I N S P I R E D B Y
E F F I C I E N C Y

User manual
Interroll Pallet Roller Flow FIFOPF 1100

Version 3.1 (September 2014)
EN - Translated from French

Manufacturer
Interroll Dynamic Storage
310, rue du Clair Bocage
Zone d'Activité Beaupuy 2
85000 Mouilleron le Captif
FranceTel. +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 inpart, nor used for any other purpose than the installation referred to in this manual, without theprior written consent of Interroll.

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Pallet Roller Flow FIFO

Contents
About this manual
Remarks concerning the use of this manual................................................ 4
Warnings in this document........................................................................... 5
Additional symbols ....................................................................................... 5
SafetyGeneral safety instructions .......................................................................... 6
Intended use ................................................................................................ 6
Unintended use............................................................................................ 6
Qualified personnel ...................................................................................... 7
Risks ............................................................................................................ 7
Product information
Product description ...................................................................................... 8
Components................................................................................................. 8
Technical characteristics of the Pallet Roller Flow FIFO ............................. 9
Transportation and storage
Transportation............................................................................................ 11
Storage ...................................................................................................... 11
Assembly and installation
Warnings concerning assembly ................................................................. 12
Assembly rules........................................................................................... 13
Lane assembly........................................................................................... 16
Step 1 - Assembly of the test bay .............................................................. 16
Step 2 – Lane test...................................................................................... 36
Step 3 - Lane assembly ............................................................................. 42
Start-up and operation
Warnings concerning operations ............................................................... 43
Checks before the initial start-up ............................................................... 44
Forklift requirements .................................................................................. 44
Loading and unloading methods................................................................ 45
Operation ................................................................................................... 46
What to do in case of an accident or failure............................................... 53
Cleaning, maintenance and repair
Cleaning..................................................................................................... 54
Remark in case of maintenance and repair ............................................... 54
Using a maintenance pallet........................................................................ 56
List of maintenance and inspection operations.......................................... 57
Troubleshooting
In the event of a failure .............................................................................. 60
Troubleshooting ......................................................................................... 61
Decommissioning and scrapping
Waste disposal........................................................................................... 63
Appendix
Identification of kits and spare parts on the modules................................. 64

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About this manual
Remarks concerning the use of this manual
Manual contents

Validity of this manualThis manual provides remarks and important information about the various operating phases of the Pallet Roller Flow:• Transport, assembly and start-up• 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, specific recommendations, specific operations modes and all contractual documents areprovided along with this manual.

This manual is an integral partof the product4• To ensure safe, reliable operation and to benefit from the guarantee, before using the Pallet Roller Flow you must follow the recommendations in this manualand the data in the order confirmation.
• Keep this manual near the Pallet Roller Flow.
• 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 thismanual. The last page lists the details of the person to contact in your country.

About this manual

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Pallet Roller Flow FIFO

Warnings in this document
The warnings in this document concern dangers which may arise while using thePallet 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:• Danger• Warning• Caution
Key word

Meaning

DangerIndicates 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.

CautionIndicates a hazardous situation, which, if not avoided, may
result in a minor or moderate injury.

Structure of warnings

DangerNature and source of hazard
Possible consequences of non-observance.
► Information about how to avoid the hazard.

NoticeThis symbol identifies possible material damage.
► Information about how to avoid damage.

Additional symbols
This symbol displays safety instructions.
This symbol marks useful and important information.
►

Version 3.1 (September 2014)
EN - Translated from FrenchThis symbol marks the steps that have to be carried out.

About this manual5Pallet Roller Flow FIFO

SafetyGeneral safety instructions
The Pallet Roller Flow is designed according to the technical state of the art.
However, certain risks may still arise.
• Risks of physical injury or death to the user or bystanders• 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.
► Always read this manual carefully and make sure you follow the safety instruc-tions.
► Only qualified and specially trained personnel may work with thePallet Roller Flow .
► Always keep this manual at hand and make it accessible to all personnel.
► Always comply with the relevant national safety regulations in your company.
► Contact Interroll Customer Service if you have any questions after reading thismanual. 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 environments. The installed lanes are intended for dynamic (gravity-based) storage
only of foreseen and previously approved isolated loads. They are reserved exclusively for storing referenced or standardised containers.
Any other use is considered inappropriate.
The installation configurations must be applied. They are defined in the order confirmation and in this manual. All other changes concerning the components andtheir 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:• inclinable upright or forks or not according to the provisions in the order confirmation• upright height adapted to the rack height
Comply with the maximum loads recommended by the rack manufacturer and indicated 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 Flowrequire prior written approval from Interroll.

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Pallet Roller Flow FIFO

Qualified personnel
Qualified personnel are persons who read and understand this manual, and taking national regulations into account, can completely execute incidental work.
Only qualified and trained personnel may work with the Pallet Roller Flow taking
the following into account :• The relevant manuals and diagrams• The warnings and safety instructions in this manual• The system specific regulations and requirements, see "Assembly and installation", page 12• National or local regulations and requirements for safety and accident prevention

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.

