AISLEGUARD TM INSTALLATION INSTRUCTIONS FOR POWER PRO

Transcription

1 AISLEGUARD TM FOR POWER PRO INSTALLATION INSTRUCTIONS by Spacesaver SECTION I INTRODUCTION SECTION II COMPONENTS INSTALLATION SECTION III SCANNER SETTINGS SECTION IV FIGURES SECTION V RETRO FITS 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 safety gear such as Hard Hats, Safety Shoes, etc. be worn when required ssc@spacesaver.com Internet:

2 TABLE OF CONTENTS Page Identification Code: AG = AISLEGUARD AGI = AISLEGUARD INSTALLATION PAGE NUMBER REV. XX/XX = LATEST REVISION DATE Page No. SECTION I - INTRODUCTION 3 Manual Purpose/Use 3 Terms 3 Support Material 3 Static Cautions 3A-B Set up and Operations Tips 4 Key to Side Profile and Reflector Stick Punching SECTION II - COMPONENTS INSTALLATION Scanner & Reflector Strip Orientation 8 Aisle Entry Orientation 9 Pantograph Modification and Orientation 9 AisleGuard Logic Box Orientation SECTION III - SCANNER SETTINGS 10 Scanner Settings Defined 11 Using the Test Switch 11 Setting Protocol 11 Confirmation of Settings SECTION IV - FIGURES 12 Fig. 1 - AisleGuard Logic Box Locations 13 Fig. 2 - Quick Reference Installation Fig. 3 - Wire Layout Codes 16 Fig. 4 - "Pitch", "Yaw" and "Arc" Explained 17 Fig. 5 - Wire Routing SECTION V - RETRO FITS Punching and Drilling the Profile 20 Aisle Entry Preparation 21 Processor Change AG/AGI - Page 2-11/03

3 SECTION I INTRODUCTION For purposes of clarity, all right, left, front, and back references assume facing the true front of the system. If the system is dual entry, the end which houses the logic board is considered the true front. The carriage at the far left is considered the leader and the carriage(s) to the right of the leader are considered followers. AisleGuard TM is referred to as being installed on aisles rather than carriages. When this manual addresses location of component parts it will often reference aisle left, right, front or rear. Not carriage left, right, front or rear. The order in which the following steps may be carried out is left to the discretion of the installer. The sequence that follows may be altered, indeed the steps may even parallel each other if more than one installer is involved. The information in this manual addresses only steps unique to the Aisle Guard safety system. For detail regarding Power Pro core installation procedure see installation manual Power Pro Controls OP-0042 and wiring drawing TERMS: Leader Control Box: Located on every other carriage, beginning with the leader, on odd number carriage systems. Drives aisles to the left and right. Last box of even number carriage systems drives only the aisle to its right but still utilizes a leader control board. Scanner: Laser scanning device for carriages 6' to 21'. One located at the aisle front right and one located at the aisle rear left. Scans on command to search for a presence in the aisle. For carriages over 21' an additional set of scanners required, located in-board from the scanner mentioned above. Reflector channel: Plastic extrusion fastened to the carriage profile which holds the reflectors seen by the scanner. Aisle entry sensor: Infra red beam projected across the aisle entrance. Detects entries and exits of personnel and activates the scanners. End of scan switch: Roller switch mounted to the end of the pantograph. Triggered by the pantograph when the aisle is nearly closed. Deactivates the scanners just prior to carriage nesting. Used only on the pantograph end attached to the carriage housing the control box. Home Carriage: Carriage housing the Power Pro and the AisleGuard logic boards. SUPPORT MATERIAL REQUIRED: 1. Job specific information supplied by the production planning department. 2. This installation book OP Power Pro electric installation OP Power Pro wiring drawing Steel Carriage Installation OP Special scanner adjustment tool. 7. Special scanner jogging switch. 8. Special tamper proof torx screwdriver. STATIC CAUTIONS: NOTE: STATIC ELECTRICITY HAS BEEN IDENTIFIED AS A MAJOR CONTRIBUTOR TO THE DEGRADATION OF ELECTRONIC COMPONENTS. THE FOLLOWING PRECAUTIONS SHOULD BE TAKEN WHENEVER WORKING WITH ELECTRONIC COMPONENTS. 1. When removing logic boxes from the shipping container and placing them on the shelving, be careful not to touch the logic board or the connectors on the ends of the cables if you are not wearing a static strap. 2. Never handle any logic board without a static strap, which is properly grounded and functional, they do wear out! 3. Always handle logic boards from the edges, being careful not to touch any component leads on the back. 4. Never put a logic board down on any surface. As soon as you remove a board from the box, place it in a static-bag. 5. Replace worn out static-bags. Any holes or tears compromise their effectiveness. 6. Treat all logic boards the same. Don t drop your guard if the board is coming back for repair anyway. Most static damage is degradation, causing undetectable flaws that shorten life, not immediate failure. 7. Taking the time to be static safe will save time and money in fewer service calls. AG/AGI - Page 3 - REV 6/03

