the forklift gt Never insert or reinsert a container on the unloading side gt In the event of a malfunction or if you see any signs of damage immediately stop the lane and set up appropriate signage gt For any damage due to impact on a rack or on the roller chas sis Immediately inform the company s Maintenance Depart ment gt If you find nuts screws or other components on the floor im m
44. ranslated from French Pallet Flow Roller Flow FIFO al E E pe z Regular TR separator WU 090l 058 7 Coa TULL Ss V UEWUOD J3 O0 CVEGWIGl a SV epod CLOLLOCLY SV JOWI 884 by COLEOS Ula SV pol Jaq PO gy WW OSOL 0S8 13 EL6L6OELD SY puewwoy WW OSOL 058 13 LSLL7OLLD SY dols JojeJedas Ww OSOL 058 73 TLOL60EL9 SV eee le Version 3 0 June 2013 JOJA GIS Je nies EN Translated from French Appendix 66 Pallet Flow Roller Flow FIFO al E E p Z Heavy TR separator WU OSOL 098 5 14 CO TOLD SY OL6ZOLELD SV WW OSL OL Pd WW OSOL 058 73 ZLLOOLELO SV yoiedsiq WW 9SL 70L Y gt 4id WW OSOL 058 73 CLCEQOLELD SV WW YOL Yid Ww 0S0 SL9L60 LD SY 33e a gnog WU 9S yid WW 0S0 js ZLOELOZLO SV 322 ajqnoq
45. roller The holes in the angle beam allow the unloading module to be centred au unloading module TR G tomatically FO3100721 HM10x30 Nut M10 HM10x30 Locknut M10 Washer 810 SA Q x Attach without tightening Version 3 0 June 2013 EN Translated from French Assembly and installation 31 Pallet Flow Roller Flow FIFO INTERROLL Floor unloading unloading module STP pallet truck Track with speed controller ytermediate module for STP Floor mounting feet to be attached to the floor Track with separator Protection to be fixed to the floor gt Centre the module between the frame uprights maintaining the distance be tween the 2 unloading tracks If the lane is installed on risers without a rack refer to the floor markings to define the alignment of the tracks compared to the lane h a OO W En E m A a A ee The floor mounting feet must all be level to ensure correct system operations A Adjust the feet if necessary to maintain a slope of 4 Refer to the assembly diagrams provided in the appendix for details of STP lane assembly Version 3 0 June 2013 32 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Check the diagonals Check that the module s two diagonals are equal Measure the diagonals from one axis to another of the holes located at each end of the profiles Lane alignment A perfect alignm
46. rovided in the order confirmation e Maintenance procedures of the various products dynamic lanes racks envi ronment e g sprinklers gt Define a safety zone around the working area gt The safety zone includes the entire height of the bay as well as the two adjacent bays gt Secure the zone and set up appropriate signage nets etc gt Remove everything from the lane involved in the intervention before starting gt Make sure that the area of intervention has sufficient lighting gt At the end of the intervention make a visual inspection of the repaired section to ensure that you did not leave any foreign materials or tools which may alter the correct operation of the installation gt Before restarting the system check the integrity of the lane the rack and its en vironment e g sprinklers Version 3 0 June 2013 Cleaning maintenance and repair Eni caine laiearerena sah Pallet Flow Roller Flow FIFO INTERROLL Maintenance equipment Lane maintenance can be performed using the following equipment e Platform with a rotary barrier e Maintenance pallet Platform The platform may be used for maintenance from the rows on either the loading or unloading side Use a safety harness and always attach yourself before mov ing Maintenance pallet The maintenance pallet allows you to e Work at a fixed position on a lane by locking the pallet on the profiles or uprights e Carry tools and components
