Compactus mekdrive 2 Compactus Side2Side 2 Mobile Storage Systems
Freetrack 2 This manual remains the sole property of Dexion Commercial (New Zealand) Limited (Precision). The information contained within this manual is to be regarded as confidential and must not be disclosed to any third party. Whilst the utmost care is taken to ensure the accuracy of the data and design details shown within, Dexion Commercial cannot, under any circumstances, be held liable for any injuries, expenses or loss which may, in any degree, be attributed to the use or adoption of such data and design details. Any modification, repair, or alteration of the products described herein by a third party without written approval voids Dexion Commercial s warranty obligations. Copyright: Dexion Commercial (New Zealand) Limited 25 Peterkin Street Wingate Lower Hutt 5045 Ph: +64 4 9205400 Fax: +64 4 9205402 Date of Issue: March 2013 Issue Date Issued Description Issue 1 February 2009 Product Launch (NZ) Issue 2 March 2011 Updated for Mekdrive2 Modified Runner Lengths
Freetrack 2 Table of Contents SECTION 1 PRODUCT INTRODUCTION... 1 INTRODUCTION... 1 PARAMETERS OF THE SYSTEM... 3 SECTION 2 COMPONENT DESCRIPTIONS... 1 RUNNERS... 1 CROSS TIES... 3 CORNER BRACKET...3 TRACKS... 4 CRINOLIN STEEL STRIP... 5 NON-SLIP TAPE - MEKDRIVE... 5 RAMPS... 6 ADHESIVE RUBBER BUMPER... 6 END STOP... 7 END STOP COVER - STANDARD... 7 END STOP COVERS MEKDRIVE... 7 TRACK JOINER... 8 LEVELLING PLATE... 8 INSTALLATION TOOL... 9 FINISHING PANELS... 9 FINISHING PANELS - MANUAL... 10 FINISHING PANELS MEKDRIVE2... 11 FINISHING PANELS MEKDRIVE (CONT)... 12 FINISHING PANEL BATTEN... 13 MANUAL HANDLE...13 DUST COVER (BIN FRONT)... 14 FIXINGS... 15 SCREW AND NUT COMB HEAD M6 X 10MM... 15 SCREW 8G X 3/8 (10MM) PAN HD SELF TAPPING... 15 NUT U 8G... 15 NUT U M6... 16 SCREW M6 X 8MM SOCKET BUTTON HEAD CAP... 16 SCREW M6 X 10MM SOCKET BUTTON HEAD CAP... 16 SQUARE NUT M6... 17 WASHER M6 EXTERNAL SHAKEPROOF... 17 STATIC PIN... 17 MEKDRIVE2 ASSEMBLY... 18 LOCK (FLUSH)... 19 LOCK PLATE... 19 LOCK ROD SPRING... 19 LOCKING ROD... 20 Page i
LOCK BRACKET... 20 LOCK BRACKET COVER... 20 LOCK ASSEMBLY FT AISLE... 21 SPARE PARTS... 21 RUNNER END CAP... 21 SCREW M5 X 10MM POZI CROSS RECESSED FLAT HD... 22 FRAME CLIP... 22 RAMP SPACER...22 SECTION 3 DESIGNERS REFERENCE... 1 GENERAL... 1 BAY SIZES... 1 TRACK AND RUNNER HEIGHT... 2 OVERALL UNIT HEIGHT... 2 MAXIMUM LEVELLING HEIGHT... 2 TRACK WIDTH... 3 OVERALL UNIT DEPTH... 4 MANUAL UNITS... 4 MEKDRIVE UNITS... 4 CONVENTIONAL CONFIGURATIONS... 5 SINGLE ENTRY STACKS... 5 STATIC STACKS... 5 DOUBLE ENTRY STACKS... 5 LATERAL CONFIGURATIONS... 6 TYPICAL FLOOR PLANS... 7 TYPICAL FLOOR PLANS - CONVENTIONAL UNITS... 7 TYPICAL FLOOR PLANS SIDE2SIDE (LATERAL) UNITS... 8 CONFIGURATION - 900MM STATIC BAYS AND 750MM MOBILE BAYS... 8 CONFIGURATION COMMON BAY WIDTHS... 8 TRACK DESIGN... 9 TRACK LENGTH... 9 LEFT AND RIGHT HANDED UNITS... 10 FLOOR COVERING... 11 HEAVY ITEMS... 11 SECTION 4 LOAD INFORMATION... 1 GENERAL... 1 SHELF LOADS... 1 BAY LOADS... 1 WHEEL LOADS... 2 WHEEL LOADS - SINGLE BAY, SINGLE ENTRY STACKS... 2 WHEEL LOADS - SINGLE BAY, DOUBLE ENTRY STACKS... 2 WHEEL LOADS - DOUBLE BAY, SINGLE ENTRY STACKS... 3 WHEEL LOADS DOUBLE BAY, DOUBLE ENTRY STACKS... 3 WHEEL LOADS TRIPLE BAY, SINGLE ENTRY STACKS... 4 WHEEL LOADS TRIPLE BAY, DOUBLE ENTRY STACKS... 4 BLOCK LOAD LIMITATIONS... 5 Page ii
Section 1 - Product Introduction SECTION 1 PRODUCT INTRODUCTION INTRODUCTION This manual describes the components, design requirements, assembly, applications and load limitations for the following Freetrack 2 products. Compactus Freetrack 2 Manual operation Conventional movement Compactus Mekdrive 2 Mechanically assisted operation Conventional movement Compactus Side2Side 2 Manual operation Lateral movement Page 1.1
