Interroll PF 1100 User manual

Version 1.0 (Sept. 2014)
FR - Original language
User manual
Interroll Pallet Roller Flow LIFO
PF 1100

Version 1.0 (Sept. 2014)
FR - Original language
Manufacturer
Interroll Dynamic Storage
310, rue du Clair Bocage
Zone d'Activité Beaupuy 2
85000 Mouilleron le Captif
France
Tel. [phone]
Fax [phone]
www.interroll.com
[e-mail]
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.

Pallet Roller Flow LIFO
3
Version 1.0 (Sept. 2014)
FR - Original language
Table des matières
About this document
Remarks concerning the use of this manual................................................ 4
Warnings in this document........................................................................... 5
Other symbols.............................................................................................. 5
Safety
General safety instructions .......................................................................... 6
Intended use ................................................................................................ 6
Unintended use............................................................................................ 6
Qualified personnel ...................................................................................... 7
Risks ............................................................................................................ 7
Information about the product
Product description ...................................................................................... 8
Components................................................................................................. 8
Technical characteristics of the Pallet Roller Flow LIFO.............................. 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...................................................................................... 33
Step 3 - Lane assembly ............................................................................. 39
Commissioning and operation
Warnings concerning operations ............................................................... 40
Checks before the initial start-up ............................................................... 41
Forklift requirements .................................................................................. 41
Loading and unloading methods................................................................ 42
Operation ................................................................................................... 42
What to do in case of an accident or failure............................................... 49
Cleaning, maintenance and repair
Cleaning..................................................................................................... 50
Remark in case of maintenance and repair ............................................... 50
Using a maintenance pallet........................................................................ 52
List of maintenance and inspection operations.......................................... 53
Troubleshooting
In the event of a failure .............................................................................. 56
Troubleshooting ......................................................................................... 56
Disabling and discarding
Waste disposal........................................................................................... 58
Appendix
Identification of kits and spare parts on the modules................................. 59

Pallet Roller Flow LIFO
About this document
4Version 1.0 (Sept. 2014)
FR - Original language
About this document
Remarks concerning the use of this manual
Manual contents This manual provides remarks and important information about the various oper-
ating phases of the Pallet Roller Flow:
• Transport, assembly and start-up
• Safe operation, maintenance, troubleshooting, waste disposal
Validity of the operating
instructions The operating instructions describe Pallet Roller Flow at the time of its delivery 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.
This manual is an integral part
of the product • To ensure safe, reliable operation and to benefit from the guarantee, before us- ing the Pallet Roller Flowyou must follow the recommendations in this manual
and the data in the order confirmation.
• Keep this manual close to the Pallet Roller Flow.
• Transmit the operating instructions to all operators or subsequent users
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.

Pallet Roller Flow LIFO
About this document 5
Version 1.0 (Sept. 2014)
FR - Original language
Warnings in this document
The warnings in this document inform us of the inherent dangers while using
Pallet Roller Flow. You will find the concerned warnings in the chapter Safety,
page 6, and at the beginning of each chapter.
The warnings have three levels. You will recognise the following keywords:
• Danger
• Warning
• Caution
Configuration of a warning
Other symbols
This symbol draws the attention to a comment relating to safety.
This symbol draws the attention to important information.
This symbol draws the attention to an action to be executed.
Keyword Meaning
Danger Warns about a directly threatening danger, which, if not
avoided, results in death or serious bodily injury.
Warning Warns about a directly threatening danger, which, if not
avoided, may result in death or serious bodily injury.
Caution Warns about a directly threatening danger, which, if not
avoided, could result in minor injuries.
Danger
You find here the type and source of the danger
You see here the possible consequences of a failure to observe
the warning.
►You see here the measures enabling to neutralize the danger.
Recommendation
This warning draws the attention to possible material
damage
►You see here the measures enabling to avoid this material
damage.
►

Pallet Roller Flow LIFO
Safety
6Version 1.0 (Sept. 2014)
FR - Original language
Safety
General safety instructions
Pallet Roller Flow even if assembled by the rule book may present certain dan-
gers when used:
• Risks of physical injury or death to the user or bystanders
• Damage caused to Pallet Roller Flow or to other material goods
Disregarding the warnings in this manual may lead to serious injury or even death.
►Please read the operating instructions carefully and respect the safety instruc-
tions.
►The use of Pallet Roller Flow must be entrusted to personnel qualified and
trained in the product, considering the following.
►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 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 and in suitable en-
vironments. 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 standardised 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:
• inclinable upright or forks or not according to the provisions in the order confir-
mation
• 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.
The applications not compliant with the intended use of the Pallet Roller Flow re-
quire prior written approval from the Interroll.

