S/6EA CARRIAGE & ELECTRICAL INSTALLATION INSTRUCTIONS PART I CARRIAGE ASSEMBLY PART II ELECTRICAL WIRING PART III THE FESTOON PART IV RACKING PART V ELECTRICAL HOOK-UPS PART VI MISCELLANEOUS This symbol indicates a connection intended for a field-installed equipment grounding conductor. CAUTION Spacesaver Recommends: 1. that Safety Glasses be worn during any cutting and drilling operations and grinding. 2. that an Air Filtration Mask be worn during the grout mixing operation and while cutting wood. 3. that safety gear such as Hard Hats, Safety Shoes, etc. be worn when required. 920-563-6362 E-mail: ssc@spacesaver.com Internet: www.spacesaver.com
PART I - CARRIAGE ASSEMBLY NOTE: All references to front, back, left or right assume standing in front of the system looking to the rear. STEP 1 This manual is intended as a continuation of "Installation Instructions" for S/6EA Rail (SC-9021). It deals with the installation of the system after the rails have been set and the floor poured. STEP 2 The system will arrive on 3 basic skids. (The wheel sections on open skids; the hardware, small parts and electrical components in boxes, the wire channel, cross braces and electrical conduit on open skids.) 2
STEP 3 A forklift is valuable for picking the wheel sections from the skid and spotting them on the rails. Place the sections as follows: 1. Flanged wheel sections on the first and last rail. Keep the beam cradles and cross brace brackets facing the inside of the carriage. 2. Motor driven wheel sections on all other rails. Keep the gearmotor on the right side of the carriage facing front. 3
STEP 4 The motor sections require a shim of some kind to bring them to level. A wedge cut from a 2x4 is used here. STEP 5 Use a dry line to line up the ends of the wheel sections. Leave as wide a working aisle between the carriages as you can. 4
STEP 6 Set the space between the wheel sections. Remember that the wheel sections with gearmotors built in are wider than the others. Be sure to maintain the space by measuring from wheel center to wheel center. The wheel section must be kept level! NOTE: This manual describes one method of installing the integral beams. It is recommended that if a large quantity of beams must be installed a drill press be brought on site. STEP 7 Drop the integral beams into place being very careful not to disturb the location of the wheel section. 5
STEP 8 Clamp the beams in place and drill the 1/2" holes. A little cutting oil makes this go much easier. You will notice that the holes in the beam cradles are elongated for some adjustment. STEP 9 Insert the bolts and tighten them. The end of each beam has a plate welded in to prevent the beam from collapsing. STEP 10 The cross braces must be field assembled. Bolt the finished end to the bracket welded to the wheel section. Be consistent in how you locate the crossbraces. 6
Carriage Squaring Procedure Single Cross Brace Type: 1 1 2 2 Double Cross Brace Type: Fig. 1 Fig. 2 1 1 2 2 4 3 4 3 Fig. 3 Fig. 4 Note: In all the above cases, all cross braces should have the slack adjusted out before squaring begins. It is imperative that all corner to corner dimensions be taken from the same points of reference!! Keep the tape measure under the cross braces to avoid any obstacles which may interfere and lessen accuracy. When both corner to corner dimensions match, the carriage section is square and the cross braces must be locked in place. Figure 1: Cross brace 2: Move the rear adjustment nut back toward carriage center to assure that the rod will not interfere with adjustment. Cross brace 1: Tighten as needed to draw opposite corners together, thus squaring the carriage section. Figure 2: Cross brace 1: Move the rear adjustment nut back toward carriage center to assure that the rod will not interfere with adjustment. Cross brace 2: Tighten as needed to draw opposite corners together, thus squaring the carriage section. Figure 3: Cross braces 2 & 4: Move the rear adjustment nuts back toward carriage center to assure that the rods will not interfere with adjustment. Cross braces 1 & 3: Tighten, in unison, as needed to draw opposite corners together, thus squaring the carriage section. Figure 4: Cross braces 1 & 3: Move the rear adjustment nuts back toward carriage center to assure that the rods will not interfere with adjustment. Cross braces 2 & 4: Tighten, in unison, as needed to draw opposite corners together, thus squaring the carriage section. 6a
STEP 11 Assemble the unfinished end using the parts provided with the job. (Heavy angle - flange locking nuts - flange locking bolt & nut.) STEP 12 Draw the carriage section into square and lock it in place with the two flange locking nuts. Both ends of the crossbrace section must be firmly tightened before squaring takes place. Always take the measurement from a constant point. Under the beams works best due to the interference from the beams on top. Work from front to back. STEP 13 Rest the wire channel sections on the welded brackets and bolt them into place. 7
PART II - ELECTRICAL WIRING NOTE: The electrical components may be installed in any order. All cables are marked to indicate where they plug in.. STEP 14 A section of flex conduit with the wires already inside is pulled through each carriage from front to rear. The end with a 90 connector is located at the carriage front. Leave enough to easily attach the conduit to the electrical enclosure later. This conduit delivers the high voltage to the electrical enclosure. STEP 15 The communication cable is pulled through the carriage. This cable will festoon over to the next carriage so the surplus cable is left at the rear of the carriage. Leave enough cable at the front to hook into the electrical enclosure later. This cable maintains communication between system carriages. 8
