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Interroll PF 1100 User Manual

Pallet roller flow fifo
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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 FIFO
PF 1100
Version 3.0 (June 2013)
EN - Translated from French

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  • Page 1 I N S P I R E D E F F I C I E N C Y User manual Interroll Pallet Roller Flow FIFO PF 1100 Version 3.0 (June 2013) EN - Translated from French...
  • Page 2 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.

  • Page 3: Table Of Contents

    Pallet Flow Roller Flow FIFO Contents About this manual Remarks concerning the use of this manual..........4 Warnings in this document................5 Additional symbols ..................5 Safety General safety instructions ................6 Intended use ....................6 Unintended use.................... 6 Qualified personnel ..................7 Risks ......................

  • Page 4: About This Manual

    Transport, assembly and start-up • Safe operation, maintenance, troubleshooting, waste disposal This manual describes the Pallet Roller Flow as it is delivered by Interroll. Validity of this manual 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.

  • Page 5: Warnings In This Document

    Pallet Flow Roller Flow FIFO Warnings in this document The warnings in this document concern dangers which may arise while using the Pallet Roller Flow. For relevant warnings see Safety, page 6, and the warnings at the beginning of each chapter. There are three categories of danger, indicated by the following key words: •...

  • Page 6: Safety

    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.

  • Page 7: Qualified Personnel

    Pallet Flow Roller Flow FIFO Qualified personnel Qualified personnel are persons who read and understand this manual, and tak- ing national regulations into account, can completely execute incidental work. Only qualified and trained personnel may work with the Pallet Roller Flow taking the following into account : •...

  • Page 8: Product Information

    Pallet Flow Roller Flow FIFO Product information Product description The Pallet Roller Flow is a dynamic storage system for heavy loads. It ensures the controlled descent of pallets. Speed controllers control the descent of loads at a constant speed. On the unloading site, the separator isolates the pallet from the pressure of the accumulated line of pallets.

  • Page 9: Technical Characteristics Of The Pallet Roller Flow Fifo

    Specified in the order confirmation Generally recommended slope: 4 % Types of pallets handled by the • Standardised EUR EPAL pallet 800 Interroll system mm x 1200 mm (W X D), see "Intended use", page 6 • Standardised EUR EPAL pallet 1000 mm x 1200 mm (W X D) •...
  • Page 10 • Decomposition • Vibration • Explosion • Radioactive radiation • Electromagnetic radiation Exceptions are possible: please contact Interroll. The contents of the loads and their containers must not: Load contents • Oxidise • Corrode • Decompose • Block the lane's components •...

  • Page 11: Transportation And Storage

    Pallet Flow Roller Flow FIFO 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. ►...

  • Page 12: Assembly And Installation

    Pallet Flow 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 instal- ► lation, you need to perform a risk analysis of the entire installa- tion.

  • Page 13: Assembly Rules

    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 a quote on request. Comply with the rack specifications. General rules ►...
  • Page 14 The rack must be attached to the floor according to the rack manufacturer's spec- Rack assembly ifications. The module risers, provided by Interroll, must be attached according to the floor specifications. The beams must be perpendicular to the supporting frames.
  • Page 15 Pallet Flow Roller Flow FIFO The space between the lane and the rack upright must be uniformly spread. A Positioning the module minimum value of 35 mm is recommended. on the rack A minimum space of 100 mm is recommended between the container and the rack upright.