4 WORK "TIPS" RELATIVE TO AISLEGUARD INSTALLATION AND SET UP The following "Tips" are in random order. They represent knowledge we have gained from various sources since the introduction of the AisleGuard safety system. You will find some or all of these "Tips" useful when installing AisleGuard. Many of the following topics address specifics relative to set up, operation, etc. We suggest you read through the manual first to familiarize yourself with nomenclature and procedure. When making the adjustments to the laser while installing AisleGuard there are a few things you can do to make sure things are working properly before firing the system up. Be very careful when installing the ribbon cable that you get it in the connector straight. If it's at an angle the ribbon cable may rub the screw holding the laser and the motor together. Watch the cable move a few times to verify it will miss the screw. While adjusting for pitch and yaw remember that both those adjustments move a "floating block", so adjusting either will affect the other. Double-check the other setting after adjusting them. Once you have made your pitch and yaw adjustments you must set the arc adjustment. A good initial setting is to have the aisle completely open and set the beam so it arcs to the center of the open aisle at the other end of the system. The beam shouldn't hit the reflectors on its side of the carriage. The arc will never be a full 90 degrees. Once you have your adjustments made connect the hand held tester to the aisle guard board and watch the tester count reflectors for you. You can use the jogger and watch the scanner count the number of reflectors on the scan pass and also the return pass. The tester should show twice the number of reflectors when it returns to home. With a careful touch on the jogger you can watch it count one reflector at a time in both directions if you need to. This technique is especially effective when the aisle has two sets of scanners in it. With two sets of scanners it's not immediately evident which AG board sees an object. So faults in the aisle require you to look in the logic box and visually check the AG boards to see which one is causing the fault. Knowing both AG boards are seeing every reflector before powering them up eliminates one problem you could have once you apply power and do an op-check. While using the hand held tester make sure you get the "- -" double dash indicating both lasers are seeing their "home switch". A tie down for the motor cable has been added. Please use this to tie the cable to the motor mounting bracket. Dealing with AisleGuard requires the laptop diagnostic. While troubleshooting, often the first thing that must be established is if AisleGuard is actually responsible for the fault. AisleGuard can be removed from the equation by jumping it out in either one or both aisles. At left limit (J3) or right limit (J4) on the AisleGuard logic board place a 2 pin jumper over the open pins. No further action is required; the Power Pro logic board will not recognize AisleGuard presence. If the scanner fails to scan, the "end of scan" switch may be installed or adjusted incorrectly. Wiring the end of scan switch backwards causes it to scan after the switch engages, when the aisle is near closed, instead of stopping. It also won't scan while the aisle is open. The switch must be wired normally open, use the bottom 2 posts. The scan switch must be set to trigger when the aisle is 10 to 12 inches from fully nested. Do not vary either high or low from this benchmark! Aisle entry sensors MUST be connected to the logic board on the same carriage as the AisleGuard board! If the scanner motor bracket gets bent the home switch may not do its job. The bending usually happens when the multi plug connection is made at the scanner motor board. The symptoms can vary but usually the count will be high. Double or single dots may also appear on the display along with the sequencing numbers. Be very cautious to not strain the wire connection! The following hand held signals may be observed. "Hf": The front scanner did not see the home switch. "Hr": The rear scanner did not see the home switch. "HH": Neither scanner sees the home switch. When all is well: Break the aisle entry sensor and the number displayed will show twice separated by a double dash. The number displayed represents the number of reflections on each side of the aisle. The number will freeze on the screen and then disapear after approximately seconds. The AisleGuard board does have some memory. Push the button on the side and the number displayed is the location of the last fault. AG/AGI - Page 3A - REV 1 11/03

