USER MANUAL (GB)INTERROLL CARTON WHEEL FLOW

Sept 2020 ‐ GB

CARTON WHEEL FLOW (EN)

About this manual

EN.3

Warnings in this manual

EN.4

SafetyEN.5

Technical characteristics of the Carton Wheel Flow

EN.6

Transportation and storage

EN.7

Assembly and installation

EN.8

Start‐up and operation

EN.9

Checks before the initial start‐up

EN.10

Cleaning, maintenance, and repair

EN.12

List of maintenance and inspection operations

EN.13

Troubleshooting

EN.15

Decommissioning and scrapping

EN.16

Spare parts

EN.17

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EN.2

CARTON WHEEL FLOW (EN)

About this manual
Remarks concerning the use of this manual
Manual contents
This manual provides remarks and important information about the various operatingphases of the Carton Wheel Flow:• Transport, assembly, and start‐up• Safe operation, maintenance, troubleshooting, waste disposal

Validity of this manualThis manual describes the Carton Wheel Flow as it is delivered by Interroll.
For systems involving non‐standard containers or contents, specific recommendations, specific operating
modes, and all the contractual documents are supplied in addition to this manual.

This manual is an integral part of the productTo ensure safe, reliable operation and to benefit from the warranty, before using the Carton Wheel Flow,
you must follow the recommendations in this manual, in particular the instructions in chapter "Assembly
and installation", page 12, and the information in the order confirmation.
• Keep this manual near the Carton Wheel Flow.
• Give this manual to any operator or subsequent user of the Carton Wheel 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.

Sept ‐ 2020 ‐ EN

EN.3

CARTON WHEEL FLOW (EN)Warnings in this manual
The warnings in this manual concern dangers which may arise while using the
Carton Wheel Flow. For relevant warnings see chapter "Safety", page 3, and the warnings at the beginningof each chapter.
There are three levels of warnings. You can recognise them from the following key‐words:• Danger• Warning• Caution

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

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

Additional symbols
This symbol draws your attention to important information.

►

This symbol draws your attention to actions that have to be carried out.

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EN.4

CARTON WHEEL FLOW (EN)

SafetyGeneral safety instructions
The Carton Wheel Flow is designed according to the technical state of the art.
However, certain risks may still arise:• Injury or a fatal accident to the user or a third party• Damage caused to the Carton Wheel Flow or to other material

Disregarding the warnings in this manual may lead to serious injury.
► Always read this manual carefully and make sure you follow the safety
instructions.
► Only qualified and specifically trained personnel may work with the
Carton Wheel Flow.
► Always keep this manual at hand and make it accessible to all personnel.
► Always comply with the relevant local safety regulations in your company.
► Contact Interroll Customer Service if you have any questions after reading thismanual.

Intended use
The Carton Wheel Flow is reserved exclusively for industrial use in suitable environments.
The installed beds are intended for dynamic (gravity‐based) storage
only of foreseen and previously approved isolated loads. They are reserved exclusively
for storing referenced or standardized containers.Any other use is consideredinappropriate.
The system configurations must be applied. They are defined in the order confirmationand in this manual. All other changes concerning the components andtheir location in the bed are not authorised.
Observe the rack manufacturer's recommended loads indicated on the load plate. Under nocircumstances may the content exceed the maximum load defined by the container manufacturer or by
the standard.

Unintended use
The Carton Wheel Flow may not be used to transport people.
Applications which do not comply with the intended use of the Carton Wheel Flowrequire prior written approval from Interroll.

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EN.5

CARTON WHEEL FLOW (EN)Technical characteristics of the Carton Wheel Flow
Gravity‐based system
Loads

Indicated in the assembly method (depend on bed)

Bed slope

Recommended slope
3% to 4.5% for plastic containers
4% to 5.5% for cartons
5.5% to 7% for KLT containers
see "Checks before the initial start‐up", Page EN.8

Handling equipment

Manual unless specified in the orderconfirmation

Atmospheric condi ons
Ambient temperature

Relative
humidity
Environnment

during operation‐30 °C to +45 °C

during assembly‐30 °C to +45 °C

for transportationand storage‐30 °C to +80 °C
Up to 90 % max., without condensation

The Carton Wheel Flow is not suitable for use in an environment
presenting the following risks:• Oxidation (either atmospheric or by chemical attack)• Projections• Decomposition• Vibrations• Explosions• Radioactive radiation• Electromagnetic radiation
Exceptions are possible: please contact Interroll.

Loads
Load contents

Sept ‐ 2020 ‐ EN

The contents of the loads and their containers must not:• Oxidise• Corrode• Decompose• Block the bed's components• Pollute the steel or plastic components• Interfere with the proper operation of any mechanism
The Carton Wheel Flow must not be used in direct contact with food products.