  • Page 16: Lane Assembly

    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. Version 3.0 (June 2013) Assembly and installation...
  • Page 17 Pallet Flow Roller Flow FIFO ► Start by installing the front row of frames, on the loading side. Align the rack Rack according to the floor markings on the front and sides Use as many wedges as required to ensure the rack is level (level height ob- ►...
  • Page 18 Pallet Flow 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 or angle beam) Tubular beam Angle beam The beams must be aligned and must have a constant slope from loading to un-...
  • Page 19 Pallet Flow Roller Flow FIFO 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.
  • Page 20 Pallet Flow Roller Flow FIFO Centre the fixing bracket on the beam then attach the bracket with 2 drill ► Tubular beam - traverse roller screws. loading module (TR) Attach without tightening Attach without tightening Depending on the corridor configuration, it is possible that the module splice ►...
  • Page 21 Pallet Flow Roller Flow FIFO Centre the 3TL fixing bracket (8 oblong holes) on the beam then attach the ► Tubular beam - 3 track loading bracket with 2 drill screws. The space between the tracks is determined by this (3TL) module bracket.
  • Page 22 Pallet Flow Roller Flow FIFO Angle beam - traverse roller The holes in the angle beam allow the loading module to be centred loading module (TR) automatically. Attach without tightening Attach without tightening Version 3.0 (June 2013) Assembly and installation EN - Translated from French...
  • Page 23 Pallet Flow Roller Flow FIFO Notice The PLJ connecting plates are assembled as follows: The PLJ connecting plates must not exceed the width of the ► modules. The PLJ connecting plate excess is between the pro- files (under the rollers). The mounting bracket for the PLJ connecting plate must be on ►...
  • Page 24 Pallet Flow Roller Flow FIFO Attach the following frames according to the floor markings. ► Intermediate modules 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. Version 3.0 (June 2013) Assembly and installation EN - Translated from French...
  • Page 25 Pallet Flow Roller Flow FIFO Installing the long intermediate modules. Attach without Attach without Attach without Attach without tightening tightening tightening tightening Reminder • Do not attach (with drill screws) the PLJ connecting plates onto the beams for the moment. •...
  • Page 26 Pallet Flow Roller Flow FIFO Installing the short intermediate modules. Attach without Attach without tightening tightening Reminder • Do not attach (with drill screws) the PLJ connecting plates onto the beams for the 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 the lanes.
  • Page 27 Pallet Flow Roller Flow FIFO On the unloading side, insert all the unloading modules for the test bay on the ► Unloading modules rack. Version 3.0 (June 2013) Assembly and installation EN - Translated from French...
  • Page 28 Pallet Flow Roller Flow FIFO Avoid impacts on the safety elements of the separator When inserting the unloading modules in the rack, ensure that the parts located in the frame below (Time Plus, separator flap, rod and separator stop) do not hit the forks of the forklift or the rack beams.
  • Page 29 Pallet Flow Roller Flow FIFO Floor unloading - traverse roller unloading module (TR) Centre the unloading module between the frame uprights. ► Attach without Attach without tightening 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%.
  • Page 30 Pallet Flow 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 the ► lane onto the unloading beam with 2 drill screws. Attach without tightening Attach without tightening Version 3.0 (June 2013)
  • Page 31 Pallet Flow Roller Flow FIFO The holes in the angle beam allow the unloading module to be centred au- Angle beam - traverse roller tomatically. unloading module (TR) Attach without tightening Attach without tightening Version 3.0 (June 2013) Assembly and installation EN - Translated from French...
  • Page 32 Pallet Flow Roller Flow FIFO Floor unloading - unloading module STP (pallet truck) Track with speed controller Intermediate module for STP Floor mounting feet to be attached to the floor Track with separator Protection to be fixed to the floor Centre the module between the frame uprights, maintaining the distance be- ►...
  • Page 33 Pallet Flow Roller Flow FIFO Check that the module's two diagonals are equal. ► Check the diagonals Measure the diagonals from one axis to another of the holes located at each end of the profiles. A perfect alignment of the modules is essential for correct lane operations. Lane alignment ►...
  • Page 34 Pallet Flow 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.
  • Page 35 Pallet Flow Roller Flow FIFO Then attach the other PLJ connecting plates (without a splicing function) using ► drill screws. Tighten the modules to the PLJ connecting plates (recommended torque ► 45 Nm). Version 3.0 (June 2013) Assembly and installation EN - Translated from French...

  • Page 36: Step 2 - Lane Test

    Pallet Flow Roller Flow FIFO Step 2 – Lane test Tests of the lanes in the test bay must be carried out in the presence of the as- sembly manager and the operator. Comply with the technical data described in the order confirmation.
  • Page 37 Operations reports must be prepared for the lanes and for validation of the installation. The end user must sign these reports. Send a copy of the report to Interroll. Refer to the example of an operations report page 38. The operations report validates the guarantee. Without the operations report, Interroll cannot guarantee the installation.
  • Page 38 Operations report - Pallet Roller Flow FIFO The operations report validates the guarantee for the dynamic storage lanes provided by Interroll. A copy of this report, countersigned by the assembly manager, the operator or rack manufacturer must be sent to Interroll within a maximum of 4 weeks after delivery of the equipment.
  • Page 39 Pallet Flow Roller Flow FIFO Avoiding swerving or Finding the causes of the problem blockage of a container Check that the rack is correctly assembled, see "Rack assembly", page 14. ► Check that the beams are in contact with the modules. ►...
  • Page 40 Pallet Flow 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 ►...
  • Page 41 Pallet Flow Roller Flow FIFO 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.

  • Page 42: Step 3 - Lane Assembly

    Pallet Flow Roller Flow FIFO Step 3 - Lane assembly To assembly the following lanes, follow the assembly method used for the test ► bay. As the rack is perpendicular, you do not need to align the frames with the floor markings.

  • Page 43: Start-Up And Operation

    Pallet Flow Roller Flow FIFO 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 com- ►...

  • Page 44: Checks Before The Initial Start-Up

    Pallet Flow 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 the ►...

  • Page 45: Loading And Unloading Methods

    Pallet Flow Roller Flow FIFO Loading and unloading methods It is recommended to use forklifts with the following equipment: Recommended 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 •...