STEP 16 Two cables are pulled through the carriage from each motor to the carriage front. Be sure to: 1. Plug the cables in as indicated on their ends. 2. Tie the wires well out of the way of the encoder wheel. 3. Use the cable restraints. 4. Use the caddy clamps to keep the cables from touching the floor. These wires carry the 90 V.D.C. power to the motor and the R.P.M. information to the logic board in the electrical enclosure. 9
STEP 17 Attach a photo electric sweep assembly to each corner of each carriage. (Carriages of extreme length may require two sets of photo electric sweeps.) Use the self tapping screws provided with the system. Pull the wires along the wheel section to the wire channel and on to the carriage front. Be sure to: 1. Avoid any pinched wires. 2. Use the caddy clamps to keep the cables from touching the floor. 3. Plug the cables in as indicated on their ends. 10
STEP 18 Attach the two stage limit switches. One on each side of the master carriage and one on the right side of all other carriages. Use the self tapping screws provided with the system. Pull the wires along the wheel section to the wire channel and on to the carriage front. Be sure to: 1. Avoid any pinched wires. 2. Use the caddy clamps to keep the cables from touching the floor. 3. Plug the cables in as indicated on their ends. Across from the limit switch attach a bumper block without the rubber end and the reflector plate for the photoelectric far limit switch. 11
STEP 19 Attach a bumper with a rubber end to all four corners of the master carriage and at the two corners on the right side of the other carriages. Place a bumper without the rubber on the two corners on the left side of each carriage except the master. STEP 20 It is most efficient to finish pulling all the wire before the racking is erected on the carriages. Caution must be used to avoid cutting any wires while erecting the rack. 12
STEP 21 The parts that make up the electrical distribution tree must be field assembled. Attach the 4x4 boxes to the conduit and push the wires through. Put the wire restraints and wire nuts in a safe place for use later on. STEP 22 Attach a short piece of "B" line channel to each of the 4x4 boxes. 13
PART III - THE FESTOON NOTE: The festoon may be attached to beams, static racking, the wall, etc... Each situtation can be different. In this manual we show the wall mount application. STEP 23 The parts that make up the cable type festoon must be field assembled. Prefab these parts before attaching the assembly to the wall. STEP 24 Attach each end of the cable and draw it tight using the turnbuckles. Do not over tighten. A slight drop in the cable is O.K. 14
STEP 25 Assemble the festoon wires on the floor and then raise them to the cable. Put the wires in loose at this time. Later the high voltage wire and communications wire can be adjusted for even drapes. The smaller communication wire may have to be wire tied to the glide. Once the glide is on the cable the split grommet can be inserted. From the power source to the first carriage there will be only a high voltage wire. Between all carriages there will be high voltage and communications wires. 15
PART IV - RACKING NOTE: Very little time is spent on rack erection in this manual. There are too many types to include here. Most rack manufacturers provide instructions for the type they sell. STEP 26 Probably the most often used type of racking is the upright & beam combination. Generally speaking uprights of 17' or less in height can be raised without special equipment. The use of a fork lift, boom or carry deck should be considered for uprights over 17' in height. STEP 27 The racking can be fastened with nut & bolt or welded onto the wheel sections. It is a customer option. In either case, be sure to locate the uprights properly before fastening. Use a dry line to maintain good alignment along the length of the carriage. 16
PART V - ELECTRICAL HOOK-UPS STEP 28 Attach the pre-fabbed electrical tree to the back side of the racking. Hardwire the flex conduit wires into the lower 4x4 box. Route the communication cable up the conduit exterior to the festoon. STEP 29 Hardwire the high voltage festoon wire into the upper 4x4 box. Be sure to use the cable restraints provided with the job. STEP 30 Attach the "pusher" to the racking upright and engage it onto the festoon cable. The 3/8" threaded rod, nuts and glide are provided with the job. The "pusher" not only moves the glides along the cable but also takes up any sag in the cable. 17
STEP 31 Attach the electrical enclosure to the rack uprights at the front of the carriage. Use the "B" line channel already attached to the enclosure. STEP 32 Feed the high voltage wires through the back side of the electrical enclosure and lock the flex conduit connector in place. Feed each of the wires through the grommetted hole into the electric enclosure. STEP 33 Take your time! Make each connection according to the way the cable end is marked. (See print #48212 in your manual.) All inner panel connections are made at the factory. Don't change anything in the enclosure without first consulting the factory! 18
PART VI - MISCELLANEOUS STEP 34 The wire channel covers snap into place giving the system a finished look. STEP 35 If the system has no natural stops at rail ends then these are sent with the system. Use an anchor with at least 1/2" diameter and 2-1/2" penetration. If the stop must also provide a target for the far limit switch, some reflector tape should be applied. 19
STEP 36 If the system has a remote control box it must be located where the customer wants it. It becomes clear that the factory must be given prior knowledge of this location. The remote box simply acts like another carriage control. It becomes part of the system and therefore must be included in the communications loop. See your manual for complete details regarding installation and use. 20
The Spacesaver Group U.S.A.: 1450 Janesville Ave., Ft. Atkinson, WI 53538-2798, (414) 563-6362, 1-800-492-3434, FAX: (414) 563-2702 CANADA: Box 806, 2857 Derry Rd. E., Mississauga, Ontario L4T 1A6, (416) 671-0391, 1-800-544-3679, FAX: (519) 746-5570 Copyright 1991, Spacesaver Corporation. Printed in U.S.A. 21 SC-9110