EN.6

CARTON WHEEL FLOW (EN)Transportation and storage
Transportation► Only qualified and authorized personnel can transport the equipment.
► Use appropriate lifting equipment to transport the equipment.
► The weight of each pallet is shown on the pallet. In the event of the lifting equipment's capacity being
unsuitable for the operation, handle the pallets one at a time.

Storage► Store the equipment indoors.
► Never store the equipment outdoors, or in an environment exposed to dust or projections.
► Ensure the ambient environmental conditions are met, see "Technical characteristicsof the Carton Wheel Flow", page EN.4.
► Do not stack additional loads on the pallets and boxes containing the Carton Wheel Flow and its
components.

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EN.7

CARTON WHEEL FLOW (EN)

Assembly and installation
Warnings concerning assembly
Risk of injury in the event of incorrect assembly► Since the Carton Wheel Flow is a sub‐system of an overall system, you will need to perform a risk
assessment of the entire system.
► Identify the protective measures required concerning risks related to the local conditions at the site andto usage.
► Define a safety zone around the working area.
► Secure the zone and set up proper signage and appropriate protection.
► When assembling modules on the rack, refer to the safety rules concerning working at height.
► Do not lean or walk on the Carton Wheel Flow components.
► Always wear suitable Personal Protective Equipment (gloves, leggings, safety shoes, etc.) throughout theassembly period.

Assembly rules
The dynamic storage beds are sub‐systems of an overall installation. They aresupplied in accordance with the technical data specified in the order confirmation.
The delivery of the Carton Wheel Flow beds comprises tracks and accessories.
These components must be assembled, installed, and positioned on a rack.
Any changes to the components or the bed cancels Interroll's responsibility, and will be considered as
unintended use of the Carton Wheel Flow.

Qualified Personnel
The assembly and installation must be carried out by qualified personnel in accordancewith the instructions concerning assembly and installation, and with the safety instructions.
The manager of the team responsible for assembling the beds must be technically competent and trainedin the following:• The products and their use• The dangers inherent in the assembly of heavy or cumbersome components in high places• The risks related to incorrect assembly• The adjustments required for correct operation of the beds.
Interroll can provide special training on the Carton Wheel Flow. We will send a quote on request.
Interroll se tient à votre disposition pour dispenser une formation dédiée au Carton Wheel Flow. Un devis
vous sera envoyé sur demande.

General Rules► Check the stability of components on the containers before cutting the straps.
► Do not move the container once the straps have been cut.
► Make sure you do not damage the components during assembly.

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EN.8

CARTON WHEEL FLOW (EN)Start‐up and operation
Warning
Risk of injury in the event of improper handling► Ensure compliance of the loading direction depending on the bed's operating mode (LIFO or FIFO).
► Do not insert containers into the bed unless they enter it completely.
► If a container protrudes from the bed, remove it immediately.
► Do not load a container if pressure is required to insert it.

NoticeDamage in the event of improper handling
Ensure that the following remarks are complied with.
► Load carefully so as not to damage the bed or the products stored on it.
► Never touch the wheel tracks, the bed, or the rack with the lifting equipment.
► Do not re‐introduce a container on the unloading side if there is not enough room in the bed.
► In the event of a malfunction or if you see any signs of damage, stop the bed immediately and set up
appropriate signage.
► For any damage due to impact on a rack, beds, or wheel tracks, inform the organisation's Maintenance
Department
immediately.
► If you find nuts, screws, or other components on the floor, immediately stop all levels of the bay and of
the neighbouringbays. Set up appropriate signage.
► If a container is jammed, determine what is causing the blockage and remove it. If the container appears
to be defective, set it aside from the storage zone.
► If the container is blocked repeatedly at the same point, inform the company's Maintenance
Department so that they can takeappropriate action.

Before the system enters service, operators must ensure that all operations personnel are trained in:• The specific use of a dynamic storage system• All the risks inherent in a dynamic storage system, such as, for example, falling
loads, moving loads or cuts.

Sept ‐ 2020 ‐ EN

EN.9

CARTON WHEEL FLOW (EN)

Checks before the initial start‐up► Carry out a test before each start‐up: load a carton to establish whether it stops
at the drop‐out tray end stop.
► For future use, always ensure compliance with loading conditions that havebeen tested and validated during the reception handover of the system.
► When connecting the storage beds to other equipment in the warehouse,
perform a risk analysis of the entire system.
► Check that the racks and beds are not visibly damaged.
► Check that there are no foreign bodies in the working area.
Before use, make sure that all the side member end caps are correctly in place.
Removal of the side member pins is FORBIDDEN (apart from maintenance, see conditions Page EN.11).
► Close down any bays with one or more missing side member pins.
► The configuration must comply with that tested when the system was received.
► Test all changes to the configuration, notably concerning the position andquantity of the " brake clips ".