Pallet Roller Flow LIFO
Safety 7
Version 1.0 (Sept. 2014)
FR - Original language
Qualified personnel
Qualified personnel are persons who read and understand this manual, and tak-
ing national regulations into account, can completely execute incidental work.
The use of Pallet Roller Flow must be entrusted to personnel qualified and trained
in the product, considering the following:
• The relevant manuals and diagrams
• Safety instructions of the operating instructions
• Prescriptions and provisions specific to the installation, see Assembly and in-
stallation, page 12
• The current legislation relating to occupational safety and accident prevention
Risks
You will find below information relating to various types of hazards or damage likely
to occur, when installing and using the Pallet Roller Flow.
Personal injury ►The equipment may be used by qualified personnel only, in any of its operations
modes.
►Respect the technical data described in the offer and the order confirmation.
►Respect the installation and operating instructions.
►Use only suitable handling equipment.
►Check and maintain the installation regularly.
►Make sure that no one walks or stands underneath loads, or in the loading or
unloading zones of the dynamic storage lane. Take the necessary measures to
prevent the presence of personnel inside the lanes. .
►Ensure that the loading/unloading aisle is sufficiently lit so as not to hamper the
handling operation.
Risk of injury : do not walk on the side profiles of the modules, or on the rollers with-
out using a safety harness.
Rotating parts ►Wear appropriate work clothes and Personal Protective Equipment (safety foot-
wear, gloves, leggings, etc.)
►Tie long hair or wear a mob-cap.
►Do not wear jewellery such as necklaces or bracelets.
►Do not walk on the rollers.
►Only maintenance personnel is authorised to enter the lanes, and only in com-
pliance with current safety standards.

Pallet Roller Flow LIFO
Information about the product
8Version 1.0 (Sept. 2014)
FR - Original language
Information about the product
Product description
The Pallet Roller Flow is a dynamic storage system for heavy loads. It ensures
the controlled descent of pallets.
In LIFO configuration, the pallets are loaded and unloaded on the same side.
Components
(1) Lane end stop
(2) Front angle beam 
(not provided by Interroll)
(3) LIFO speed controller
(4) Side profile
(5) Handling rollers
(6) Cross-tie
(7) Rear angle beam 
(not provided by Interroll)
(8) Rear stop
(9) Rear module
(10) Intermediate module
(11) Front module

Pallet Roller Flow LIFO
Information about the product 9
Version 1.0 (Sept. 2014)
FR - Original language
Technical characteristics of the Pallet Roller Flow LIFO
Gravity-based system
Atmospheric conditions
Load 60 to 1,250 kg per pallet
Maximum deceleration 1 m/sec.2
Slope Specified in the order confirmation
Generally recommended slope: 4 %
Types of pallets handled by the In-
terroll system
• Standardised EUR EPAL pallet 800
mm x 1200 mm (W X D), see "Intend-
ed 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 and uni-
formly spread in their container
• Other containers: please contact In-
terroll.
Forklifts Specified in the order confirmation
Ambient tem-
perature
in operation -30 °C to +45 °C
of the assembly -30 °C to +45 °C
for transportation
and storage
- 30 °C to +80 °C
Humidity Up to max. 90%, without condensation
Environment The Pallet Roller Flow is not suitable for use in an environ-
ment 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.

Pallet Roller Flow LIFO
Information about the product
10 Version 1.0 (Sept. 2014)
FR - Original language
Load contents The contents of the loads and their containers must not:
• Oxidise
• Corrode
• Decompose
• Block the lane's components
• Pollute steel and plastic components
• Prevent correct operation of any mechanisms
Pallet Roller Flow must not be used in direct contact with food products.

Pallet Roller Flow LIFO
Transportation and storage 11
Version 1.0 (Sept. 2014)
FR - Original language
Transportation and storage
Transportation
►Have only qualified and authorised personnel carry out the transportation.
►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 the 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 LIFO", page 9.
►Do not stack additional loads on the pallets and crates containing the
Pallet Roller Flow and its components.