5 Upon power up of the 120 V.A.C. the following behavior should be expected. The scanners will cycle in all aisles without turning on the laser beam. This is an automatic start up test. Thereafter, the laser will be turned on for all scan's. The open aisle will require a manual reset. Thereafter the system will automatically reset open aisles. When programming is preformed the following behavior will take place to indicate success. Observe the action at LED-DS2/RIGHT on the Aisle Guard circuit board. This light will toggle if the programming sequence has been successful. If it is on at the time of programming it will toggle off and back on. If it is off at the time of programming it will toggle on and back off. AG/AGI - Page3B -6/04

6 POWER PRO WITH AISLE GUARD AISLE SELECTION SCENARIO The following information is a brief description of what Aisle Guard behavior should be expected during aisle selection and scanner interruption. CALL FOR A CARRIAGE MOVE: Carriage is idle and the control head LED is green. Initiate carriage movement. The LED is out during carriage travel. A continuous scan is taking place as the aisle closes. This scan continues until the aisle scan limit switch is engaged, which takes place when the aisle is 10 to 12 inches from being closed. The scanners in the opening aisle remain idle. ENTER AN OPEN AISLE: The scanners will remain idle as long as the aisle entry sensor beam is being blocked. Break the aisle entry beam and enter the aisle and scanning commences. The scan aborts as soon as you block the laser beam. The appropriate left or right "Aisle in Use" light comes on. The control head LED is red. EXIT AN OPEN AISLE: Break the aisle entry sensor while exiting the aisle. 2 scans will take place. The "Aisle in Use" light goes out. The control head LED returns to green. ACCIDENTALLY ENTER A CLOSING AISLE: Break the aisle entry sensor beam and carriage travel stops abruptly. AG/AGI - Page 3C - 6/04

7 KEY TO SIDE PROFILE AND REFLECTOR STICK PUNCHING For purposes of clarity, samples of the factory punched carriage profile and reflector sticks are shown here. NOTE: All the fastening holes required to attach the motor housing and scanner portions of the set are shown here. 1 The 2 holes furthest from center on a horizontal line are for the scanner guard. 2 The 4 large holes forming a four corner square are for the scanner housing. 3 The remaining 2 holes are for the motor housing attached to the interior of the carriage. 4 The large square hole provides motor, scanner and cable clearance NOTE: 1 The plastic reflector housing is punched with a large opening to allow the scanner to make direct contact with the carriage profile. 2 The other 2 small holes provide clearance for mounting the scanner guard to the carriage profile AG/AGI - Page 4-10/02