Operation
Close down the bay if you observe any of the following:• Suspicious noise• A visibly worn component• A damaged or worn rack
• A defective attachment between the bed and the rack
• Wheel tracks not held parallel• A component which has failed or which is not operating correctly• A missing or partly inserted side member pin

Checks before each start‐up► Check that everyone present is informed and trained in the use of the system,and that no one is a dangerous position.
► Check that there is no visible damage to the bays or the rack.
► Check that there are no foreign bodies preventing correct operation of the system.

Warning: Loading a container
Risk of injury in the event of improper handling► Ensure compliance of the loading direction depending on the bed's operating mode (LIFO or FIFO).
► Do not insert containers into the bed unless they enter it completely.
► If a container protrudes from the bed, remove it immediately.
► Do not load a container if pressure is required to insert it.
► In the event of a blocked container, remove it and determine the cause of the blockage.

Sept ‐ 2020 ‐ EN

EN.10

CARTON WHEEL FLOW (EN)

NoticeDamage in the event of improper handling► Load carefully so as not to damage the bed or the products stored on it.
► Never touch the wheel tracks, the bed, or the rack with the lifting equipment.
► Do not re‐introduce a container on the unloading side if there is not enough room in the bed.
►Check the bottom of the container to detect possible damage or foreign bodies.
Damaged containers must not be used in a dynamic bed and must be removed
from the storage zone.
► Make sure that the container to be loaded is one of the containers approved
during verifications prior to initial start‐up, see Checks before the initial start‐up,
page EN.8.
► Make sure that the loading conditions are identical to those approved during
verifications prior to initial start‐up, see Checks before the initial start‐up,
page EN.8.
Do not stack containers without prior written authorisation from Interroll.
When handling containers during loading and unloading, refer to the ergonomic standards in force.

When loading manually:► do not place your fingers under the container.
► do not insert your hands inside the bed.
► load the container along the axis of the lane.
► do not let go of the load if it is not stable.
► If a container protrudes from the bed, remove it immediately.
► Do not load a container if pressure is required to insert it.
► Make sure there is enough back up distance.

When unloading manually:► do not place your fingers under the container.
► do not insert your hands inside the bed.
► Make sure there is enough back up distance.
► To facilitate unloading of a container, free it from the stop by pushing it
backwards, then lift it to remove it from the bed.
► Ensure compliance of the loading direction depending on the bed's operating
mode (LIFO or FIFO).

Sept ‐ 2020 ‐ EN

EN.11

CARTON WHEEL FLOW (EN)

Cleaning, maintenance, and repair
NoticeDamage in the event of improper cleaning► Do not use abrasive products, pressurized jets, or products
which may cause oxidation or damage the equipment.
► Clean the bed using dry cloths.
Remark in the event of maintenance and repair

NoticeRisk of injury in the event of improper intervention► Maintenance and repairs must be carried out by qualified, properly
trained personnel only and in accordance with safety andother instructions.
► Wear Personal Protective Equipment (PPE).
Before any intervention, you must take into account:• Safety instructions concerning the work area, e.g. movement in the area, welding,
grinding, and the duration of the maintenance operations for cold rooms.
• Specifications particular to the company where the system is used.
• Technical data provided in the order confirmation.
• Maintenance procedures of the various products: dynamic storage beds, rack,environment, e.g. sprinklers.

Preparing an intervention► Define a safety zone around the working area.
► The safety zone covers the entire height of the bay.
► Secure the zone and set up appropriate signage, nets, etc.
► Remove everything from the lane or the bed 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 do not leave any foreign bodies or tools which may interferewith the correct operation of the system.
► Before restarting the system, check that the bed, the rack and its environment,
e.g. sprinklers are in good working order.
► During an intervention, disassemble the bed by following the assembly procedurein reverse order► Use only components supplied by Interroll when replacing components.
► Never straighten out a defective component.
► Before re‐starting check that pins are correctly inserted (the hole in the pins
cannot be seen)

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EN.12

CARTON WHEEL FLOW (EN)

List of maintenance and inspection operations
In order to keep the system in perfect working order, you must systematicallyreplace any damaged components.
Maintain a log of the checks and maintenance performed on the system. Failingwhich, the operator shall be held responsible in the event of an incident or an
accident on the system, and cannot claim any guarantee or compensation fromInterroll.

Component

Tasks/Checks

Work required

End cap

Check it is positioned
correctly

The side member end cap
must not come free from the side member.
If necessary, replace it with a new Interroll end cap.

Locking Key

Check it is positioned
correctly

The hole in the pin must not
protrude from the side member. If necessary use amallet to fully insert the pin (see joined assembly
instruction section 19 or 35 or 36 or 37).

Screw

Check that the screws are The recommended tightening
tightened correctly.
torque is between a 23 Nm minimum and 28 Nm
maximum.
If necessary, tighten the screws to the recommended
torque.