47. ssembly diagram in the appendix gt On the loading side insert all the loading modules for the test bay on the rack way X SZ A AS _ SK i av lt t 7 2 7 Align and attaching the first module gt Align the first module on the loading side in relation to the pallet descent axis gt Check that both distances a between the rack uprights and the profiles are equal Version 3 0 June 2013 EN Translated from French Assembly and installation Pallet Flow Roller Flow FIFO INTERROLL Tubular beam traverse roller Centre the fixing bracket on the beam then attach the bracket with 2 drill loading module TR screws F04030720 F03100721 HM10x30 Nut M10 Screw 6 3x19 oo x2 0009900 0080000000 0090009009 eooo0d 56 9e000000000090009 oocoooo0o0000000000000000000 FRE ooooococo0o0oo0o0o000000002 2 Attach without tightening Attach without tightening gt Depending on the corridor configuration it is possible that the module splice plates are to be used for the entire corridor at each module connection F03102722 HM10x30 Nut M10 Version 3 0 June 2013 EN Translated from French 20 Assembly and installation Pallet Flow Roller Flow FIFO INTERROLL Tubular beam 3 track loading Centre the 3TL fixing bracket 8 oblong holes on the beam then attach the 3TL module bracket with 2 drill screws The space between the tracks is determined by this bracket
48. stallation gt Clean the work site at the end of the installation Do not leave components or tools in the installation area or its surroundings gt Test the lanes before use Version 3 0 June 2013 EN Translated from French Assembly and installation 13 Pallet Flow Roller Flow FIFO INTERROLL Rack assembly The rack must be attached to the floor according to the rack manufacturer s spec ifications The module risers provided by Interroll must be attached according to the floor specifications The beams must be perpendicular to the supporting frames The beams must be aligned and must have a constant slope from loading to un loading The slope matches the slope of the lane Adjusting the slope The roller modules are installed with a slope of 4 unless indicated in the mas ter diagram gt Ensure each type of beam is correctly located according to the overall rack di agram Version 3 0 June 2013 14 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Positioning the module The space between the lane and the rack upright must be uniformly spread A onthe rack minimum value of 35 mm is recommended A minimum space of 100 mm is recommended between the container and the rack upright o o o o oO o oO a Single lane a The space between the lane and the rack upright min 35 mm Dual lane a The space between the lane and the rack upright
49. stributed on their container gt Check that the loads are held correctly on their container when the container stops against the separator stop and or the end stop Operations reports must be prepared for the lanes and for validation of the installation The end user must sign these reports Send a copy of the report to Interroll Refer to the example of an operations report page 38 The operations report validates the guarantee Without the operations report Interroll cannot guarantee the installation Assembly and installation 37 Pallet Flow Roller Flow FIFO INTERROLLE Operations report Pallet Roller Flow FIFO The operations report validates the guarantee for the dynamic storage lanes provided by Interroll A copy of this report countersigned by the assembly manager the operator or rack manufacturer must be sent to Interroll within a maximum of 4 weeks after delivery of the equipment Interroll SAS Service clients 310 rue du Clair Bocage BP255 Mouilleron le Captif F 85006 La Roche sur Yon Cedex dynamicstorage interroll com Tests must be carried out in presence of the assembly manager the operator or the rack manufacturer Comply with the data described in the conditions initially set out in the contract maximum and minimum loads loading and unloading modes containers The 5 tests described below must all be validated for the guarantee to be in effect Follow the instructions for lane tests described in the
50. t Only loosen the link between the PLJ connecting plate and the module gt Identify the position where the swerving occurs gt Loosen the screws connecting the PLJ connecting plates to the module on the opposite side from the swerving gt Loosen the cross ties to align the modules gt Bring the profiles of the two consecutive modules closer together by 1 or 2mm Version 3 0 June 2013 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL mi J g 3 lao o i oe ee eee D g a EA EE EELE z z I F ee SS SS LL Le e a 2 Maiggahniga a amp a ee Ce Swerving Correction gt Re tighten the modules on the PLJ connecting plates gt Re tighten the cross ties gt Retest the lane see Step 2 Lane test page 36 Eliminating pallet blockage Check the slope is the recommended 4 If the slope is correct see Troubleshooting page 60 When all the tests have been validated proceed to the assembly of the remaining a lanes Version 3 0 June 2013 EN Translated from French Assembly and installation 41 al E E p Z i WN Wy SY OANA Wy GU Sf ONS NNW ANE fe fi P 1 afi io hs ar at i if wks j i F y a r i iy UUN BNL v i r f ay DU oe Fe kh oo a YW iff OBZ Lane assembly Pallet Flow Roller Flow FIFO gt To assembly the following lanes follow the assembly method used fo