8 NOTE: SECTION II COMPONENT INSTALLATION The step 1 sequence is taken from the perspective of the front right side of the aisle. The installation of the scanner is being carried out on a carriage. Shown here are the 2 halves of the scanner. The motor and drive portion on the right goes to the inside of the carriage. The laser scanner portion on the left goes to the outside of the carriage. NOTE: A 1/4 inch spacer is required behind all photo sweep units. Consult Power Pro Manual OP-0042 for Photo Sweep installation and steel carriage installation manual OP-9516 for bumper installation. Scanner Motor Housing Note: Observe the following protocol to determine the proper reflector stick locations. Locate the "Aisle Guard" cut sheet in the planning envelope. Always begin by placing the reflector stick with the scanner cut out first in line. Always place the reflector strips in ascending order, starting with the least dense to the most dense reflector count. The "Aisle Guard" cut sheet will give information in the following order: Each different stick length given in inches. The bold oversized number indicates the total number of reflector targets programmed for. The number of reflector targets found on each stick length. The F1 indicates the first carriage length configuration for the front set of scanners. The F2 indicates the second carriage length configuration (if required) for the front set of scanners. The R1 and R2 indicates the same information as above for rear scanners if required. The carriage numbers indicate which configurations fit which carriages. Immediately below the "standard configuration chart" is found the "alternate configuration chart". This chart may be used if circumstances dictate different length sticks. To further assist you, the stick lengths and part numbers are noted on the box exteriors. Step 1: 1.1 Set the first channel in place using the cutout for the scanner to align to the carriage. Fasten in place through one hole which will later be used for the scanner guard. The strip is molded with a 90 degree return on the top side. Rest the return on the top edge of the carriage profile and the strips automatically align themselves from top to bottom. The reflector strips attach to the carriage profile with tek screws. Each strip butts to the proceeding strip. A splice plate is tek screwed in place to stabilize the joint. TEK it to the right of the splice. The next strip is slid underneath. AG/AGI - Page 5-7/04

9 NOTE: Do not anchor shelving uprights to the carriage using screws through the profile. Anchor instead through the shelf supports down into profile lip. 1.2 Attach all the strips end to end to complete the aisle on both sides. Splice Plate Tek Screw Step 2: 2.1 Mount the motor portion to the inside of the carriage. Fasten using the holes designated 3 and shown on page 4. Notice how the ribbon connecting cable passes through the square hole. Do not crimp or pinch this cable. Pan Head Screw Remove the cable restraint strap form the back of the scanner housing. NOTE: The use of the static strap for the next few steps. AG/AGI - Page 6-12/03

10 2.3 Plug the ribbon cable into the receptacle on the back of the scanner. Hold the laser scanner assembly to keep it from moving as you attach the ribbon cable. Use a needle nose pliers to apply adequate pressure. Press the end of the cable into the receptacle from the restraint side. The 4 silver wire ends should face away from the scanner body. Make sure the cable is fully seated into the receptacle. 2.4 Replace the wire restraint. Caution: If the restraint is not installed properly the ribbon cable may rub on a screw head in the motor assembly. Be sure to confirm that it does not rub while making our settings later. 2.5 Screw the scanner body to the carriage profile in 4 places. See Page 4 location 2. Do not over tighten the screws. A special tamper proof apex bit is required. Tamper Proof Screw NOTE: The bumper/1/4 spacer combination shown is required only for dual sweep applications. Typical is 1 bumpers placed opposite one another on each side of the aisle. AG/AGI - Page 7 - REV 12/03

11 2.6 Remove the TEK which was installed in Step 1.1. Fasten the scanner guard in two places. End caps are tek screwed in place to dress the reflector ends. End Cap Tek Screw Step 3: 3.1 Attach the wires to the aisle entry sensors, push the sensor into the bezel. For more detail see the "Aisle Entry" tab in this section of the binder. The small alignment tab on the aisle entry will mate with a slot in the factory installed bezel. The tab must point toward the floor. Note: See Figures 2, 3 & 5 for wire routing detail. AG/AGI - Page 8 - REV 6/04

12 Note: The pantograph must be fitted with a special "end of scan" switch assembly. The pantograph is modified with an extension channel, a switch bracket with adjusting slots and a roller micro switch. Step 4: 4.1 The extension channel mates with the existing pantograph channel by sharing the elevator post and nut. Place the extension channel over the threaded post and thread the nut on. Adjust the elevation as needed. The switch bracket sandwiches between the shelving canopy top and the pantograph post base. The roller switch is attached and adjusted so that the extension tube contacts it when the aisle is about 12 inches from being closed. Wire the switch normally open. This photo is taken from the carriage front looking to the rear. Switches are located only on the carriages housing an AisleGuard logic board. Note: The switch must be wired normally open, use the bottom 2 posts. The scan switch must be set to trigger when the aisle is 10 to 12 inches from fully nested. Do not vary either high or low from this benchmark! Step 5: 5.1 Once the "works in a drawer" box is positioned, all the wires may be routed to the components, and the connections made. Refer to Figures 1, 2, 3 & 5. Note: Some applications may call for top mount boxes. AG/AGI - Page 9 - REV 6/03

