SECTION I INTRODUCTION SECTION II COMPONENTS INSTALLATION SECTION III SCANNER SETTINGS SECTION IV FIGURES SECTION V RETRO FITS 920-563-6362 E-mail: [email protected]Internet: www.spacesaver.com 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. AISLEGUARD TM FOR POWER PRO ® by Spacesaver ® INSTALLATION INSTRUCTIONS
18-19 Punching and Drilling the Profile20 Aisle Entry Preparation21 Processor Change
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SECTION IINTRODUCTION
For purposes of clarity, all right, left, front, and back references assume facing the true front of the system. If thesystem is dual entry, the end which houses the logic board is considered the true front. The carriage at the far leftis considered the leader and the carriage(s) to the right of the leader are considered followers.
AisleGuardTM
is referred to as being installed on aisles rather than carriages. When this manual address-es 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 sequencethat 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 regard-ing Power Pro core installation procedure see installation manual “Power Pro Controls” OP-0042 and wiringdrawing 480269.
TERMS: Leader Control Box:Located on every other carriage, beginning with the leader, on odd number carriage systems. Drivesaisles to the left and right. Last box of even number carriage systems drives only the aisle to its rightbut 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 atthe 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 acti-vates the scanners.
End of scan switch:Roller switch mounted to the end of the pantograph. Triggered by the pantograph when the aisle isnearly closed. Deactivates the scanners just prior to carriage nesting. Used only on the pantographend 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-0217.3. Power Pro electric installation OP-0042.4. Power Pro wiring drawing 480269.5. Steel Carriage Installation OP-9516.6. 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 THEDEGRADATION OF ELECTRONIC COMPONENTS. THE FOLLOWING PRECAUTIONS SHOULD BETAKEN 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.
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WORK "TIPS" RELATIVE TO AISLEGUARD INSTALLATION AND SET UP
The following "Tips" are in random order. They represent knowledge we have gained from various sourcessince the introduction of the AisleGuard safety system. You will find some or all of these "Tips" useful wheninstalling AisleGuard. Many of the following topics address specifics relative to set up, operation, etc. Wesuggest 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 makesure 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 anangle the ribbon cable may rub the screw holding the laser and the motor together. Watch the cablemove 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", soadjusting 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 initialsetting is to have the aisle completely open and set the beam so it arcs to the center of the open aisleat the other end of the system. The beam shouldn't hit the reflectors on its side of the carriage. The arcwill never be a full 90 degrees.
➣ Once you have your adjustments made connect the hand held tester to the aisle guard board andwatch the tester count reflectors for you. You can use the jogger and watch the scanner count the num-ber of reflectors on the scan pass and also the return pass. The tester should show twice the numberof reflectors when it returns to home. With a careful touch on the jogger you can watch it count onereflector 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 twosets of scanners it's not immediately evident which AG board sees an object. So faults in theaisle require you to look in the logic box and visually check the AG boards to see which one iscausing the fault. Knowing both AG boards are seeing every reflector before powering them upeliminates 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 see-ing 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 isrequired; 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 trig-
ger when the aisle is 10 to 12 inches from fully nested. Do not vary either high or low from this bench-mark!
✻ 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 willbe high. Double or single dots may also appear on the display along with the sequencing numbers. Be verycautious 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 willfreeze on the screen and then disapear after approximately 15-20 seconds.
➣ The AisleGuard board does have some memory. Push the button on the side and the number dis-played is the location of the last fault.
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✻ 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 offand back on. If it is off at the time of programming it will toggle on and back off.
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POWER PRO WITH AISLE GUARDAISLE SELECTION SCENARIO
The following information is a brief description of what Aisle Guard behavior should be expected duringaisle 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.
4
3 2 2
3 2 1
2 2 1 2
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.
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1 2
NOTE:All the fastening holes required to attach the motor hous-ing 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 forminga four corner square are for the scanner housing. 3 Theremaining 2 holes are for the motor housing attached tothe interior of the carriage. 4 The large square hole pro-vides 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 withthe carriage profile. 2 The other 2 small holes provideclearance for mounting the scanner guard to the carriageprofile.