Section 1 - Product Introduction These Freetrack 2 products utilise an attractive low profile track and runner system, which can be installed onto most floor surfaces. The system consists of aluminium extrusion tracks, which rest directly on the floor, and a series of aluminium runners with wheels to give mobility. Ultima CI-80 Shelving is designed to attach directly to these runners. Each track has two full-length inserts of hardened steel, which provide a wear resistant running surface for the wheels. A track stop is secured at each end of the unit and a fixed or static bay can be installed. The runners and track can be installed to allow conventional movement, as shown above, or can be installed as lateral, side ways moving units. Conventional units are limited to single or two bays deep which can be moved manually or by mechanical assistance, whilst the lateral units are limited to single bay assemblies. Unlike other systems, Freetrack 2 does not require a prefabricated base. A lightweight runner frame supports the Ultima CI-80 shelving bays to provide structure, rigidity and mobility. This unique application provides a very cost efficient office storage system, particularly in the case of two bay deep units. Note that bay depths can be mixed within conventional movement stacks. For shelving components and assembly details not described in this manual refer to the Ultima CI-80 Manuals. Freetrack 2 can be installed directly onto most existing floor surfaces, always providing the floor has the capability of accepting the load of a fully laden unit. Reference must be made to the load tables in this manual. As there are no major construction items involved in this system, installation can be carried out quickly, quietly and with a minimum of disruption. This is especially important in an established office environment. Floor fixing is kept to a minimum and in most conventionally moving installations is considered unnecessary. There are no problems associated with matching existing office décor as Freetrack 2 requires no auxiliary flooring items, such as chipboard or carpet. When it becomes necessary to relocate a Freetrack 2 installation, providing that the installation remains on the same floor level, this can be achieved without the major dismantling and reassembly costs associated with other storage systems. Where a customer requires additional storage space in an "add on" configuration, then this can be achieved by splicing new track on to the existing installation as required. A locking system can be used to secure the whole installation if required. Where an installation is in a general/open office area with specific bays containing information, which is available to selected personnel only, individual aisles can be secured using the unique locking system provided for the purpose. IMPORTANT: Section 3 of this manual clearly outlines the design and load limitations of this system. It is essential that all installations remain strictly within the guidelines as stated in this manual. When quoting Freetrack 2, the systems limitations and safe use requirements should be stated on the quotation - i.e. maximum load on units, etc. Page 1.2
Section 1 - Product Introduction PARAMETERS OF THE SYSTEM +40 o C +3 o C The Freetrack 2 range of storage cabinets has been designed to operate within the following standard parameters. Floor The floor should be of solid construction designed to accept loads imposed by the unit. Installations on carpet or similar floor coverings should be mindful of the floor substrate below and that the floor covering will not compress in an uneven manner. Loads Individual loads should be stable and self supporting, with a maximum unit weight within the safe working recommendations. Operating Conditions Components and load data are based on dry internal applications. Temperature range 0 C to +40 C Note: For applications that require operating parameters that are outside those indicated above, please contact Precision for technical guidance on your particular application. Page 1.3
Section 1 - Product Introduction Blank Page 1.4
Section 2 Component Descriptions SECTION 2 COMPONENT DESCRIPTIONS RUNNERS Runners are made from an aluminium extrusion. These extrusions are then fitted with roller cartridges, end caps, and frame panel clips and supplied as a complete assembly. Runners are available to suit Ultima CI-80 single and double entry shelving bays, with shelf depths of 300, 400, 450 & 600mm. Single Entry Runner Double Entry Runner Material: Finish: Quantity: Aluminium extrusion and steel roller cartridges Clear anodised aluminium and galvanised steel cartridges Two per starter bay (single or double entry) and one per extension bay for conventional units Two per mobile bay for lateral units Conventional Movement Runners Code Description Total Length (mm) Shelving (SE) Weight (Kg) 162636 RUNNER FT2 318 (300 SE) AN 330 300SE 0.560 162640 RUNNER FT2 418 (400 SE) AN 430 400SE 0.729 162642 RUNNER FT2 468 (450 SE) AN 480 450SE 0.801 162648 RUNNER FT2 618 (600 SE) AN 630 600SE 1.042 Continued over Page 2.1