13 SECTION III SCANNER SETTINGS NOTE: Scanners need final adjustment from 3 perspectives; pitch, yaw and degrees of arc. Each of these adjustments are finite in nature and must be done with care and in the order shown. The following adjustment protocol applies to all scanners in the system. See Figure 4 for clarification. Aisles wider than 36 inches may require that pitch be adjusted the maximum distance from the first scanner. Contact Factory for more detail. Plug the tester assembly into the two pin header provided on the motor housing. Pressing the switch will turn the laser on. The laser will turn off after about ten seconds. Pressing and holding the test switch will turn on the laser and after two to three seconds begin scanning (the motor will begin to rotate the laser assembly). When the scanner has returned to the home position it will turn off the motor for about two to three seconds. If the home sensor is not working properly the motor will not stop. When the tester switch is released the motor will stop at the present position, however the laser will remain lit for about ten seconds. CAUTION: When aligning the laser scanner, do not stare directly into the laser. Observe laser position on the opposite side channel. Step 1: 1.1 A tester is required to light the laser and drive the scanner through its arc during set up. The button of this tester will allow you to jog the scanner through its entire arc, stopping whenever necessary. This tester plugs to the two position connector located on the motor housing. NOTE: Start the following adjustment sequence with a rough arc setting. The sequence will end with a final arc setting. See step 1.5 for arc setting details. 1.2 Stop the laser beam at a point where it strikes the reflector strip directly across from the scanner. 1.3 (See Figure 4) Insert the special allen wrench into the adjustment port at the front of the scanner. Turn the wrench to set the laser beam in the middle of the reflector strip form top to bottom. This represents the pitch setting. AG/AGI - Page 10 - REV 8/04

14 1.4 (See Figure 4) Jog the beam until it projects to the far opposite corner of the aisle. Insert the allen wrench into the adjustment port on the side of the scanner. Turn the wrench to set the beam in the middle of the reflector strip, from top to bottom, at the opposite corner of the carriage/platform across the aisle. This represents the yaw setting. 1.5 (See Figure 4) At the back side of the motor housing is found a phillips head screw. Turning this screw will set the 90 degree arc of travel. Correct adjustment will allow the beam to move from a position directly across the aisle, to a position that lines the beam up parallel to the carriage face. This represents the "Degree of Arc" setting. NOTE: Jog the scanner through its full 90 degree arc as final confirmation for pitch, yaw and arc settings. The arc should take the beam from pointing directly across the aisle to pointing parallel along the length of the carriage on which the scanner is mounted. NOTE: The ZFS hand held tester works with AisleGuard. NOTE: The basics of operation remain unchanged: 1. Always stand in front of the system, facing the carriages. 2. Always hold the hand held tester with the screen facing you. 3. Always keep the toggle switch pointing toward the ceiling. 4. Always toggle the switch toward the aisle you want to check. The signals are as follows: HH Both home switches not located HR Rear home switch not located HF Front home switch not located. Revolving figure 8 indicates recalibration Plug in tester, push the side button and the last reflector not seen in the selected aisle will be displayed. Toggle to the left aisle: If the total number of reflectors shows on the screen all is well. The number will show twice as it monitors the front scanner first and then the rear scanner. If 1 dot and a number shows on the screen all is not well. The single dot indicates the front scanner and the number indicates the reflector which cannot be seen. If 2 dots and a number shows on the screen the information is for the rear scanner. Toggle to the right aisle: Follow the same procedure described above. AG/AGI - Page 11-11/03

