SPACESAVER EC-300 A ELECTRICS

INSTALLATION INSTRUCTIONS SPACESAVER EC-300 A ELECTRICS SECTION I TOP MOUNTED ELECTRICS SECTION II FACE PANEL MOUNTED ELECTRICS SECTION III ZFS INSTALLATION INSTRUCTIONS 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 a Dust 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. 1

NOTE: The purpose of this installation manual is not to offer trouble shooting suggestions. Please refer to other sources for that information. For the purpose of clarity, all right and left, front and back references assume facing the front of the system. The master carriage is at the far left. Other carriages are slaves. SECTION I STEP 1 All the component parts for a two carriage system are seen here. This first series concerns a top mounted system. Every effort is made to enclose the logic boxes behind the face panels, but it is not always possible. Each of the components shown will be dealt with as we move along. STEP 2 The 20 amp breaker box houses a toroid filter in addition to the circuit breaker. This filter helps protect the system from interference. The top layout provided with each job will indicate where to fasten this box. The breaker box must be hard wired to the customer s service with metal conduit and must be securely grounded to a metal canopy top. NOTE: When top mounting electrical components through sheet metal, always use a machine screw and nut. Self tapping screws or tek screws leave a sharp hazard on the bottom side. Customer-supplied wiring coming into the field wiring terminal strip must be permanently installed in accordance with the National Electrical Code and all applicable state and local codes. STEP 3 The wire coming down to the safety floor plugs into the connectors crimped onto the floor wires. NOTE: When connecting the pink tabs and receptacles, make certain that the tab does not slip in between the plastic insulations. It will appear that a good connection has been made when in fact it hasn't. 3

STEP 4 At the other end of the safety floor wire is a two position amp connector. Plug this to the safety floor adapter board (position J1 ) added to the logic box. The four position cable coming from position J2 on the safety floor relay board plugs to ( J6 floor) on the logic board. (See Figures 1-4-6) 4

STEP 5 The motor sensor cable, the smaller of the two cables, plugs to the pins inside the box. Notice the position of the connector, it is possible to plug this in backwards. The motor power cable is connected using the familiar pink tabs and receptacles. Plug together the black wires, and the white and red wires, so the polarity (rotation) is correct. The ground wire has a fork connector attached that slides under the screw holding the box. Both wires must have heycos attached to protect the wires. The wires must be secured in such a way that they cannot come in contact with the encoder wheel. Before operating the carriages the box cover should be attached. 8 new 5

STEP 6 The motor sensor cable coming from the encoder at the motor plugs into the logic board at J13. The motor power cable hard wires into terminal strip TB2 white to negative, black to positive, and green to ground. The main 110 VAC power from the breaker box hard wires into terminal strip TB1. One side will be wired at the factory. Match the wire colors for the 110 VAC wire going to the next carriage on the right. Under some circumstances reverse motor rotation may be required. Follow the instructions silk screened on to the logic board at TB2. When carriages exceed 20 feet in length a 2x4 utility box is provided for power distribution. A 3 conductor wire and wire nuts are provided to make a pigtail connection between the utility box and the logic board. STEP 7 The safety sweep wires plug into the pink connectors which terminate the sweep loops. The wires are marked right or left sweep. At the logic end they plug to positions: (Left J4 - J5 or J20 ; Right J8 - J9 or J25 ). If photo sweeps are used an adder board must be used. See Figures 1-2-8 for proper wiring procedure. 6

STEP 8 The communication wire and the 110 VAC power wire are routed to the slave carriage(s) through the power pantographs. They are field mounted at carriage center and fold pointing to the rear. Grey fiber washers are placed between the pantograph and pantograph post to elevate it slightly, thus avoiding metal to metal contact. Be certain to secure these wires and leave enough slack to avoid strain and pinch. The nylon wire sock dresses the area where the wires can be seen. 12 STEP 9 The communication wire between carriages plug into position J7 on the left carriage and position J3 on the right carriage. This sequence is followed throughout the entire system regardless of the number of carriages. At the last carriage on the right an end of system jumper is plugged to position J7. At the carriage on the far left an end of system jumper is plugged into position J3. STEP 10 Each logic box is protected with a 5 amp slow blow fuse located in a fuse holder at the top of the box. A small screwdriver is required to quarter turn the fuse holder and withdraw the fuse. 7