Section 2 Component Descriptions Continued Code Description Total Length (mm) Shelving (DE) Weight (Kg) 162656 RUNNER FT2 644 (300/300) AN 656 300/300 1.085 162660 RUNNER FT2 844 (400/400) AN 856 400/400 1.412 162662 RUNNER FT2 944 (450/450) AN 956 450/450 1.575 162668 RUNNER FT2 1244 (600/600) AN 1256 600/600 2.066 Side2Side (Lateral Movement) Runners Code Description Total Length (mm) Shelving (Bay Width) Weight (Kg) 162680 RUNNER FT2 814 (750 S2S) AN 826 750 1.355 162682 RUNNER FT2 964 (900 S2S) AN 976 900 1.600 162686 RUNNER FT2 1264 (1200S2S) AN 1276 1200 2.090 Note: Please refer to your current price list to confirm the range of standard sizes available, or consult Precision Customer Service regarding size availability. Overall runner length for lateral movement units equals nominal bay width, plus 70mm for finishing panels and 12mm for end caps. Allowance should also be made for the adhesive rubber bumpers. Refer to Section 3 of this manual for additional information Page 2.2
Section 2 Component Descriptions CROSS TIES Cross ties connect to the runners with corner brackets to form a strong, lightweight trolley assembly that supports the shelving bays. Material: Finish: Quantity: Aluminium Clear anodised Two per bay Crosstie extrusion Conventional Movement Crossties Code Description Length (mm) Weight (kg) 162670 CROSS TIE FT2 750 AN 712 0.457 162672 CROSS TIE FT2 900 AN 862 0.553 162676 CROSS TIE FT2 1200 AN 1162 0.745 Side2Side (Lateral Movement) Crossties Code Description Length (mm) Weight (kg) 162690 CROSS TIE FT2 300 LATERAL AN 262 0.168 162692 CROSS TIE FT2 400 LATERAL AN 362 0.232 162694 CROSS TIE FT2 450 LATERAL AN 412 0.264 162698 CROSS TIE FT2 600 LATERAL AN 562 0.360 Note: Please refer to your current price list to confirm the range of standard sizes available, or consult Precision Office Customer Service regarding size availability. CORNER BRACKET Corner brackets are used to attach the cross ties to the runners. It includes two holes to accommodate the M6 x 10mm socket head cap screws fitted with star washers and square nuts. Code: 162606 Material: Aluminium Weight: 33g Finish: Die-cast Quantity: 2 per cross tie Corner Bracket Page 2.3
Section 2 Component Descriptions TRACKS The track is an aluminium extrusion that includes recesses for track joiners and for two hardened crinolin steel strips which serve as the running surface for the wheels. The track is available in a standard version and a mekdrive version that is used as the front (drive) track for mechanically assisted Freetrack 2 units. The mekdrive version includes an extension on one side with a recess for a non-slip tape. Material: Finish: Quantity: Aluminium Clear anodised As required Standard track extrusion mekdrive track extrusion Code Description Length (m) Weight (kg) 162700 TRACK EXT FT2 3000 STD AN (Standard Track) 3.0 5.981 162702 TRACK EXT FT2 3000 MKD AN (Mekdrive Track) 3.0 8.413 Note: The cut length required needs to be specified on all construction documentation. Page 2.4
Section 2 Component Descriptions CRINOLIN STEEL STRIP Crinolin steel strips are fitted into the slots in the aluminium track extrusion to provide a continuous, hard wearing running surface for the runner wheels. The strip is pre-cut to the full length of the track based on the measurements supplied at time of ordering. Two strips are fitted into the track on-site. Code: 159580 Material: Hardened steel Weight: 0.0653kg/metre Finish: Natural Quantity: Full track lengths as required - cut to length in store Crinolin steel strip NON-SLIP TAPE - MEKDRIVE Non-slip tape is 25mm wide with a self adhesive backing. The tape is applied to the groove in the Mekdrive track to increase the friction for the rubber mechanical drive wheel. Code: Material: Weight: Quantity: 159833 (18.2 metre roll) Self adhesive carborundum tape. 0.46kg 1 roll every 18 metres or less of Mekdrive track Page 2.5