Pallet Roller Flow LIFO
Assembly and installation
12 Version 1.0 (Sept. 2014)
FR - Original language
Assembly and installation
Warnings concerning assembly
Warning
Risk of injury in case of incorrect assembly
►Pallet Roller Flowis a sub-system of the overall installation, you
need to perform a risk analysis of the entire installation.
►Study the protective measures necessary with respect to the
risks linked to the local installation and operating conditions.
►Define a safety zone for the work area.
►Secure the area and install a signalling and a suitable protec-
tion.
►For the assembly of modules on the rack, refer to the safety
rules relating to work at a height.
►Never climb on the rollers nor on the lane profiles without a
safety harness.
►During assembly, wear appropriate Personal Protective Equip-
ment (gloves, safety shoes, safety harness, helmet, etc.).

Pallet Roller Flow LIFO
Assembly and installation 13
Version 1.0 (Sept. 2014)
FR - Original language
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 sub-systems of the overall installation. They are
delivered in accordance with the technical data specified 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 Inter-
roll is no longer responsible for the installation, as this represents unintended use
of the Pallet Roller Flow.
The racks must be assembled at the time as roller modules are inserted on the
beams. The racks must be attached to the floor to provide rigidity to the entire sys-
tem.
Qualified personnel The assembly and installation must be carried out by qualified personnel in ac-
cordance with the instructions of these activities and with the safety instructions.
The manager of the team responsible for assembling the lanes must be techni-
cally competent and trained concerning the following:
• Products and their use
• Dangers inherent in the assembly of heavy or bulky elements at great height
• Risks resulting from faulty 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 is at your disposal for training dedicated to Pallet Roller Flow. We will send
a quote 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 begin the assembly by the rear of the lane.
►It is recommended to install a stop on the ground at the front face. The stop is
used to halt the forklift and thus prevent any contact with the rack.
►Contact Interroll before attaching or hanging any equipment (such as sprin-
klers) in the area surrounding the dynamic storage installation.
►Clean the work site at the end of the installation. Do not leave components or
tools in the installation area or its surroundings.
►Test the lanes before use.

Pallet Roller Flow LIFO
Assembly and installation
14 Version 1.0 (Sept. 2014)
FR - Original language
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 horizontal.
The beams must be aligned and must have a constant slope from the front to the
rear of the lane. 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 di-
agram.
Beam perpendicular to the supporting frames (top view)

Pallet Roller Flow LIFO
Assembly and installation 15
Version 1.0 (Sept. 2014)
FR - Original language
Positioning the module
on 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 the
rack upright.
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 (a) is half the distance
(2a) between two lanes

Pallet Roller Flow LIFO
Assembly and installation
16 Version 1.0 (Sept. 2014)
FR - Original language
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 impor-
tant 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 the
master 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 up-
right.
The rack uprights must 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.

Pallet Roller Flow LIFO
Assembly and installation 17
Version 1.0 (Sept. 2014)
FR - Original language
Rack ►Start by installing the row of frames at the rear of the lane. Align the rack ac-
cording to the ground indications.
►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%

Pallet Roller Flow LIFO
Assembly and installation
18 Version 1.0 (Sept. 2014)
FR - Original language
►Position the beams along the row of frames according to the master diagram
provided by the rack manufacturer.
The beams must be aligned and have a constant slope over the lane (4% = rise
of 50 mm every 1250 mm).
►Drill then fasten the uprights to the floor.

Ensure you use the correct beam type (tubular beam or angle beam)
Tubular beam Angle beam

Pallet Roller Flow LIFO
Assembly and installation 19
Version 1.0 (Sept. 2014)
FR - Original language
Rear modules For installation of the Pallet Roller Flow lanes, see the assembly diagram in
the appendix.
►At the rear, insert all the modules for the test bay on the rack.
Aligning and attaching the first module
►Align the first module in relation to the pallet descent axis.
►Check that both distances (a) between the rack uprights and the rails are equal.

Pallet Roller Flow LIFO
Assembly and installation
20 Version 1.0 (Sept. 2014)
FR - Original language
Tubular beam -
rear module
►Centre the module on the beam then attach the 2 brackets with drill screws.
►According to the lane configuration, it is possible that module splice plates are
to be used throughout the lane at each module junction.
Attach without
tightening
Attach without
tightening