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Scanner Motor Housing
Step 1:
1.1Set the first channel in place using the cutout for thescanner to align to the carriage. Fasten in place throughone hole which will later be used for the scanner guard.The strip is molded with a 90 degree return on the topside. Rest the return on the top edge of the carriageprofile and the strips automatically align themselves fromtop to bottom. The reflector strips attach to the carriageprofile with tek screws. Each strip butts to the proceed-ing strip. A splice plate is tek screwed in place to stabi-lize the joint. TEK it to the right of the splice. The nextstrip is slid underneath.
NOTE:The step 1 sequence is taken from the perspective of thefront right side of the aisle. The installation of the scan-ner is being carried out on a carriage. Shown here arethe 2 halves of the scanner. The motor and drive portionon the right goes to the inside of the carriage. The laserscanner portion on the left goes to the outside of the car-riage.
NOTE:A 1/4 inch spacer is required behind all photo sweepunits. Consult Power Pro® Manual OP-0042 for PhotoSweep installation and steel carriage installation manualOP-9516 for bumper installation.
SECTION IICOMPONENT INSTALLATION
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 denseto 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 pro-grammed for.The number of reflector targets found on each stick length.The F1 indicates the first carriage length configuration for the front set ofscanners.The F2 indicates the second carriage length configuration (if required) for thefront set of scanners.The R1 and R2 indicates the same information as above for rear scanners ifrequired.The carriage numbers indicate which configurations fit which carriages.
Immediately below the "standard configuration chart" is found the "alternate con-figuration chart". This chart may be used if circumstances dictate different lengthsticks.To further assist you, the stick lengths and part numbers are noted on the boxexteriors.
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2.2Remove the cable restraint strap form the back of thescanner housing.
NOTE:The use of the static strap for the next few steps.
Step 2:
2.1Mount the motor portion to the inside of the carriage.Fasten using the holes designated 3 and shown onpage 4. Notice how the ribbon connecting cable passesthrough the square hole. Do not crimp or pinch thiscable.
Pan Head Screw 96002.02
NOTE:Do not anchor shelving uprights to the carriage usingscrews through the profile. Anchor instead through theshelf supports down into profile lip.
1.2Attach all the strips end to end to complete the aisle onboth sides.
Splice Plate 290943.001Tek Screw 960212.001
2.5Screw the scanner body to the carriage profile in 4 places.See Page 4 location 2 . Do not over tighten thescrews. A special tamper proof apex bit is required.
Tamper Proof Screw 960199.001
NOTE:The bumper/1/4” spacer combination shown is requiredonly for dual sweep applications. Typical is 1” bumpersplaced opposite one another on each side of the aisle.
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2.4Replace the wire restraint.
Caution: If the restraint is not installed properly theribbon cable may rub on a screw head in the motorassembly. Be sure to confirm that it does not rubwhile making our settings later.
2.3Plug the ribbon cable into the receptacle on the back ofthe scanner. Hold the laser scanner assembly to keep itfrom moving as you attach the ribbon cable. Use a nee-dle nose pliers to apply adequate pressure. Press theend of the cable into the receptacle from the restraintside. The 4 silver wire ends should face away from thescanner body. Make sure the cable is fully seated intothe receptacle.
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Step 3:
3.1Attach the wires to the aisle entry sensors, push thesensor into the bezel. For more detail see the "AisleEntry" tab in this section of the binder. The smallalignment tab on the aisle entry will mate with a slot inthe factory installed bezel. The tab must point towardthe floor.
Note:See Figures 2, 3 & 5 for wire routing detail.
2.6Remove 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 reflectorends.
End Cap 290935.001Tek Screw 960213.001
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Step 5:
5.1Once the "works in a drawer" box is positioned, all thewires may be routed to the components, and the con-nections made. Refer to Figures 1, 2, 3 & 5.
Note:Some applications may call for top mount boxes.