Personal injury► The equipment may be used by qualified personnel only, in any of its operations

modes.
► Comply with the technical data provided in the order confirmation.
► Follow the assembly and operating instructions.
► Use suitable forklifts only.
► Check the installation and perform maintenance on a regular basis.
► 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.
► 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 without using a safety harness.

Rotating parts► Wear suitable work clothes and Personal Protection Equipment (safety shoes,

gloves, etc.)► Tie up long hair or wear a cap.
► Remove jewellery such as necklaces or bracelets.
► Do not walk on the rollers.
► Only maintenance personnel is authorised to enter the lanes, and only in compliance with current safety standards.

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Safety7

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Product information
Product description
The Pallet Roller Flow is a dynamic storage system for heavy loads. It ensuresthe 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 theaccumulated line of pallets.

Components(1) Separator flap
(2) Side profile(3) Handling rollers(4) Separator stop(5) Speed controller(6) Cross-tie(7) Pallet guide(8) Loading plate(9) Loading module(10) Module riser(11) Intermediate module(12) Unloading module(13) Lane end stop(14) "Time plus" retarder

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Product information

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Pallet Roller Flow FIFO

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.2

SlopeSpecified in the order confirmation
Generally recommended slope: 4 %Types of pallets handled by theInterroll system• Standardised EUR EPAL pallet 800
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 mm (W X D)
• The loads must be stable anduniformly distributed over theircontainer.
• Other containers: please contact
Interroll.

Forklifts

Specified in the order confirmation

Atmospheric conditions
Ambient temperatureduringoperation-30 °C to +45 °C

during assembly-30 °C to +45 °C

for transportationand storage- 30 °C to +80 °C

Humidity

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Up to max. 90%, without condensation

Product information

9Pallet Roller Flow FIFO

Environment

Load contents

10

The Pallet Roller Flow is not suitable for use in anenvironment 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.

The contents of the loads and their containers must not:• Oxidise• Corrode• Decompose• Block the lane's components• Pollute steel or plastic components• Prevent correct operation of any mechanisms
The Pallet Roller Flow must not be used in direct contact with food products.

Product information

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Transportation and storage
Transportation► Only qualified and authorised personnel should transport the equipment.
► Use slings or appropriate lifting equipment to transport the equipment.
► If the content is unstable, unload the container unit by unit and not by truck.
► 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► Store equipment indoors.
► Never store the equipment outdoors, or in a dusty or humid environment.
► Respect the ambient conditions, see "Technical characteristics of the Pallet

Roller Flow FIFO", page 9.
► Do not add additional loads to the pallets and boxes containing thePallet Roller Flow and its components.

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Transportation and storage

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Pallet Roller Flow FIFO

Assembly and installation
Warnings concerning assembly

Warning
Risk of injury in case of incorrect assembly► As the Pallet Roller Flow is the subsystem of the overall installation, you need to perform a risk analysis of the entire installation.
► Identify the protective measures required concerning risks related to the local conditions at the site and to usage.
► Define a safety zone in the working area.
► Secure the zone and set up proper signalling and appropriate
protection.
► For assembling modules on the rack, refer to the safety rules
concerning working at height.
► Never climb on the rollers nor on the lane profiles without asafety harness.
► During assembly, wear appropriate Personal Protective Equipment (gloves, safety shoes, safety harness, helmet, etc.).

12

Assembly and installation

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Assembly rules
There are several methods for assembling the Pallet Roller Flow. Adapt the assembly 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 aredelivered in compliance with the technical data indicated in the order confirmation.
The delivery of Pallet Roller Flow lanes comprises pre-assembled roller chassis
and accessories. These components must be assembled, installed and positioned on a rack or on module risers.
If any changes are made to the components or their location in the lanes, thenInterroll 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.

Qualified personnel

The assembly and installation must be carried out by qualified personnel in compliance with the instructions concerning assembly and installation, and with safety
instructions,
The manager of the team responsible for assembling the lanes must be technically competent and trained concerning the following:• The products and their use• The dangers inherent in the assembly of heavy or cumbersome components inhigh places.
• The risks related to incorrect assembly• Uncontrolled speeds or propulsion of loads stored on the lane may may cause
serious accidents.
• The adjustments required for correct operation of the lanes.
Interroll can provide dedicated training on the Pallet Roller Flow. We will send aquote on request.