Section 2 Component Descriptions RAMPS Ramps attach to the side of the track to hide any gaps caused by uneven flooring and to minimise any potential tripping hazard. Ramps are supplied with 1 ramp spacer pre-fitted to provide a 1mm gap between the ramps. Ramp Spacers are detailed under Spare Parts later in this section. Code: 162720 Material: Aluminium Weight: 81g Finish: Clear anodised Quantity: 1 per 80mm of track (per side where required) Ramp 79mm ADHESIVE RUBBER BUMPER This is a self-adhesive rubber bumper used on one end of lateral movement (Side2Side) runners to prevent the finishing panels striking each other. It is fixed centrally onto the runner end cap. Code: 157545 Material: Rubber (Black) Weight: 2g Quantity: 1 per lateral runner Adhesive Rubber Bumper Page 2.6
Section 2 Component Descriptions END STOP End stops are fitted with a rubber end stop cover then fastened to each end of the track to provide a soft stop for the runner. The end stop includes four tapped M6 holes for fastening to the track (on site) using M6x8mm socket head cap screws and star washers. Code: 162710 Material: Steel Weight: 52g Finish: Zinc plated Quantity: 2 per track (standard or mekdrive) End stop END STOP COVER - STANDARD The End stop covers fit on to the end stop and provide a soft stop for mobile bays. Code: 162712 Material: Thermoplastic elastomer End stop cover - standard Weight: 11g Finish: Black Quantity: 2 per track (standard tracks) END STOP COVERS MEKDRIVE End Stop Cover - Mekdrive Right End Stop Cover - Mekdrive Left Code: 162714 Code: 162716 Material: Thermoplastic elastomer Material: Thermoplastic elastomer Weight: 17g Weight: 17g Finish: Black Finish: Black Quantity: 1 per Mekdrive track Quantity: 1 per Mekdrive track Page 2.7
Section 2 Component Descriptions TRACK JOINER Track joiners are used to join tracks together to achieve lengths greater than 3 metres. Two track joiners are used at each track joint. The track joiner incorporates four M6 threaded holes and is fitted into the ends of the track extrusions. It is then fastened with screws and star washers. Code: 162706 Material: Steel Weight: 32g Finish: Zinc plated Quantity: 2 per track join (Standard and Mekdrive tracks) Track Joiner LEVELLING PLATE The injection moulded levelling plate provides a means of levelling the tracks on uneven floors. Each levelling plate lifts the track by 2mm. The bosses on the top levelling plate locate into the grooved underside of the track. The bosses on plates fitted below the top plate lock into the square cut outs in the plate above. No adhesives are required. Levelling plates are fitted length wise under the standard track and cross wise under the Mekdrive track. Levelling plates are non-handed. Note: The maximum levelling plate stack is 50mm. Levelling Plate Code: 162708 Material: Plastic Weight: 8g Finish: Black Quantity: As required (1 stack every 300mm of track length) Page 2.8
Section 2 Component Descriptions INSTALLATION TOOL The installation tool is designed to assist with two aspects of installation of the Freetrack 2 system: Drilling holes in the track for locking pins Locate the two folded arms in the main channel of the track. Use the small guide hole to drill a pilot hole in the track then align the larger guide hole with the pilot hole and drill the final hole. The guide holes provide for correct alignment of drilled holes with locking pins. Fitting levelling plates beneath the track The main recess in the tool fits snugly around the levelling plate. Use the tool to slide levelling plates under the track. When the tool abuts the edge of the track extrusion the levelling plate will be correctly positioned to engage with the channels on the underside of the track. Code: 162608 Material: Aluminium Weight: 44g Finish: Plain Quantity: 1 per Freetrack2 installation Installation tool FINISHING PANELS Finishing panels are used to cover the visible ends of shelving bays. There are three types of finishing panel used for Freetrack 2 units: Plain - (refer to the Ultima CI-80 Shelving manual) Manual - with four holes to suit the handle, see following pages Mekdrive - with a cut out at the bottom of the panel and a single large hole, see following pages. Page 2.9