Note:The pantograph must be fitted with a special "end ofscan" switch assembly. The pantograph is modified withan extension channel, a switch bracket with adjustingslots and a roller micro switch.
Step 4:4.1The extension channel mates with the existing panto-graph channel by sharing the elevator post and nut.Place the extension channel over the threaded post andthread the nut on. Adjust the elevation as needed. Theswitch bracket sandwiches between the shelving canopytop and the pantograph post base. The roller switch isattached and adjusted so that the extension tube con-tacts it when the aisle is about 12 inches from beingclosed. Wire the switch normally open. This photo istaken from the carriage front looking to the rear.Switches are located only on the carriages housingan AisleGuard logic board.
Note:The switch must be wired normally open, use the bottom2 posts. The scan switch must be set to trigger when theaisle is 10 to 12 inches from fully nested. Do not varyeither high or low from this benchmark!
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1.3 (See Figure 4)Insert the special allen wrench into the adjustment portat the front of the scanner. Turn the wrench to set thelaser beam in the middle of the reflector strip form top tobottom. This represents the “pitch” setting.
1.2Stop the laser beam at a point where it strikes the reflector strip directly across from the scanner.
NOTE: Scanners need final adjustment from 3 perspectives; pitch, yaw and degrees of arc. Each ofthese adjustments are finite in nature and must be done with care and in the order shown. The followingadjustment protocol applies to all scanners in the system. See Figure 4 for clarification. Aisles widerthan 36 inches may require that pitch be adjusted the maximum distance from the first scanner. ContactFactory for more detail.
Plug the tester assembly into the two pin header provided on the motor housing. Pressing the switch willturn the laser on. The laser will turn off after about ten seconds. Pressing and holding the test switch willturn on the laser and after two to three seconds begin scanning (the motor will begin to rotate the laserassembly). When the scanner has returned to the “home” position it will turn off the motor for about two tothree seconds. If the home sensor is not working properly the motor will not stop. When the tester switch isreleased 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 direct-ly into the laser. Observe laser position on the oppo-site side channel.
Step 1:
1.1A tester is required to light the laserand drive the scanner through itsarc during set up. The button of thistester will allow you to jog the scan-ner through its entire arc, stoppingwhenever necessary. This testerplugs to the two position connector located on the motor housing.
SECTION IIISCANNER SETTINGS
NOTE:Start the following adjustment sequence with a “rough”arc setting. The sequence will end with a “final” arc set-ting. See step 1.5 for arc setting details.
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 locatedHR Rear home switch not locatedHF 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 showtwice as it monitors the front scanner first and then the rear scanner. If 1 dot and a number shows on the screenall is not well. The single dot indicates the front scanner and the number indicates the reflector which cannot beseen. 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.
NOTE:Jog the scanner through its full 90 degree arc as finalconfirmation for pitch, yaw and arc settings. The arcshould take the beam from pointing directly across theaisle to pointing parallel along the length of the carriageon which the scanner is mounted.
1.5 (See Figure 4)At the back side of the motor housing is found a phillipshead screw. Turning this screw will set the 90 degree arcof travel. Correct adjustment will allow the beam to movefrom a position directly across the aisle, to a position thatlines the beam up parallel to the carriage face. This rep-resents the "Degree of Arc" setting.
1.4 (See Figure 4)Jog the beam until it projects to the far opposite cornerof the aisle. Insert the allen wrench into the adjustmentport on the side of the scanner. Turn the wrench to setthe beam in the middle of the reflector strip, from top tobottom, at the opposite corner of the carriage/platformacross the aisle. This represents the “yaw” setting.
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FIGURE 1
SECTION IVFIGURES
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FIGURE 2
Aisle entry WIRES LABELEDsensors 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
FIGURE 3
WIRE LAYOUT CODES
Note: The following codes are used to identify and locate Aisle Entry Sensors, Pantograph side of "endof scan" switches, IC Buss cables and Scanners. The term “remote” implies that the component is locat-ed 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 con-troller box. (Home carriage.) The wire labels are color coded. Wire labels to left side components will be greenand for right side components the labels will be red. This excludes Aisle Entry wires.