General rules► Comply with the rack specifications.
► If other systems interface with the Pallet Roller Flow, use the same reference

point as the other systems to level the frames.
► Check the stability of the modules on the containers before cutting the bands.
► Recommended torque for modules on connecting plates: 45 Nm.
► Always start assembly from the loading site.
► Make sure you do not damage the modules nor the other components duringassembly. Pay particular attention to the speed controllers, the separator andthe end stop.
► It is recommended to install a floor stop in front of both the loading and unloading sides. The stop is used to halt the forklift and thus prevent any contact withthe rack.
► Contact Interroll before attaching or hanging any equipment (such as sprinklers) in the area surrounding the dynamic storage installation.
► Clean the work site at the end of the installation. Do not leave components ortools in the installation area or its surroundings.
► Test the lanes before use.

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Pallet Roller Flow FIFO

Rack assembly

The rack must be attached to the floor according to the rack manufacturer's specifications.
The module risers, provided by Interroll, must be attached according to the floor
specifications.
The beams must be perpendicular to the supporting frames.

Beam perpendicular to the supporting frames (top view)

The beams must be horizontal.

The beams must be aligned and must have a constant slope from loading to unloading. 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.
► Ensure each type of beam is correctly located according to the overall rack diagram.

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Assembly and installation

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Pallet Roller Flow FIFO

Positioning the moduleon the rack

The space between the lane and the rack upright must be uniformly spread. A
minimum value of 35 mm is recommended.
A minimum space of 100 mm is recommended between the container and therack upright.

Single lanea : The space between the lane and the rack upright: min. 35 mm

Dual lanea : The space between the lane and the rack upright (a) is half the distance(2a) between the lanes

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Assembly and installation15

Pallet Roller Flow FIFO

Lane assembly
Identifying the components

The attached diagrams show the composition of the Pallet Roller Flow lane. The
diagrams are included in an envelope inside the spare parts box.
► Identify each component by referring to the diagrams. This is especially important when you must assemble different types of lanes.
► Check that all the parts required and indicated for the assembly are available.
If anything is missing, you must inform Interroll within 8 days.

Checking the rack

► Check that the rack is installed according to instructions, see "Rack assembly",

page 14.
► 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.
► Start by defining the location of the dynamic storage block by referring to themaster diagram.
► If necessary, remove the module pallets from the assembly area.
► Sweep the zone and secure the work area.
► Mark on the floor the grid which will enable you to position each of the frame

uprights.
► Using a laser or site laser level, define the aligning heights for each frame upright.
The rack uprights must all be level to ensure correct system operations. In the eventof incorrect rack installation, Interroll shall not be held responsible for any operating
malfunctions.

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Assembly and installation

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Pallet Roller Flow FIFO

Rack

► Start by installing the front row of frames, on the loading side. Align the rackaccording to the floor markings on the front and sides► 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 uprights vertical.

Vertical ±0.25%

Horizontal ±0.25%

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Assembly and installation17

Pallet Roller Flow FIFO

► 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 orangle beam)

Tubular beam

Angle beam

The beams must be aligned and must have a constant slope from loading to unloading. The slope matches the slope of the lane (4% = rise of 50 mm every 1250mm).

► Drill then fasten the uprights to the floor.

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Assembly and installation

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Loading modules

For installation of the Pallet Roller Flow lanes, see the assembly diagram in
the appendix.
► On the loading side, insert all the loading modules for the test bay on the rack.

Align and attaching the first module► Align the first module on the loading side in relation to the pallet descent axis.
► Check that both distances (a) between the rack uprights and the profiles areequal.

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Pallet Roller Flow FIFO

Tubular beam - traverse roller
loading module (TR)► Centre the fixing bracket on the beam then attach the bracket with 2 drill

screws.

Attach without tightening

Attach without tightening► 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.

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Assembly and installation

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Pallet Roller Flow FIFO

Tubular beam - 3 track loading(3TL) module► Centre the 3TL fixing bracket (8 oblong holes) on the beam then attach thebracket with 2 drill screws. The space between the tracks is determined by thisbracket.

Attach without tightening
Attach without tightening

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Assembly and installation21

Pallet Roller Flow FIFO

Angle beam - traverse roller
loading module (TR)The holes in the angle beam allow the loading module to be centred
automatically.

Attach without tightening
Attach without tightening

22

Assembly and installation

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Pallet Roller Flow FIFO

NoticeThe PLJ connecting plates are assembled as follows:► The PLJ connecting plates must not exceed the width of themodules. The PLJ connecting plate excess is between the profiles (under the rollers).
► The mounting bracket for the PLJ connecting plate must be on
the loading side.
► The screw fixing the profile to the PLJ connecting plate is inserted into the second hole of the profile, with the screw head at the
top (recommended torque 45 Nm).

PLJ connecting plates overhang
to the interior of the module

2nd hole
Mounting bracket for the PLJ
connecting plate loading side

Reminder• Do not attach (with drill screws) the PLJ connecting plates onto the beams forthe moment.
• 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 thelanes.

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Assembly and installation23

Pallet Roller Flow FIFOIntermediate modules► Attach the following frames according to the floor markings.

► Next insert the intermediate modules to all levels of the test bay. Load the mod-ules from the front (unloading side). Install the modules from bottom to top.