Section 2 Component Descriptions FINISHING PANELS - MANUAL The handle is positioned centrally on 1875 and 2175mm high finishing panels, therefore these panels are not handed, whilst 2400mm high panels are handed. If a lock is required the hole is drilled on site. Material: Finish: Quantity: 0.95mm cold rolled steel Powder coated 1 per mobile stack Code Description Weight (kg) 159885 FINPAN FT 1875 x 300 5.64 159889 FINPAN FT 1875 x 400 7.07 159893 FINPAN FT 1875 x 450 7.79 159901 FINPAN FT 1875 x 600 9.94 159915 FINPAN FT 2175 x 300 6.54 159919 FINPAN FT 2175 x 400 8.21 159923 FINPAN FT 2175 x 450 9.04 159931 FINPAN FT 2175 x 600 11.53 159945 FINPAN FT LH 2400 x 300 7.22 159949 FINPAN FT LH 2400 x 400 9.05 159953 FINPAN FT LH 2400 x 450 9.97 159961 FINPAN FT LH 2400 x 600 12.73 159975 FINPAN FT RH 2400 x 300 7.22 159979 FINPAN FT RH 2400 x 400 9.05 159983 FINPAN FT RH 2400 x 450 9.97 159991 FINPAN FT RH 2400 x 600 12.73 Note: Please refer to your current price list to confirm the range of standard sizes available, or consult Precision Customer Service regarding size availability. Page 2.10
Section 2 Component Descriptions FINISHING PANELS MEKDRIVE2 Mekdrive finishing panels have a cut-out at the bottom of the panel for the drive mechanism and a large slot for the hand wheel spigot. All Mekdrive finishing panels are handed. If a lock is required the hole is drilled on site. Material: Finish: Quantity: 0.9mm cold rolled steel Powder coated One per mobile stack Code Description Weight 160405 FINPAN MEK2 LH 1875x300 5.64 160409 FINPAN MEK2 LH 1875x400 7.07 160413 FINPAN MEK2 LH 1875x450 7.79 160421 FINPAN MEK2 LH 1875x600 9.68 160435 FINPAN MEK2 RH 1875x300 5.64 160439 FINPAN MEK2 RH 1875x400 7.07 160443 FINPAN MEK2 RH 1875x450 7.79 160451 FINPAN MEK2 RH 1875x600 9.68 160465 FINPAN MEK2 LH 2175x300 6.54 160469 FINPAN MEK2 LH 2175x400 8.21 160473 FINPAN MEK2 LH 2175x450 9.04 160481 FINPAN MEK2 LH 2175x600 11.2 160495 FINPAN MEK2 RH 2175x300 6.54 160499 FINPAN MEK2 RH 2175x400 8.21 160503 FINPAN MEK2 RH 2175x450 9.04 160511 FINPAN MEK2 RH 2175x600 11.2 160525 FINPAN MEK2 LH 2400x300 7.22 160529 FINPAN MEK2 LH 2400x400 9.05 160533 FINPAN MEK2 LH 2400x450 9.97 160541 FINPAN MEK2 LH 2400x600 12.38 160555 FINPAN MEK2 RH 2400x300 7.22 160559 FINPAN MEK2 RH 2400x400 9.05 160563 FINPAN MEK2 RH 2400x450 9.97 160571 FINPAN MEK2 RH 2400x600 12.38 Note: Please refer to your current price list to confirm the range of standard sizes available, or consult Precision Customer Service regarding size availability. Page 2.11
Section 2 Component Descriptions FINISHING PANELS MEKDRIVE (CONT) The position of the cut outs on mekdrive finishing panels is as per the diagram below. PANEL DEPTH W A B 300SE 305 36 149 400SE 405 86 199 450SE 455 111 224 600SE 605 186 299 Note: LH finishing panels are shown, RH panels opposite orientation. Page 2.12
Section 2 Component Descriptions FINISHING PANEL BATTEN The finishing panel batten is fitted between the finishing panel and the frame panel and is used to transfer the load from the handle to the frame panel. The handle is fitted to two battens and the finishing panel using four - M6 x 10mm bolts, the finishing panel battens are then fixed to the frame panel using two - M6 x 10mm bolts into M6 U nuts on each batten. A B Material: Finish: Quantity: 1mm electro galvanised steel Natural Two per handle 38mm Finishing Panel Batten Frame Depth 300 400 450 600 A 254 354 404 554 B 224 324 374 524 Code Description Weight (kg) 159592 FINPAN BATTEN FT 300 0.12 159593 FINPAN BATTEN FT 400 0.15 159594 FINPAN BATTEN FT 450 0.17 159596 FINPAN BATTEN FT 600 0.23 Note: Please refer to your current price list to confirm the range of standard sizes available, or consult Precision Customer Service regarding size availability. MANUAL HANDLE The Freetrack manual handle is an aluminium section that is formed into the shape of a D. The ends have four drilled and tapped M6 holes to allow for fixing. 50mm 50mm 38mm Material: Finish: Quantity: Aluminium 8mm x 50mm round edge flat Powder coated One per manual movement mobile stack 250mm hole centres Code Description Wt (kg) 152510 HANDLE FT MANUAL 0.42 M6 thread Page 2.13