Track

Check that it functions
correctly

Check the flowability with a container approved
during the start‐up.
If necessary, replace it with a new Interroll wheel
track.

Replacing a track

Keep the side member pin when it is removed. Pull
the loading beam by 24 mm
maximum (in order not to remove it from its
housing), then re‐insert the side member to lock theloading beam.
Replace the track then return the loading beam into
position by following the assembly instruction
section 23 or 24 or 25 or 26 or 27 or 28.

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EN.13

CARTON WHEEL FLOW (EN)Work required

Component

Tasks/Checks

Back stop

Check that it functions Turn by hand. It must return to its initialcorrectly
position

Entry guide

Check that it is correctly
attached to the loadingbeam

It should not be possible to move the guide by hand.
Replace it if necessary.

If spare parts are needed, contact Interroll for a quote.

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EN.14

CARTON WHEEL FLOW (EN)

Troubleshooting
In the event of a failure► Stop using the lane and any lane which might be damaged by the failure.
► Secure the area and set up appropriate signage.
► Only qualified maintenance personnel must repair the failure.
► Never try to hold back a container freed during an intervention.
► Before restarting the system, check that the bed, the rack and its environment,
e.g. sprinklers are present and correct.
Follow the maintenance procedures of the various products : dynamic storage bed, rack, environment.

Blocked container
There may be many reasons causing a container to be blocked and preventing it from starting.
This is not necessarily a defect in the system. Inserting a new container usually corrects the
problem.
► If a container is blocked in the middle of a lane and/or against the rack, load
another container or use a " pole " to free it.
Content falls to the floor► If content has fallen to the floor, you must secure the area before taking any
further action.

FailureBlocked container

Cause

Correction

Damaged container► Withdraw thecontainer fromservice.

Container non‐compliant with tests
performed during start‐up
Foreign bodies attached to thecontainer► Remove the foreign
bodies.

Foreign bodies on the wheel track
Damaged wheel track

Container stops
Brake clip wornabruptly at an end stop
Brake clip missing

Sept ‐ 2020 ‐ EN

► Replace it with a
new Interroll wheel
track.
► Replace it with a
new Interroll brakeclip.
► Add a brake clip.

EN.15

CARTON WHEEL FLOW (EN)

Decommissioning and scrapping
Waste disposal
Recommendations for protecting the environment
Insofar as possible, the packaging should be disposed of in an environmentallyfriendly manner.
Interroll can provide the component contents (type and quantity) upon request.
► For all maintenance work and when disposing of equipment, please comply
with environmental standards and use appropriate disposal methods.
When disassembling for scrapping:► Follow the assembly procedure in reverse order.
► Store the components in a suitable container to avoid falls or injury.

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EN.16

CARTON WHEEL FLOW (EN)

Spare parts
This table provides only an indication of requirements for most users. Each user
should determine the stock levels required according to their specific usage.
These components must only be replaced by qualified maintenance personnel.

Keep in stock

Recommended stock
Wheel track

Brake clip 28 & 42mm

Brake clip 56mm

See original order1018399

1018400

Recommended stock
Entry guide

Full length guideHigh guide

64100604

G090923100

B19090461

Low support

Side member

High beam

Plug high

F17022765

F16100561

F17022762

1112983

Optional stock

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EN.17

CARTON WHEEL FLOW (EN)

Optional stock
Plug low

End cap left

End cap right

Loading beam

111298464100605

64100606

F17041661

Removable plate

LS beam

Alignement beam

DOT Support

F19091720

F19010861

F18080661

F17033062

DOT 5° et 10°

DOT 15°Right bracket

Left bracket

F18021961

F17111564

11147241114730

Locking Key

Clamp

Alignement bracket

Splice for guide11139751118598

62102539

1020449

Unniversal connector 32

Unniversal connector 23

Splice for side frame

Jig62102068

62102067

62102192

1114813

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CARTON WHEEL FLOW (EN)

Stock facultatif
Rail locker

SleeveSelf drilling screw 6,3x19

Screw HM8‐201114489

62102225

1019797

1019906

Tensylock nut 81018223

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EN.19

CARTON WHEEL FLOW (EN)

Manufacturer
Interroll Dynamic Storage
310, rue du Clair Bocage
Zone d'Activité Beaupuy 2
85000 Mouilleron le Captif
FranceTél. +33 251 37 12 32
www.interroll.com
dynamicstorage@interroll.com

Copyright for this manual
Interroll Dynamic Storage holds the copyright of this manual. The manual contains standards,drawings andillustrations which may not be disclosed, published, or duplicated, either fully or inpart, nor used for any
other purpose than the system referred to in this manual, without the priorwritten consent of Interroll.

Manual available for download from the following address:
https://www.interroll.com/support/product‐information/pallet‐carton‐flow/

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EN.20