STEP 11 The limit switches fasten to the top shelf through elongated slots. Adjustment of the limits can be made with the cover screwed in place. STEP 12 The limit switch stop mounts opposite the switch so that the switch rod is pushed in when the carriages nest together. There are two micro-switches in each limit. The cam on the rod holds the first switch closed when the carriages are apart. When the carriages come to within 4" of each other the first switch is released and the carriage begins to creep. The creep speed continues until the second switch is made and power is cut to the motor. This two stage system allows very smooth stops and protects the drive train and the stored media. STEP 13 There is a risk of loose wires becoming entangled with the E-Ring on the back of the limit switch rod. If this happens the carriage will not ramp up properly. The cariage will stay in creep speed for about 8 seconds and time out. To avoid this, simply tie the wires off in the slots provided on the cover. 8

STEP 14 If the carriage requires two limit switches, they should be positioned offset from one another. There is a risk that the rods may bottom out on a limit switch set directly in line. Properly placed limit switches with wires tied neatly will cause no problems when the system is ready for power up. STEP 15 The limit switch(s) plugs onto position(s) J16 right or J28 left. If secondary limit switches are not needed, jumpers will be installed at position J15 and J27. Jumpers are required only behind used limit switch positions. 9

STEP 16 If aisle lights are required, the relay box must be attached. The 110 VAC power is supplied either directly out of the pantograph or from the logic box. The top layout provided with the job will illustrate the method used. The box will contain one relay on the slave carriages and two relays on the master carriage. The box also houses its own protective 5 amp slow blow fuse. Make sure that all items are placed so that nothing is damaged when the carriages come together. The communication wire plugs onto position J1 on the logic board. 10

STEP 17 Bring the face panel to the front of the carriage and feed the primary and secondary control cables through the openings. The master requires two control heads. The slaves require only one control head. The logic end of these cables is attached at the factory. For dual control carriages see Figures 1-3-9 for wiring procedure. Set the face panel on the carriage panel brackets, align it from side to side and fasten it through previously drilled holes in the upright. CAUTION - Do not over tighten these #8-5/8" pan head screws! Use five to six screws on each side of the panel. 26 NOTE: Normally a closed upright will be used to hide the wires. For the purpose of providing better visibility we have used open uprights. STEP 18 Aisle Entry Sensors must line up across the aisle. Panels have to be securely fastened to the upright. The encapsulated aisle entry sensor unit plugs on the wire from the logic board and is then pressed into the housing attached to the face panel edge. An alignment notch assures proper orientation. The left side of the panel houses the transmitter. The logic end of its wire plugs to J10 or J26. The right side of the panel houses the receiver. The logic end of its wire plugs to J4 or J8. Some circumstances may require the use of an adder board. (See Figures 1-2-8 for proper wiring procedure.) 11

STEP 19 The primary and secondary control cables plug onto the pins at the control head circuit board. The secondary connector is missing a pin so that the two cables cannot be reversed. CAUTION - Be certain that these connectors are not mis-aligned. NOTE: If the system is provided with dual controls, the switch heads intended for the rear will be marked with a silver "R". Aside from this difference all switch heads are interchangeable. 12

STEP 20 Feed the wires through the opening in the face panel and push the switch head until fully seated. The plastic turn buckle wings at the rear of the switch must be turned out of the way to accomplish this. With the switch fully seated into the face panel, turn the two phillips screws until snug. CAUTION - Do not over tighten. As you turn the screw the wings will swing outward and pull tight against the back of the panel. 32 13

STEP 21 When the system is ready for testing please refer to Switch Functions and Sections 1 through 7 in the Operation Instructions For EC-300 Electric Controls, #SC-8920.(Rev. 1-92) 36 38 14

STEP 22 For detail on the use of the safety override key please refer to Operations Instructions for EC-300 Safety Override Key #SC-9032. (Rev. 4-92) WARNING: The Safety Override Key must be used only by supervisory or maintenance personnel. The Safety Override is NOT required to clear an object from an aisle in normal operation. 40 STEP 23 For detail on the use of the power override pack please refer to Section 14 in the Operation Instructions for EC-300 Electric Controls, #SC-8920. (Rev. 1-92) WARNING: While using the Power Override, the safety devices will not work. Extreme care should be exercised while using the Power Override unit. 41 STEP 24 Once testing is complete return to the top of the system. Screw the box tops in place and tie up all the wires to create a neat finished job. 42 15