15 SECTION IV FIGURES FIGURE 1 AG/AGI - Page 12-10/02

16 FIGURE 2 CAUTION! The connection at all scanner motors MUST be made with care. Apply only straight on pressure to the connector. Any side pressure may bend the mounting bracket and have an adverse effect on the scanner home switch. Final adjustment may become impossible. Don t apply pressure when securing with wire ties. AG/AGI - Page 13-6/04

17 WIRE LAYOUT CODES Note: The following codes are used to identify and locate Aisle Entry Sensors, Pantograph side of "end of scan" switches, IC Buss cables and Scanners. The term remote implies that the component is located across an aisle from its controller. These cables will pass through the pantograph or festoon. Any wire not labeled remote is considered local and will lead to a component on the carriage holding the controller box. (Home carriage.) The wire labels are color coded. Wire labels to left side components will be green and for right side components the labels will be red. This excludes Aisle Entry wires. Aisle entry sensors WIRES LABELED FROM THE PERSPECTIVE OF THE CARRIAGE Component name Wire code To Power Pro board at: Right aisle receivers Right front receiver R F aisle entry J16 * Rear remote receiver R remote receiver J17 Right aisle transmitters * Front remote transmitter FR remote Trans J19 Right rear transmitter RR aisle Entry J18 Left aisle receivers * Front remote receiver FR remote Receiver J14 Left rear receiver L R aisle entry J15 Left aisle transmitters * Rear remote transmitter R remote Trans J13 Left front transmitter L F aisle Entry J12 * Aisle Entry wires only cross the first and last aisles. All others connect directly to the Power Pro logic board. See figure #2. FIGURE 3 AG/AGI - Page 14-6/04

18 Scanners WIRES LABELED FROM THE PERSPECTIVE OF THE AISLE Component name Wire code To AisleGuard board at: Right aisle scanners Right rear scanner RT rear scanner J7 Right front scanner remote RT front rem. scan J8 Left aisle scanners Left rear scanner remote LT rear rem scan J9 Left front scanner LT front scanner J10 End of scan switch WIRES LABELED FROM THE PERSPECTIVE OF THE CARRIAGE Component name Wire code To AisleGuard board at: Right aisle end Right aisle end of scan switch Right scan end switch J4 of scan switch Pins 1 & 2 Expansion from controller Right scan end switch From J4 pins 3 & 4 to J4 A to controller B Pins 1 & 2 Left aisle end Left aisle end of scan switch Left scan end switch J3 of scan switch Pins 1 & 2 Expansion from controller Left scan end switch From J3 pins 3 & 4 to J3 A to controller B Pins 1 & 2 I 2C buss communication cable LOGIC TO LOGIC INTERCONNECTING COMMUNICATION CABLE Component name Wire code To AisleGuard board at: AisleGuard communication cable Ag ctl 12 c bus J1 To Power Pro logic board at J24 This cable used AisleGuard communication cable Ag ctl 12 c bus J2 To AisleGuard expansion only for carriages logic board at J1 over 22' in length FIGURE 3 - Continued AG/AGI - Page 15 - REV 2/03

19 "PITCH", "YAW" AND "ARC" EXPLAINED Adjust the laser beam to strike the center of the reflector strip from top to bottom. Use the special adjustment tool for this purpose. Insert the tool into the adjustment port at the front of the laser sender. Adjust the laser beam to strike the center of the reflector strip from top to bottom at the far opposite corner from the laser sender. Use the special adjustment tool for this purpose. Insert the tool into the adjustment port at the side of the laser sender. Yaw is similar to Pitch except that it is carried out with the beam striking the reflector strip in the far opposite corner from the laser sender. Adjust the laser beam to project/swing in a 90 degree arc. Use a phillips screwdriver to turn the screw head exposed at the rear of the motor housing. See the solid arrow head for location. CAUTION: Never allow the beam to contact the carriage profile on which the scanner is mounted. DO NOT exceed 90 o! FIGURE 4 AG/AGI - Page 16 - REV 10/03