  • Page 46: Operation

    Pallet Flow Roller Flow FIFO With the Time Plus function, the separator flap moves up after 5 to 30 seconds depending on the settings. The separator stop is then unlocked and the next pallet is freed. A space is created between the pallets. The pallet activates the separator flap and slides over the separator stop.
  • Page 47 Pallet Flow Roller Flow FIFO 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 com- ►...
  • Page 48 Pallet Flow Roller Flow FIFO 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%). ►...
  • Page 49 Pallet Flow Roller Flow FIFO As soon as the forks no longer hold the container, it starts to move down the ► lane 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 ►...
  • Page 50 Pallet Flow Roller Flow FIFO Unloading a container Warning Risk of injury in case of improper handling Remove the containers using only the forklift described in the ► order confirmation. Never remove containers by hand (picking). ► Notice Damage in case of improper handling Unload carefully so as not to damage the lane or the products ►...
  • Page 51 Pallet Flow Roller Flow FIFO Angle beam Insert the forks under the container and incline progressively to 4%. TR unloading mode Lift the container. Thanks to the Time Plus function, the separator flap remains in the low position for 5 to 30 seconds (depending on the settings). In case of a picking error, the Time Plus function even enables the container to be replaced in the lane as long as the separator stop is not locked.
  • Page 52 Pallet Flow Roller Flow FIFO When reversing the forklift, remain in the axis of the lane. Unloading uses the same method as for TR unloading, but without inclining the 3TL unloading mode forks, as these descend between the tracks Enter the forklift between the protections. STP unloading mode Lift the container.

  • Page 53: What To Do In Case Of An Accident Or Failure

    Pallet Flow Roller Flow FIFO 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. ►...

  • Page 54: Cleaning, Maintenance And Repair

    Pallet Flow Roller Flow FIFO Cleaning, maintenance and repair Cleaning Notice Damage 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. ►...

  • Page 55: Using A Maintenance Pallet

    Pallet Flow Roller Flow FIFO Lane maintenance can be performed using the following equipment: Maintenance equipment • Platform with a rotary barrier • Maintenance pallet Platform The platform may be used for maintenance from the rows, on either the loading or unloading side.

  • Page 56: List Of Maintenance And Inspection Operations

    Pallet Flow Roller Flow FIFO 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 ac- cording to the rules applicable in the country.
  • Page 57 Interroll. 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...
  • Page 58 When in doubt, contact Interroll for a quote for replacement. No deterioration on tightening Perform a visual inspection of...
  • Page 59 Pallet Flow Roller Flow FIFO Pallet Roller Flow FIFO Date: Component Tasks/Checks Work required Performed by Separator flap and stop Check that nothing obstructs Free the mechanism if neces- the movement of the separa- sary, or replace it if required. tor, see "Operating principle of the separator", page 45 Visual inspection...

  • Page 60: Troubleshooting

    Pallet Flow 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. ►...

  • Page 61: Troubleshooting

    Pallet Flow Roller Flow FIFO Troubleshooting Technical data in the order confirmation is noted below by the abbreviation "OCTD". Failure Cause Correction Immobilised pallet Damaged pallet: Remove the pallet from operation. • Nails sticking out under the pallet • Cracked, broken or missing skid •...
  • Page 62 Pallet Flow Roller Flow FIFO Failure Cause Correction No separation between pallets Damaged speed control rollers before Replace them if necessary. and/or after the separator stop, see "List of maintenance and inspection operations", page 56 Weight ratio between the lightest and Ensure the load ratio is compliant with heaviest pallet non-complaint with the the OCTD.

  • Page 63: Decommissioning And Scrapping

    Recommendation for friendly way. protecting the environment 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 ►...

  • Page 64: Appendix

    Pallet Flow Roller Flow FIFO Appendix Identification of kits and spare parts on the modules Spare parts Version 3.0 (June 2013) Appendix EN - Translated from French...
  • Page 65 Pallet Flow Roller Flow FIFO Version 3.0 (June 2013) Appendix EN - Translated from French...
  • Page 66 Pallet Flow Roller Flow FIFO Regular TR separator Version 3.0 (June 2013) Appendix EN - Translated from French...
  • Page 67 Pallet Flow Roller Flow FIFO Heavy TR separator Version 3.0 (June 2013) Appendix EN - Translated from French...
  • Page 68 Pallet Flow Roller Flow FIFO Regular S3R separator Version 3.0 (June 2013) Appendix EN - Translated from French...
  • Page 69 Pallet Flow Roller Flow FIFO Heavy S3R separator Version 3.0 (June 2013) Appendix EN - Translated from French...
  • Page 70 Pallet Flow Roller Flow FIFO STP tracks Version 3.0 (June 2013) Appendix EN - Translated from French...
  • Page 71 Pallet Flow Roller Flow FIFO Before placing your order, have Interroll confirm the reference numbers by pro- List of spare parts viding your order number. Recommended inventory status: A = Keep in stock, B = Recommended stock, C = Optional stock Machine no.
  • Page 72 Short: AS-F03100722 * these components should be replaced exclusively by qualified maintenance per- sonnel, trained and certified by Interroll. This table provides an indication of requirements for most users. Each user should determine the stock levels required according to their actual usage.
  • Page 73 8503-044 Warszawa Bairro Distrito Industrial Thailand it.sales@interroll.com Tel. +48 22 741 741 0 Pindamonhangaba - SP Interroll DS Asia Pacific Co. Ltd Fax +48 22 741 741 1 CEP 12412-800 Amata Nakorn Industrial Estate pl-sales.ds@interroll.com Brazil 700/685 Moo 1, Tambol Phanthong, Spain &...

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