51. tion provides the following data e Loads maxi mini mixed e Loading unloading mode e Containers Check the following e Correct adjustment of the gravity descent speed for loads e Loads do not swerve e Loads restart correctly e The separator works correctly e Loads are held correctly on their support e The end stop works correctly gt Load the lightest pallet defined in the order confirmation gt Check that the load descends correctly without swerving or stopping gt Repeat the operation with the maximum load hr a e e e e e le ile e e e e e e e e e e e e e e e e e e e e e rt e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e Version 3 0 June 2013 Assembly and installation EN Translated from French Loads restart correctly The separator works correctly Loads are held correctly on their container Operations reports as Version 3 0 June 2013 EN Translated from French Pallet Flow Roller Flow FIFO INTERROLLE gt Unload the container from the front gt Check that the following containers restart correctly For a description of the separator operation see page 45 gt Before loading the lane check that nothing restrains the movement of the sep arator flap rod end stop To prevent loads from falling due to sliding or tipping over they must be stable and evenly di
52. ts to move down the lane and frees the forks Reposition the forks horizontally before reversing gt If the container is stopped because the lane is full keep the slope and adjust the height of the forks while withdrawing them gt Gently remove the forklift from the lane while keeping the alignment inm B 2s ine LV A MO N E T T ENT H Tn STL loading mode Loading uses the same method as for TR loading but without inclining the forks as these descend between the tracks Version 3 0 June 2013 EN Translated from French Start up and operation 49 50 Unloading a container Pallet Flow Roller Flow FIFO INTERROLL Warning Risk of injury in case of improper handling gt Remove the containers using only the forklift described in the order confirmation p gt Never remove containers by hand picking Notice Damage in case of improper handling gt Unload carefully so as not to damage the lane or the products stored in it gt Never touch the rollers tracks or the rack with the forks of the forklift gt Never insert or reinsert a container on the unloading side gt Advance the forklift gently on the unloading side of the installation keep it cen tred and in the axis of the lane i a as yy ooh eI HRN W A I Pi Lot gt Position the forks at the correct height Ensure that the thickness of the forks is compatible with the height of passage X The extremity of the f
53. user manual page 36 Compliant 1 Pallet descent speed L 2 Loads do not swerve L 3 Loads restart correctly L 4 The separator works correctly L 5 Loads are held correctly on their support L N OF _ _ Fill in the OF number indicated on the labels attached to the module pallets re Assembly manager The operator or rack manufacturer Surname First name Surname First name Company Company Date Date Signature Signature Version 3 0 June 2013 Assembly and installation EN Translated from French Pallet Flow Roller Flow FIFO INTERROLL Avoiding swerving or Finding the causes of the problem blockage of a container Check that the rack is correctly assembled see Rack assembly page 14 gt Check that the beams are in contact with the modules Eliminating pallet blockage gt Check the slope General recommendation is 4 or other slope specified in the order confirmation gt Check that all the beams are in contact with the modules gt If the slope is correct see Troubleshooting page 60 Version 3 0 June 2013 EN Translated from French Assembly and installation 39 40 Pallet Flow Roller Flow FIFO INTERROLL Eliminating swerving If the rack assembly is correct you can correct swerving by modifying the 6 mm clearance between the modules Warning Risk of injury due to the module tipping gt Never loosen the connection between the PLJ connecting plate and the beam g

User manual Interroll Pallet Roller Flow FIFO

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