20 WIRE ROUTING Note: Power Pro systems equipped with Aisle Guard will usually have all logic boards housed in Works In A Drawer enclosures. For details on this type of logic box installation see OP-9616, the EC400 electric installation instructions. Note: Aisle Entry wires only cross the first and last aisles. All others connect directly to the Power Pro logic board. See figure #2. The following wiring map assumes facing the system front with the leader carriage positioned on the left. All locations are oriented from the aisle perspective, not carriage perspective. Remote rear left transmitter front, Remote front left receiver front, Local rear right receiver Local front right transmitter Rear Scanner Remote Front scanner Local end of scan switch LEFT AISLE OF HOME CARRIAGE Up carriage/platform rear, across shelving, through pantograph, to OR down to logic box. Up carriage/platform front, across shelving, through pantograph, to OR down to logic box. Up carriage rear, across shelving to OR, down to logic box. Up to logic box. Up carriage/platform rear, across shelving, through pantograph, to OR, down to logic box. Up to logic box. To OR, down to logic box. RIGHT AISLE OF HOME CARRIAGE Remote rear right receiver Remote front right transmitter Local rear left transmitter Local front receiver Front Scanner Remote Rear scanner Local end of scan switch Up carriage/platform rear, across shelving, through pantograph, to OR, down to logic box. Up carriage/platform front, across shelving, through pantograph, to OR, down to logic box. Up carriage rear, across shelving, to OR, down to logic box. Up to logic box. Up carriage/platform front, across shelving, through pantograph, to OR, down to logic box. Up carriage rear, across shelving, to OR, down to logic box. To OR, down to logic box. Note: Carriages greater than 21 feet in length will require a second set of scanners. They will be wire routed as follows. Middle Scanner Remote Middle Scanner LEFT AISLE OF HOME CARRIAGE Through carriage/platform, to front, up front, across shelving, through pantograph, to OR, down to logic box. Through carriage, to OR, up to logic box. Middle Scanner Remote Middle Scanner RIGHT AISLE OF HOME CARRIAGE Through carriage/platform, to front, up front, across shelving, through pantograph, to OR, down to logic box. Through carriage, to OR, up to logic box. FIGURE 5 RIGHT AISLE OF HOME CARRIAGE AG/AGI - Page 17 - REV 6/04

21 PUNCHING AND DRILLING OF THE CARRIAGE PROFILE: Step 1: 1.1 Use the template supplied with the retrofit kit to locate all holes which must be punched and drilled. Rest the template on the carriage profile edge. Align the end of the template with the end of the carriage profile and clamp it in place. This position provides automatic hole location. An array of holes is required at each scanner location. One scanner at the front right side of the aisle and one scanner at the rear left side of the aisle. NOTE: It is important to lay a drop of some sort under the work area. The drill chips are very difficult to remove from carpet fibers. 1.2 Drill each hole with the appropriate bit. Three (3) bit sizes are required. Use the holes in the template to locate the 6 holes to be drilled. Start each hole with the bit passing through the template. Remove the template and finish the holes freehand. Bit sizes: 1/4" and #29, #25 SECTION V AISLE GUARD RETROFIT TO EXISTING POWER PRO SYSTEMS The material in this section deals only with additional steps required to accomplish a field retrofit of Aisle Guard to an existing Power Pro system. All material in the previous sections of this manual remain valid. Read through the first 4 sections of this manual before beginning the retrofit, to develop a better understanding of the information in this section. It is important to remember that all references to orientation assume standing in front of the system with the leader carriage on the left with all follower carriages to the right. 1.3 The center hole in the array provides tool alignment for punching the large square scanner opening. Use the step drill supplied with the retrofit kit to enlarge the center hole to 1 1/8", enough to pass the punch mandrel through. AG/AGI - Page 18 - REV 6/03