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Assembly and installation

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Pallet Roller Flow FIFO

Installing the longintermediate modules.

Attach without
Attach without
tightening
tightening

Attach without Attach without
tightening
tightening

Reminder• Do not attach (with drill screws) the PLJ connecting plates onto the beams forthe moment.
• 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 thelanes.

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Assembly and installation25

Pallet Roller Flow FIFO

Installing the shortintermediate modules.

Attach without
tightening

Attach without
tightening

Reminder• Do not attach (with drill screws) the PLJ connecting plates onto the beams forthe moment.
• 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 thelanes.

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Assembly and installation

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Pallet Roller Flow FIFO

Unloading modules► On the unloading side, insert all the unloading modules for the test bay on therack.

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Assembly and installation27

Pallet Roller Flow FIFO

Avoid impacts on the safety elements of the separator

When inserting the unloading modules in the rack, ensure that the parts locatedin 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)► Centre the module on the beam then attach the 2 short PLJ connecting plateswith 2 drill screws.

Attach without
tightening

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Assembly and installation

Attach without
tightening

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Pallet Roller Flow FIFO

Floor unloading - traverse
roller unloading module (TR)► Centre the unloading module between the frame uprights.

Attach without
tightening

Attach without
tightening

The floor mounting feet must all be level to ensure correct system operations.
Adjust the feet if necessary to maintain a slope of 4%.
Refer to the assembly diagrams provided in the appendix for details of laneassembly on floor mounting feet.

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Assembly and installation29

Pallet Roller Flow FIFO

Tubular beam - 3 track
unloading (3TL) module► Centre the module on the frame, then attach the fixing bracket at the end of thelane onto the unloading beam with 2 drill screws.

Attach without
tightening

30

Assembly and installation

Attach without tightening

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Pallet Roller Flow FIFO

Angle beam - traverse roller
unloading module (TR)The holes in the angle beam allow the unloading module to be centred automatically.

Attach without tightening

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Assembly and installation

Attach without tightening

31Pallet Roller Flow FIFO

Floor unloading - unloading
module STP (pallet truck)

Track with speed
controller
Intermediate
module for STP

Track withseparator

Floor mounting feet
to be attached to
the floor

Protection to be fixed to the floor► 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 thelane.

The floor mounting feet must all be level to ensure correct system operations.
Adjust the feet if necessary to maintain a slope of 4%.
Refer to the assembly diagrams provided in the appendix for details of STP laneassembly.

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Assembly and installation

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Pallet Roller Flow FIFO

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 alignment of the modules is essential for correct lane operations.

Reference line

Realign the modules if necessary.

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Pallet Roller Flow FIFO

Example of re-alignment.
► 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 under the screws 10x30.

► Leave 6 mm between modules and tighten the modules to the PLJ connecting

plates (recommended torque 45 Nm).

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Assembly and installation

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► Then attach the other PLJ connecting plates (without a splicing function) using

drill screws.

► Tighten the modules to the PLJ connecting plates (recommended torque45 Nm).

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Pallet Roller Flow FIFO

Step 2 – Lane test
Tests of the lanes in the test bay must be carried out in the presence of the assembly manager and the operator. Comply with the technical data described in
the order confirmation.
The order confirmation provides the following data:• Loads (maxi/mini/ mixed)• Loading/unloading mode
• Containers
Check the following:• Correct adjustment of the gravity descent speed for loads• Loads do not swerve• Loads restart correctly• The separator works correctly• Loads are held correctly on their support• The end stop works correctly
Pallet descent speed► Load the lightest pallet defined in the order confirmation.
► Check that the load descends correctly, without swerving or stopping.
► Repeat the operation with the maximum load.

Loads do not swerve

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Assembly and installation

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Loads restart correctly► Unload the container from the front.
► Check that the following containers restart correctly.

The separator
works correctly

For a description of the separator operation, see page 45.
► Before loading the lane, check that nothing restrains the movement of the separator (flap, rod, end stop).

Loads are held correctlyon their container

To prevent loads from falling due to sliding or tipping over, they must be stableand evenly distributed on their container.
► 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

Operations reports must be prepared for the lanes and for validation of theinstallation. 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.

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Operations report - Pallet Roller Flow FIFO
The operations report validates the guarantee for the dynamic storage lanes provided by Interroll. A copy ofthis 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 ineffect.
Follow the instructions for lane tests described in the user manual page 36.

Compliant
1- Pallet descent speed

2- Loads do not swerve

3- Loads restart correctly

4- The separator works correctly

5- Loads are held correctly on their support

N° OF __ __ __ __ __Fill in the OF number indicated on the labels attached to the module pallets

38

Assembly manager

The operator or rack manufacturer

Surname / First name:Company:
Date:

Surname / First name:Company:
Date:

Signature

Signature

Assembly and installation

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Avoiding swerving or
blockage of a container

Finding the causes of the problem► Check that the rack is correctly assembled, see "Rack assembly", page 14.
► Check that the beams are in contact with the modules.