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* Aisle Entry wires only cross the first and last aisles. All others connect directly to the Power Pro logic board.See figure #2.
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I 2C buss LOGIC TO LOGICcommunication INTERCONNECTING
cable COMMUNICATIONCABLE
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 J1over 22' in length
FIGURE 3 - Continued
End of scan WIRES LABELEDswitch 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 J4of 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 J3of 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
Scanners WIRES LABELEDFROM 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
Adjust the laser beam to project/swing in a 90 degreearc. Use a phillips screwdriver to turn the screw headexposed at the rear of the motor housing. See the solidarrow head for location.
CAUTION:Never allow the beam to contact the carriage profile onwhich the scanner is mounted. DO NOT exceed 90o!
Adjust the laser beam to strike the center of the reflectorstrip from top to bottom at the far opposite corner fromthe laser sender. Use the special adjustment tool for thispurpose. Insert the tool into the adjustment port at theside of the laser sender.
“Yaw” is similar to “Pitch” except that it is carried out withthe beam striking the reflector strip in the far oppositecorner from the laser sender.
Adjust the laser beam to strike the center of the reflectorstrip from top to bottom. Use the special adjustment toolfor this purpose. Insert the tool into the adjustment portat the front of the laser sender.
FIGURE 4
"PITCH", "YAW" AND "ARC" EXPLAINED
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RIGHT AISLE OF HOME CARRIAGE
Middle Scanner Remote Through carriage/platform, to front, up front, across shelving, through pantograph, to OR, down to logic box.
Middle Scanner Through carriage, to OR, up to logic box.
RIGHT AISLE OF HOME CARRIAGE
LEFT AISLE OF HOME CARRIAGE
Middle Scanner Remote Through carriage/platform, to front, up front, across shelving, through pantograph, to OR, down to logic box.
Middle Scanner Through carriage, to OR, up to logic box.
Note: Carriages greater than 21 feet in length will require a second set of scanners. They will be wirerouted as follows.
RIGHT AISLE OF HOME CARRIAGE
Remote rear right receiver Up carriage/platform rear, across shelving, through pantograph, to OR, down to logic box.
Remote front right transmitter Up carriage/platform front, across shelving, through pantograph, to OR, down to logic box.
Local rear left transmitter Up carriage rear, across shelving, to OR, down to logic box.
Local front receiver Up to logic box.
Front Scanner Remote Up carriage/platform front, across shelving, through pantograph, to OR, down to logic box.
Rear scanner Up carriage rear, across shelving, to OR, down to logic box.
Local end of scan switch To OR, down to logic box.
LEFT AISLE OF HOME CARRIAGE
Note: Power Pro systems equipped with Aisle Guard will usually have all logic boards housed in “WorksIn A Drawer” enclosures. For details on this type of logic box installation see OP-9616, the EC400 elec-tric installation instructions.
Note: Aisle Entry wires only cross the first and last aisles. All others connect directly to the Power Prologic board. See figure #2.
The following wiring map assumes facing the system front with the leader carriage positioned on the left. Alllocations are oriented from the aisle perspective, not carriage perspective.
WIRE ROUTING
FIGURE 5
Remote rear left transmitter Up carriage/platform rear, across shelving, through pantograph, to ORfront, down to logic box.
Remote front left receiver Up carriage/platform front, across shelving, through pantograph, to ORfront, down to logic box.
Local rear right receiver Up carriage rear, across shelving to OR, down to logic box.
Local front right transmitter Up to logic box.
Rear Scanner Remote Up carriage/platform rear, across shelving, through pantograph, to OR, down to logic box.
Front scanner Up to logic box.
Local end of scan switch To OR, down to logic box.
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1.3The center hole in the array provides tool alignment forpunching the large square scanner opening. Use thestep drill supplied with the retrofit kit to enlarge thecenter hole to 1 1/8", enough to pass the punch man-drel through.