22 1.4 Position the punch with the female portion on the exterior and the male portion on the interior of the carriage profile. Use the template to line up the female portion of the punch. The top of the hole about to be punched must be parallel to the top of the carriage profile! 1.5 Screw the hydraulic pump to the mandrel. Pump the hydraulic handle until the hole is formed. Note: Use some oil on the punch for a cleaner hole and to preserve the punch. The hole array is now ready to accept the scanner motor, scanner and scanner guard. The reflector strip is shown here for reference only. From this point the installation follows the standard sequence. Refer to the earlier sections in this manual. AG/AGI - Page 19 - REV 6/03

23 AISLE ENTRY PREPARATION NOTE: This information is valid only for systems not originally equipped with aisle entry sensors. Existing aisle entry sensors may be left as is and will properly interact with the new Aisle Guard safety system. Note: A fixture to aid in the following steps is included as part of the retrofit kit. ORIENT A BEZEL CENTERED OVER EACH HOLE JUST DRILLED IN THE PANEL PLASTIC TUBE. THE NOTCH ON THE BEZEL MUST BE ON THE BOTTOM EDGE. DRILL 3/32 INCH PILOT HOLES FOR THE SMALL SCREWS WHICH HOLD THE BEZEL IN PLACE. BE CAREFUL NOT TO OVER TIGHTEN AND STRIP THE THREADS. EXISTING AISLE ENTRY SENSORS MAY BE AT 36 INCH ELEVATION. THEY NEED NOT BE RELOCATED. AG/AGI - Page 20 - REV 2/03

24 NOTE: THE EPROM ON THE POWER PRO LOGIC BOARD MUST BE CHANGED TO ENABLE AISLEGUARD FUNCTION. CAREFULLY FOLLOW THE GENERIC INSTRUCTIONS BELOW, ALL STEPS MAY NOT APPLY TO THIS SITUATION. EPROM CHANGING INSTRUCTIONS NOTE: THERE MAY BE OCCASIONS WHEN AN EPROM CHANGE IS NECESSARY. ON RARE OCCA- SIONS, MISMATCHED EPROMS MAY INTERFERE WITH SYSTEM COMMUNICATION AND/OR FUNCTION. FOLLOW THE INSTRUCTIONS OUTLINED BELOW. 1. Open the access drawer or remove the lid. 2. Remove the fuse, power down the system or in some cases, remove the jumper at JP4. Never attempt an eprom change with low voltage power still on. 3. For units that apply: If the eprom is tucked under the heatsink do the following. Unfasten the heatsink plastic standoffs and gently lift upward to gain clearance to more easily change the eprom. Do not lift more than 2 inches to avoid stress to components still attached to the heatsink at the other end. 4. Remove the old eprom. Gently slide a small flat bladed screwdriver between the eprom and its socket. A screwdriver modified like the one shown below will be helpful. Carefully pry up one end of the eprom and then the other continuing to work it upward. NOTE: OBSERVE THE NOTCH AT ONE END OF THE EPROM. THIS NOTCH MUST MATCH UP WITH THE SILK SCREENED NOTCH SHOWN ON THE LOGIC BOARD! 5. Insert the new eprom into its socket making certain that the notches line up and that no pins get bent. When alignment is confirmed, then press the eprom firmly into its socket. 6. Re-establish power to the logic board by reversing the procedure used in step Update the label on the heatsink to reflect the revision level of the new eprom. Close the drawer or re-install the lid. NOTE: WEAR STATIC STRAP WHEN CHANGING. AG/AGI - Page 21-12/02

25 Spacesaver Corporation a division of KI U.S.A.: 1450 Janesville Avenue, Fort Atkinson, WI , (920) , , FAX: (920) CANADA: 266 King Street East, Toronto, Ontario M5A 4L5, (416) , , FAX: (416) EUROPE: Commonwealth House, High Holborn, London WC1V 6PJ, UK, +44 (0) , FAX: +44 (0) WEBSITE: ssc@spacesaver.com Copyright, 2003 by Spacesaver Corporation. All Rights Reserved. Printed in U.S.A. REV. 3.0/OP-0217 SSC/EPD 70/4