Eliminating pallet blockage► Check the slope. General recommendation is 4% (or other slope specified in

the order confirmation).
► Check that all the beams are in contact with the modules.

► If the slope is correct, see "Troubleshooting", page 60.

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Pallet Roller Flow FIFO

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► Never loosen the connection between the PLJ connecting plate
and the beam.
► Only loosen the link between the PLJ connecting plate and themodule.

► Identify the position where the swerving occurs.
► Loosen the screws connecting the PLJ connecting plates to the module on the

opposite side from the swerving.
► Loosen the cross-ties to align the modules.
► Bring the profiles of the two consecutive modules closer together (by 1 or
2 mm).

40

Assembly and installation

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Swerving

Correction► Re-tighten the modules on the PLJ connecting plates.
► Re-tighten the cross-ties► 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
lanes.

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Assembly and installation

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Pallet Roller Flow FIFO

Step 3 - Lane assembly► To assembly the following lanes, follow the assembly method used for the testbay.

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.
► Insert the unloading modules on all levels.

► Align the modules and attach the lanes to the rack.

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Assembly and installation

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Start-up and operation
Warnings concerning operations

Warning
Risk of injury in case of improper handling► Insert the containers in the lane on the loading side only.
► Do not insert containers in the lane if they do not enter completely into it.
► If a container sticks out of the lane, remove it immediately.
► Do not load a container if pressure is required to insert it.

NoticeDamage in case of improper handling
Note the following remarks.
► Load carefully so as not to damage the lane or the products
stored in it.
► Never touch the rollers, tracks or the rack with the forks of theforklift.
► Never insert or reinsert a container on the unloading side.
► In the event of a malfunction or if you see any signs of damage,
immediately stop the lane and set up appropriate signage.
► For any damage due to impact on a rack or on the roller chassis, immediately inform the company's Maintenance Department.
► If you find nuts, screws, or other components on the floor, immediately stop all levels of the bay and the neighbouring bays.
Set up appropriate signage.
► In the event of a blocked container, remove it and determine thecause of the blockage. If the container appears to be defective,
set it aside from the storage zone.
► If the container is blocked repeatedly at a given point, inform thecompany's Maintenance Department so they can take appropriate action.
► 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:• 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.

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Pallet Roller Flow FIFO

Checks before the initial start-up► When connecting the storage lanes and other equipment in the warehouse,

perform a risk analysis of the entire installation.
► In order to use the installation in a safe configuration, verify the suitability of thewidth of the rows, the height of the installation, and the characteristics of theforklifts, e.g. original manufacturer's protections, turning radius, stability andmaximum load compared to the height.
► Check that the racks and lanes do not have any visible damage.
► Check that there is no foreign material in the working area.
► 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.
• The fork spacing changes according to the type of pallet used so as to carry theloads in a stable manner without damaging the container.

Lifting height• The maximum lifting height of the forklift should enable risk-free loading and unloading at all levels of the installation.

Technical characteristics

44

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.

Start-up and operation

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Loading and unloading methods
Recommended equipment

It is recommended to use forklifts with the following equipment:• A angle measuring system, in order to accurately adjust the forks• A (vertical) or dual (vertical and horizontal) indexing system if two pallets must
be front loaded at the same time
• An embedded camera system for the forks• Visual markers

Operating principle of theseparator

The separator comprises two components:(1) Separator flap
(2) Separator stop (regular, heavy or double front)

Pressing on the separator flap locks the stop. This stops the second pallet andcreates a separation.

This separation enables the first pallet to be unloaded without hindrance from theaccumulated 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.

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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 palletis freed.

A space is created between the pallets. The pallet activates the separator flap andslides 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:• Suspicious noise• A visibly worn component• A blocked or swerved container• A deteriorated rack
• A defective attachment between the lane and the rack.
• A component which has failed or which is not operating correctly
Checks before eachstart-up46► Check that everyone present is informed and trained on the use of the system,and that no one is in a position of danger.
► Check that there is no visible degradation to the lanes or the rack.
► Check that there is no foreign material preventing correct operation of the installation.
► Check that all signage is in place (load capacity and restrictions for use).

Start-up and operation

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Loading a container

Warning
Risk of injury in case of improper handling► Insert the containers in the lane on the loading side only.
► Do not insert containers in the lane if they do not enter completely into it.
► Do not load a container if pressure is required to insert it.
► In the event of a blocked container, remove it and determine thecause of the blockage.

NoticeDamage in case of improper handling► Load carefully so as not to damage the lane or the products
stored in it.
► Never touch the rollers or the rack with the forks of the forklift.
► Never insert or reinsert a container on the unloading side.
The time between two loadings must be:• For a standard speed controller: 30 loads per hour maximum• 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 2hours.
► 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.
► Damaged containers should not be used in a dynamic lane; they should be removed from the storage zone.
Make sure that the container to be loaded is one of those described in the orderconfirmation.
► Insert the forks of the forklift under the container.
► Raise the container gently.
► Slowly approach the installation on the loading side.
► Align and centre the container correctly in the lane.