Section 2 Component Descriptions DUST COVER (BIN FRONT) The dust cover is a formed sheet metal panel. It is designed to be screw fixed to the top shelf of a mobile unit and is shaped to go over the top of the opposing shelf to cover the gap and exclude entry of dust from above when aisles are closed. his part is also used as a bin front fixed to the front of the shelf - refer to the Ultima CI-80 Shelving manual for details. A B 74mm Bay Width 750 900 1200 A 744 894 1194 B 670 820 1120 Material: Finish: Quantity: 1.6mm cold rolled steel Powder coated One side of each aisle in conventional movement units Code Description Weight (kg) 202791 BIN FRONT UL 750 x 80 1.07 202801 BIN FRONT UL 900 x 80 1.29 202821 BIN FRONT UL 1200 x 80 1.72 Note: Please refer to your current price list to confirm the range of standard sizes available, or consult Precision Customer Service regarding size availability. Page 2.14
Section 2 Component Descriptions FIXINGS SCREW AND NUT COMB HEAD M6 X 10MM The M6 x 10mm combination head screw and nut are used for assembly of Ultima CI-80 shelving bays. On Freetrack units this screw and nut is also used to fix dust cover to the top shelf in conventional movement units, and also to fix the finishing panel battens to handle and frame panel. Code: 151330 Material: Mild steel Weight: 3g Finish: Zinc plated Quantity: 3 per dust cover 4 per finishing panel batten SCREW 8G X 3/8 (10MM) PAN HD SELF TAPPING The 8g x 10mm pan head self tapping screw is used to fix the rear cover to the finishing panel and the finishing panel to frame panel. Also fitted to the ends of Mekdrive tracks to retain the ramps. Code: 160249 Material: Mild steel Weight: 1g Finish: Zinc plated Quantity: 3 per rear cover 4 per finishing panel 2 per Mekdrive track NUT U 8G The 8 gauge U nut is fitted to the return flange on a finishing panel and used in conjunction with an 8g self tapping screw to fix the finishing panel to the frame panel. Code: 160250 Material: Spring steel Weight: 1g Finish: Zinc plated Quantity: 4 per finishing panel 11mm 17.5mm Page 2.15
Section 2 Component Descriptions NUT U M6 The M6 'U' nut is fitted to the finishing panel batten and used to fix the battens to the frame panel. Code: 152507 Material: Spring steel Weight: 5g Finish: Zinc plated Quantity: 2 per finishing panel batten 12mm 30mm M6 thread SCREW M6 x 8MM SOCKET BUTTON HEAD CAP The M6 x 8mm socket button head cap screw is used with a star washer and a square nut to fasten track joiners and end stops to the track and to fasten the frame clip to the runner. Code: 162610 Material: Steel Weight: 3g Finish: Zinc flake coated Quantity: 2 per frame panel (included with runners) 4 per track end stop 4 per track joiner SCREW M6 x 10MM SOCKET BUTTON HEAD CAP The M6 x 10mm socket button head cap screw is used with star washers and square nuts to fasten the corner bracket to the runner and cross tie, and also to fasten the lock bracket to the side of the runner. Code: 162612 Material: Steel Weight: 4g Finish: Zinc flake coated Quantity: 2 per corner bracket 1 per lock bracket Page 2.16
Section 2 Component Descriptions SQUARE NUT M6 The M6 square nut (DIN562) fits into slots on the track extrusions and cross ties to permit fastening of various components. Code: 162614 Material: Steel Weight: 1.75g Finish: Zinc plated Quantity: 2 per frame panel (included with runners) 1 per lock bracket 2 per corner bracket WASHER M6 EXTERNAL SHAKEPROOF This is an external toothed washer, used to prevent loosening of M6 screws due to vibrations. Code: 162618 Material: Spring steel Weight: 4g Finish: Zinc plated Quantity: One per M6 screw STATIC PIN The static pin is used to lock a static stack in the required position. The pin is fixed to the runner using the lock bracket. A groove is provided at the top end of the static pin to assist with removal of the pin if it is necessary to release a static stack. Code: 162624 Material: Steel Weight: 13.5g Finish: Zinc coated Quantity: 1 for each runner of every static stack Page 2.17