NOTE: The second series of photos deals with the Works In A Drawer type of installation. The basic procedure does not change. The box placement and wire routing varies somewhat. STEP 1 Job information that may be needed to identify and trace each system can be found on a label attached to the back of each logic box. The information important for the moment is the carriage number. Although all logic boards are interchangeable, there may be circumstances dictating just where each box must be placed within the system. For example, if a lock is required it must be plugged to a particular board on a particular carriage. If the logic boxes are top mounted the information will be attached to the cover. SECTION II STEP 2 For convenience sake, either temporarily attach or suspend on a wire, each logic box. Locate it roughly at the height where it will finally end up. All the wires can be attached without concern that the box might fall. 16

STEP 3 If safety edge is a system option its location will be pointed out in the materials provided with the job. Assuming it is to be placed along the front edge of the shelving the channel should be attached with the small flat head screws sent along with the job. Flat head screws must be used to avoid doing damage to the safety edge as it is slid into the channel. If the safety edge resists being fed through the channel, DON T FORCE IT - The interior is rather delicate. Spray some soapy water on the channel. If after the run is completed and the connections have been made you get a bad sweep indication, reverse the plug-in leads. Polarity is important when hooking up safety edge. 47 17

STEP 4 The safety edge and safety sweeps utilize the same circuit on the logic board. An adder board is used to split the signals. The adder board is attached at the factory and the connection from the adder to the logic board will be complete J5 or J6 on the adder board to J5 or J9 on the logic board. You must make the connection from the safety edge to the adder board at J2 or J4. (See Figures 1-5-7 for proper wiring procedure.) STEP 5 A common problem experienced with the limit switches is failing to secure the wire, thus allowing it to tangle with the limit switch rod. If while testing the system a carriage will start in the creep mode and shut down after 5 or 10 seconds, look for this condition first. 18

NOTE: In the installation instructions for safety floors we outlined the procedure for hooking the floor wire harness to the standard safety floor and how to ring out the circuits. (See SC-9016) STEP 6 The safety floor monitor logic board looks much like the carriage logic board, but a close look will reveal some difference. A system with up to eight safety floor sections can be hooked to a single safety floor logic board. For larger systems an expansion logic board must be added. The connector from the floor sections plugs to J2. The unused post pairs are factory jumped. The board shown in the photo is located on the left side of the system so the end of system jumper is plugged to J4. The communication cable to the master carriage plugs to position J5. The primary and secondary cables to the safety floor display head plug to J7 and J10. If an expansion logic board is required a communication line will pass from J1 on the expansion logic board to J3 on the primary logic board. If an expansion logic board is not required a jumper will be at pins 11 & 12 on J3. STEP 7 Before fastening the face panel to the static shelving, remove the box from its temporary location and hold it in place behind the face panel. Rest the panel on the support brackets, adjust it side to side, and fasten it from the back through the previously drilled holes in the shelving upright. DO NOT OVER TIGHTEN THE SCREWS! 19

STEP 8 The safety floor display head fastens to the panel in the same way the carriage control switches do. The area across the front center has no buttons. Instead, the floor condition is displayed here. The trap door above the display area tilts down to expose the electronic key slot. The floor can be overriden by placing the safety override key here. For more detail refer back to Section I, Step 22. STEP 9 All the works in a drawer logic boxes slide behind the face panel. A section of plastic face panel tube is factory fastened to the logic box so when pushed in it blends with the panel edge. Quarter turn phillips screws at the top and bottom swing turn buckles inside the tube to lock the box in place while closed. A small strike bar is located at the upper left corner of the box. When it is pushed up and locked into place, the box cannot come all the way out. 20

STEP 10 If the system is equipped with a waist high security lock the switch, switch and cable mounting plate, and the lock will be factory attached to the appropriate face panel. STEP 11 Clamp the cable jacket in place with 1 1 / 4 " of jacket above the bottom edge of the mounting bracket. Clamp the end of the braided cable onto the lock cam arm. Leaving some slack in the cable. Do this while in the locked position. The key should be in the 3 o clock - 9 o clock position at this point in the installation. 21

STEP 12 Make the electrical connection at the micro-switch. The switch is wired normally closed. The logic end of the cable plugs to J14. STEP 13 The key slot is the only part of the lock visible from the front of the panel. CAUTION: When in the unlocked position the key must be removed. STEP 14 Keep all visible wires as neat as possible. 22