► Position the container at the correct height. The container must be aligned andcentred in the lane. The entry guides are used only for guiding - they should not
be used as support points to position the container.

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TR loading mode

► Tilt the forks at 1% towards the forklift.
► Slowly move the forklift forward in the axis of the lane on the loading side until

the container is fully engaged in the lane.

► Tilt the forks using the forklift at the same slope as the dynamic lane (4%).

► 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.

► 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.

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► As soon as the forks no longer hold the container, it starts to move down thelane and frees the forks. Reposition the forks horizontally before reversing.

► If the container is stopped (because the lane is full), keep the slope and adjust

the height of the forks while withdrawing them.
► Gently remove the forklift from the lane while keeping the alignment.

3TL loading mode

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Loading uses the same method as for TR loading, but without inclining the forks,
as these descend between the tracks

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Pallet Roller Flow FIFO

Unloading a container

Warning
Risk of injury in case of improper handling► Remove the containers using only the forklift described in theorder confirmation.
► Never remove containers by hand (picking).

NoticeDamage in case of improper handling► Unload carefully so as not to damage the lane or the products
stored in it.
► Never touch the rollers, tracks or the rack with the forks of theforklift.
► Never insert or reinsert a container on the unloading side.
► Advance the forklift gently on the unloading side of the installation: keep it cen-tred and in the axis of the lane.

► 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 forks must not hit the rollers.
Closed beam

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Angle beam

TR unloading mode

Insert the forks under the container and incline progressively to 4%.

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.
► If the top of the container touches the bottom of the upper beam, reposition theforks horizontally or adjust their height.

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Pallet Roller Flow FIFO

When reversing the forklift, remain in the axis of the lane.

3TL unloading mode

Unloading uses the same method as for TR unloading, but without inclining theforks, as these descend between the tracks

STP unloading modeEnter 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).
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.

When reversing the forklift, remain in the axis of the lane.

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What to do in case of an accident or failure► Stop the lane.
► Secure the area and set up appropriate signage► In the event of an accident:provide first aid and call the emergency services.
► Inform qualified maintenance personnel.
► Have the system repaired by qualified maintenance personnel.
► Do not use the lane until authorised by qualified maintenance personnel.

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Pallet Roller Flow FIFO

Cleaning, maintenance and repair
Cleaning

NoticeDamage in case of improper cleaning► Do not use abrasive products, pressurised jets, or products
which may cause oxidisation or damage the equipment.
► Clean the lane using dry cloths.

Remark in case of maintenance and repair

Warning
Risk of injury in case of improper intervention► Maintenance must only be carried out by qualified and regularly
trained personnel, in compliance with safety and other instructions.
► Wear Personal Protective Equipment (PPE).
Before any intervention, you must take into account:• Safety instructions concerning the work area, e.g. movements in the area, welding, grinding, and the duration of maintenance operations for cold rooms.
• Specifications particular to the company where the installation is used.
• Technical data provided in the order confirmation.
• Maintenance procedures of the various products: dynamic lanes, racks, environment (e.g. sprinklers).
Preparing an intervention► Define a safety zone around the working area.
► The safety zone includes the entire height of the bay as well as the two adjacentbays.
► Secure the zone and set up appropriate signage, nets, etc.
► Remove everything from the lane involved in the intervention before starting.
► Make sure that the area of intervention has sufficient lighting.

Performing an intervention► 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.
► Before restarting the system, check the integrity of the lane, the rack and its environment, e.g. sprinklers.

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Cleaning, maintenance and repair

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Maintenance equipment

Lane maintenance can be performed using the following equipment:• Platform with a rotary barrier• Maintenance pallet
Platform
The platform may be used for maintenance from the rows, on either the loadingor unloading side. Use a safety harness and always attach yourself before moving.
Maintenance pallet
The maintenance pallet allows you to:• Work at a fixed position on a lane, by locking the pallet on the profiles or uprights• Carry tools and components

Example of maintenance pallet

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Pallet Roller Flow FIFO

Using a maintenance pallet
Two people are required in order to use a maintenance pallet :• one who works on the pallet• 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 according to the rules applicable in the country.