1.2Drill each hole with the appropriate bit. Three (3) bitsizes are required. Use the holes in the template tolocate the 6 holes to be drilled. Start each hole withthe bit passing through the template. Remove the tem-plate and finish the holes freehand.
Bit sizes: 1/4" and #29, #25
Step 1:
1.1Use the template supplied with the retrofit kit to locateall holes which must be punched and drilled. Rest thetemplate on the carriage profile edge. Align the end ofthe template with the end of the carriage profile andclamp it in place. This position provides automatichole location. An array of holes is required at eachscanner location. One scanner at the front right side ofthe aisle and one scanner at the rear left side of theaisle.
NOTE: It is important to lay a drop of some sortunder the work area. The drill chips are very diffi-cult to remove from carpet fibers.
SECTION VAISLE 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 Guardto an existing Power Pro system. All material in the previous sections of this manual remain valid. Read throughthe first 4 sections of this manual before beginning the retrofit, to develop a better understanding of the informa-tion in this section. It is important to remember that all references to orientation assume standing in front of thesystem with the leader carriage on the left with all follower carriages to the right.
PUNCHING AND DRILLING OF THE CARRIAGE PROFILE:
The hole array is now ready to accept the scannermotor, scanner and scanner guard. The reflector stripis shown here for reference only. From this point theinstallation follows the standard sequence. Refer to theearlier sections in this manual.
1.5Screw the hydraulic pump to the mandrel. Pump thehydraulic handle until the hole is formed.
Note:Use some oil on the punch for a cleaner hole and topreserve the punch.
1.4Position the punch with the female portion on the exte-rior and the male portion on the interior of the carriageprofile. Use the template to line up the female portionof the punch. The top of the hole about to be punchedmust be parallel to the top of the carriage profile!
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Note: A fixture to aid in the followingsteps is included as part of the retrofitkit.
ORIENT A BEZEL CENTERED OVEREACH HOLE JUST DRILLED IN THEPANEL PLASTIC TUBE. THE NOTCH ONTHE BEZEL MUST BE ON THE BOTTOMEDGE.
DRILL 3/32 INCH PILOT HOLES FOR THESMALL SCREWS WHICH HOLD THEBEZEL IN PLACE. BE CAREFUL NOT TOOVER TIGHTEN AND STRIP THETHREADS.
EXISTING AISLE ENTRY SENSORS MAYBE AT 36 INCH ELEVATION. THEY NEEDNOT BE RELOCATED.
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 safetysystem.
NOTE:WEAR STATICSTRAP WHENCHANGING.
NOTE: THE EPROM ON THE POWER PRO LOGIC BOARD MUST BE CHANGED TO ENABLE AISLEGUARDFUNCTION. CAREFULLY FOLLOW THE GENERIC INSTRUCTIONS BELOW, ALL STEPS MAY NOT APPLYTO 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 moreeasily change the eprom. Do not lift more than 2 inches to avoid stress to componentsstill attached to the heatsink at the other end.
4. Remove the old eprom. Gently slide a small flat bladed screwdriver between the epromand 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 THESILK SCREENED NOTCH SHOWN ON THE LOGIC BOARD!
5. Insert the new eprom into its socket making certain that the notches line up and that nopins 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 2.
7. Update the label on the heatsink to reflect the revision level of the new eprom. Closethe drawer or re-install the lid.
AG/AGI - Page 21 - 12/02
Spacesaver Corporationa division of KI
U.S.A.: 1450 Janesville Avenue, Fort Atkinson, WI 53538-2798, (920) 563-6362, 1-800-492-3434, FAX: (920) 563-2702CANADA: 266 King Street East, Toronto, Ontario M5A 4L5, (416) 360-1022, 1-800-544-3679, FAX: (416) 360-7290EUROPE: Commonwealth House, 148-153 High Holborn, London WC1V 6PJ, UK, +44 (0)20 7404-7441, FAX: +44 (0)20 7404-7442WEBSITE: www.spacesaver.com E-MAIL: [email protected]