Section 2 Component Descriptions MEKDRIVE2 ASSEMBLY A Mekdrive assembly contains the drive unit for a Freetrack shelving stack. It is used to mechanically assist the movement of a stack by turning the handwheel, which drives a reduction mechanism to readily move the stack on the Mekdrive track. The Deluxe Mekdrive assembly is designed for use with finishing panels. The Standard Mekdrive Assembly is designed for use without finishing panels. Mekdrive2 assemblies are supplied pre-assembled ready to fit to the end frame panel and runners. Handwheel Drive Assembly Cover Panel Drive Belt Mekdrive Assembly Code: Weight: Colour: Quantity: 160700 Deluxe version for use with Finishing Panels 160702 Standard version for use without Finishing Panels 6.5kg Cover charcoal Handwheel silver 1 per mobile stack Page 2.18
Section 2 Component Descriptions LOCK (FLUSH) The lock flush is an L&F chrome flush fitting barrel lock, which is fitted to the finishing panel. The lock assembly is connected to a 6mm diameter rod which passes through a lock bracket fixed to the runner and into a hole drilled in the track on-site. This lock is only used on conventional movement units. Cam plate Keeper plate Spring washer Flat washer Screw Fixing nut Lock Code: 152525 Material: Steel Finish: Chrome plated Weight 65g Quantity: 1 per unit lock Notes: The lock supplied is keyed to differ Two keys are included The locking rod, locking rod spring, and lock plate are ordered separately. LOCK PLATE The lock plate is a piece of flat sheet metal with a flat sided hole punched through the centre. It is attached to the back of the finishing panel with double sided tape and its purpose is to prevent the lock housing from turning during operation. Code: 158600 Material: 1.0mm electro galvanised steel Finish: Natural Weight 11g Quantity: 1 per unit lock 40mm 44mm 1.0mm LOCK ROD SPRING This standard compression spring is fitted to the locking rod to counterbalance the weight of the rod. Code: 152533 Material: Spring steel Weight: 1g Finish: Oiled Quantity: 1 per unit lock Page 2.19
Section 2 Component Descriptions LOCKING ROD The locking rod is a 6mm diameter rod that attaches to the lock flush and passes through the lock bracket (fixed to the runner) and engages into a drilled hole in the track. 777mm or 927mm Material: Finish: Quantity: 6mm diameter mild steel Zinc plated 1 per unit lock Code Description Length (mm) Weight (kg) 162626 LOCK ROD FT2 1875-2400 MKD ZP Used for 1875 and 2400mm bay heights, and all Mekdrive bay heights 777 0.173 162628 LOCK ROD FT2 2175 ZP Used for 2175mm bay heights (manual units) LOCK BRACKET 927 0.206 The lock bracket fastens to the runner and constrains the locking rod or static pin. Code: 162630 Material: Plastic Weight: 4.2g Finish: Grey Quantity: 1 per unit lock 1 for each runner of every static stack. LOCK BRACKET COVER The lock bracket cover clips onto the lock bracket to provide a neat appearance. The cover can be pried loose using a flat head screwdriver pushed into one of the slots. Note: The cover is not fitted to lock brackets used for static pins as these are hidden under the shelving bay. Code: 162632 Material: Plastic Weight: 6.6g Finish: Grey Quantity: 1 per unit lock Page 2.20
Section 2 Component Descriptions LOCK ASSEMBLY FT AISLE This assembly is for use with conventional movement units only, to lock individual aisles. It is not suitable for lateral installations. The two parts of the lock are fitted to the opposing end frames of the storage bays in an aisle. The lock fixings are covered by the finishing panels. Note: The standard lock (lock flush) should be used to secure a unit to the track. Code: 159561 Material: Cast aluminium Weight: 0.5kg Finish: Silver powder coat Quantity: As required SPARE PARTS The following items are not usually sold as separate items, but are available individually as spare parts. RUNNER END CAP Runner end caps fit to the ends of the runners and incorporate anti-tilt features that prevent the runners from lifting off the tracks. Code: 162600 Material: Plastic Weight: 11.5g Finish: Grey Quantity: 2 per runner Page 2.21