Warning
Risk of falling due to the rotating rollers► Never walk on the rollers nor on the profiles.
► When working on the lane, you must always be attached usinga safety harness.
► Check that the system for locking the pallet on the profiles is
working correctly.
► Check the operation of the system for attaching the hoist next
to the pallet.
► Check the operation of the system for attaching the hoist aheadof the lane to the rollers on the rack.
► Using a lifting device or boom, position yourself on the loadingside in front of the lane located next to the lane requiring maintenance.
► Use a forklift to position the maintenance pallet next to the loading side of the lane where maintenance is required. Position it
in that lane.
► Block the pallet when it is loaded using the locking system.
► Position yourself opposite the lane using a boom or lifting device.
► Attach yourself to the rack using the safety harness.
► Climb onto the maintenance pallet and sit down in it.
► With the assistance from the second operator in the boom, install the system for attaching the hoist ahead of the lane to therollers on the rack.
► Install the attachment system on the side of the pallet.
► Unlock the pallet and control its descent to the location requiring maintenance. Readjust the safety harness.
► When you reach the location requiring maintenance, lock thepallet to the profile and attach yourself to the rack using thesafety harness.
► Perform the maintenance.
► When finished, unlock the pallet and let it descend.
► Position the boom lift opposite.
► Remove the safety harness from the rack.
► Move out of the maintenance pallet and into the boom lift.
► Use a forklift to remove the maintenance pallet, like any otherpallet.

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List of maintenance and inspection operations
In order to keep the installation in perfect operational condition, you must systematically replace any damaged components.
Maintain a log of the checks and maintenance performed on the installation. Failing which, the operator shall be held responsible in case of an incident or an accident on the installation, and cannot claim any guarantee nor indemnity fromInterroll.
The safety mechanisms (speed controller, separator and end of lane stop) should be
replaced exclusively by trained personnel certified by Interroll.

Pallet Roller Flow FIFO

Date:

Component

Tasks/Checks

Work required

Loading plate

Visual inspection

Inspection: no impact, no
trace of the start of a fracture

Check the tightening

Re-tighten if necessary to 45
Nm.

Visual inspection

Inspection: no impact (on the
tube or the ends)

Check that the roller rotates
freelyTurn the roller. Free the roller
if necessary, or replace it if required.

Check the tightening of the inserts on the profiles

Raise the roller and checkthat the insert is held properly. Re-tighten if necessary to
45 Nm.

Check the condition and tightening of the roller ends. Gap
tolerance: max. 3 mm of axial
clearance

Slide the roller from side toside to check the axial clearance. Replace the roller ifnecessary.

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Cleaning, maintenance and repair

Performed by57

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Pallet Roller Flow FIFO

Date:

Component

Tasks/Checks

Work required

Speed controllers

Check the condition and tightening 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 on eachside of the roller

Check the tolerance. Replace
it if necessary. Contact Interroll for a quote for replacement.

Check that effort is requiredfor pallet descent.

If the brake is blocked, or if it
rotates freely, if only a slighteffort is required to turn it, or if
it makes a suspicious noise,have it replaced. When in
doubt, contact Interroll for aquote for replacement.

No deterioration on tightening

Perform a visual inspection oftightening

Perform a visual inspection of
the attachment of the speed
controller roller to the BU80
profile.

Replace the speed controller
if necessary. Contact Interroll
for a quote for replacement.

Check that the insert is correctly tightened.

Perform a visual inspection,
Tighten it if required, with atorque of 45 Nm.

Visual inspection of the tube

Inspection: no impact (on the
tube or the end)

Check the tightening of thescrews on the profiles

Raise the roller and checkthat the screws are held properly. Re-tighten if necessary
to 45 Nm.

58

Cleaning, maintenance and repair

Performed by

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Pallet Roller Flow FIFO

Date:

Component

Tasks/Checks

Work required

Separator flap and stop

Check that nothing obstructs
the movement of the separator, see "Operating principleof the separator", page 45

Free the mechanism if necessary, or replace it if required.

Visual inspection

Inspection: no impact, no
trace of the start of a fracture

Check that the real operation
time of the "Time Plus" corresponds to the time of use

Time from the moment when
the container is lifted to thelocking of the separator stop

Components for attaching themodules to the rack or the
floor

Check the tightening

Re-tighten if necessary to
45 Nm.

Visual inspection

Inspection: no impact, no
trace of the start of a fracture

Cross-tie

Check the tightening

Re-tighten if necessary to
45 Nm.

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Pallet Roller Flow FIFO

Troubleshooting
In the event of a failure► Stop using the lane and any lane which may be damaged by the failure.
► Secure the area and set up appropriate signage► Only qualified maintenance personnel should repair the failure.
► Never try to hold back a container freed during a manipulation.
► 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.
Blocked container

There may be many reasons causing a container to be blocked and preventing itfrom starting; this is not necessarily a defect in the installation. Inserting a new container usually corrects the problem.
► In the event of a container blocked in the middle of a lane and/or against therack, remove the containers via the lanes located to either side by transferring
them to another pallet.
► 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.
► In the event of unstable content, first secure the area. Then use a boom lift toaccess the content and either stabilise or unload it.
► Check whether the lane or the rack were damaged by the blocked container.
Content falls to the floor► If content has fallen to the floor, you must secure the area before taking any

further action.

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Troubleshooting
Technical data in the order confirmation is noted below by the abbreviation "OCTD".

FailureCause

Correction

Immobilised pallet

Damaged pallet:• Nails sticking out under the pallet• Cracked, broken or missing skid
• Damaged block• Nails loose on skid
• The condition of the pallet is nolonger compliant with the standard
indicated on page 9

Remove the pallet from operation.

Pallet characteristics not compliant
with OCTD (type, dimensions, moisture content, weight and stored load)

Remove the pallet from operation.

Foreign particles attached to the pallet or when the pallet is packed underplastic film

Remove the foreign particles.

Load unevenly distributed on pallets

Recondition the pallet.

Damaged speed control roller, voir
"List of maintenance and inspection
operations", page 57

Replace it if necessary.

Damaged roller, voir "List of maintenance and inspection operations",
page 57

Replace the roller if necessary.

Lane alignment incorrect if the palletis in contact with the rack, voir "Rackassembly", page 14

Correct the alignment if necessary.

Damaged rack: see the rack maintenance procedure

Replace the rack if necessary.

Damaged speed control roller, voir
"List of maintenance and inspection
operations", page 57

Replace the speed controller if necessary.

Pallet load greater than the OCTD

Ensure the load is compliant with the
OCTD.

Pallet characteristics not compliant
with OCTD (type, dimensions, moisture content, weight and stored load)
and with the standard indicated on
page 9Remove the pallet from operation.

Speed not controlled (> 0.3 m/
sec.)

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FailureCause

Correction

No separation between pallets

Damaged speed control rollers before
and/or after the separator stop, voir
"List of maintenance and inspection
operations", page 57

Replace them if necessary.

Weight ratio between the lightest andheaviest pallet non-complaint with the
OCTD

Ensure the load ratio is compliant with
the OCTD.

Damaged separator, voir "List of
maintenance and inspection operations", page 57

Replace it if necessary.

Incorrect handling

Comply with the unloading procedures, voir "Unloading a container",
page 50.

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Decommissioning and scrapping
Waste disposal
Recommendation forprotecting the environment

As far as possible, the packaging should be disposed of in an environmentallyfriendly 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.
► For all maintenance work, and when disposing of equipment, please comply
with environmental standards and use appropriate disposal methods.
► In the event of cleaning with substances which may harm the environment,
store those substances in suitable containers which may be handled. Closeand dispose of them using appropriate methods. Comply with the warnings on
the packaging of harmful substances.

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Appendix
Identification of kits and spare parts on the modules
Spare parts

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Appendix65Pallet Roller Flow FIFO

Regular TR separator

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Heavy TR separator

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Appendix67

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Regular S3R separator

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Heavy S3R separator

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Appendix69

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STP tracks

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List of spare parts

Before placing your order, have Interroll confirm the reference numbers by providing your order number.
Recommended inventory status:
A = Keep in stock, B = Recommended stock, C = Optional stock

Machine no.
No.

Name

Reference(1)

Pallet guideAS-F11113070

B(2)

Loading plate

AS-F04013020

A(3)

PL cross-tie

AS-F04030221

C(4)

Rollers

Diam. 60 (1.5 mm thick.)
AS-G11041523

A

Diam. 60 (2 mm thick.)
AS-G11041522

A

(5)

(6)

Speed control roller

Quantity

Inventory
statusEL: 130
Basic: AS-G14072671
Magnetic: AS-G14072477
Magnetic Deep Freeze: AS-G14072672

A
A
A

EL: 230
Basic: AS-13091872
Magnetic: AS-G13052972
Magnetic deep freeze: AS-G14042471

AA
A

EL: 850 / 1050
Basic: AS-13052110
Magnetic: AS-G11031452
Magnetic deep freeze: AS-G14011771

A
A
A

Regular separator stop

AS-G11041151

A*

Heavy separator stopSingle front - no rollers: 130/156
AS-G100913100

A

Single front - no rollers: 104
AS-G13091674

A

Dual front - no rollers: 130/156
AS-G12073012

A*

Dual front - no rollers: 104
AS-G13091675

A** these components should be replaced exclusively by qualified maintenance personnel, trained and certified by Interroll.

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Machine no.
No.

Name

Reference(7)

Regular separator flap

TR module: AS-G13091973

A*

S3R module: AS-G13092470

A*

TR module - no rollers: 130/156
AS-G13032510

A*

TR module - no rollers: 104
AS-G13091373

A*

S3R module - no rollers: 104/130/156
AS-G13092571

A*

TR stop: AS-A06111621

A

S3R stop: AS-A03101520

A

Long: AS-F03100721

C

Short: AS-F03100722

C

Heavy separator flap

(8)

(9)

Lane end stop

Connecting plate

Quantity

Inventory
status* these components should be replaced exclusively by qualified maintenance personnel, 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.

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Appendix

Version 3.1 (September 2014)
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copyright
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