Section 2 Component Descriptions SCREW M5 x 10MM POZI CROSS RECESSED FLAT HD The M5 x 10mm Pozi cross recessed flat head screw is used to fasten the runner end cap to the runner. Code: 162616 Material: Steel case hardened Weight: 1.5g Finish: Zinc plated Quantity: 1 per runner end cap FRAME CLIP Frame clips are used to secure shelving units to the runners using an M6x8 socket head cap screw, star washer and a square nut. Code: 162604 Material: Heat Treated Spring Steel Weight: 4g Finish: Black Quantity: 2 per frame panel RAMP SPACER Ramp spacers are fitted to one side of each ramp to create a uniform 1mm gap between adjacent ramps. This gap allows for independent rotation of the ramps. Code: 162722 Material: Plastic Weight: 0.07g Finish: Black Quantity: 1 per ramp Page 2.22
Section 3 Designers Reference SECTION 3 DESIGNERS REFERENCE GENERAL The general office layout, available space, doorways, pedestrian aisle ways etc., will play an important role when determining the floor plan of an installation. When designing the installation it must be remembered that a number of limitations apply, these are outlined clearly later in this manual. As indicated in the component descriptions, all runners are pre-assembled. Some runner sizes are made to order and a longer lead time is applicable for these components Assembly of the frames and shelves to the runners is carried out on-site. Refer to the Ultima CI-80 Shelving Manual for detailed assembly instructions for the shelving components. BAY SIZES Freetrack Compactus covers the sizes as follows: Bay heights - 1875 and 2175 and 2400mm Bay depths - 300, 400, 450 and 600mm Bay widths - 750, 900, and 1200mm Note: Not all sizes are considered standard items in all markets. Please refer to your current price list for the range of standard sizes available in your region, or consult your local office regarding size availability. Page 3.1
Section 3 Designers Reference TRACK AND RUNNER HEIGHT Overall Unit Height On a Freetrack unit, the runners and tracks add 65mm to the bay height to determine the overall height of the unit. Therefore the following shows the overall unit heights: 1875 Bay - 1940mm Overall Unit Height 2175 Bay - 2240mm Overall Unit Height 2400 Bay - 2465mm Overall Unit Height Note: Overall unit heights do not include levelling plates. Standard track with 1 levelling plate fitted. (2mm) Maximum Levelling Height Note that in addition to the 65mm stated above, allowance also needs to be made for levelling the tracks on the unit. The amount of levelling required will depend on the condition of the clients floor, up to a maximum dimension of 50mm. Standard track raised to the maximum 50mm (25 levelling plates) Page 3.2
Section 3 Designers Reference TRACK WIDTH The diagrams below show the width of both Standard and Mekdrive tracks, with and without ramps. Page 3.3
Section 3 Designers Reference Overall Unit Depth On a Freetrack unit, the runners, tracks, and ramps add to the overall depth of the unit. The diagrams below show the dimensions that need to be added to the nominal bay dimension to determine the overall depth of the unit. Manual Units Manually operated units have standard tracks on the front and rear of the unit. Standard tracks add 44mm per side to the nominal bay dimension, therefore the overall unit depth is: Overall Unit Depth = Bay Width + 44mm + 44mm Mekdrive Units Mekdrive units have a Mekdrive track on the front and a Standard track rear of the unit. Standard tracks add 44mm, and Mekdrive tracks add 81mm to the nominal bay dimension, therefore the overall unit depth is: Overall Unit Depth = Bay Width + 44mm + 81mm Note: If a ramp is used at the front of the unit, then an additional 100mm is added to the overall unit depth. If ramps are used at the front and rear of the unit, then an additional 200mm is added to the overall unit depth. Page 3.4
Section 3 Designers Reference CONVENTIONAL CONFIGURATIONS Compactus Freetrack2 (Manual) Compactus mekdrive2 (Mechanical Assisted) Note: Generally, unit overall length should not exceed 9,000mm Unit depth configurations are possible from a 750mm wide single bay up to 3x900mm (2700mm) wide triple bay unit. Note that mekdrive is recommended for all configurations above 2 x 900. Bay heights - 1875 and 2175 and 2400mm Bay depths - 300, 400, 450, and 600mm Single Entry Stacks Single Entry stacks are available in all standard bay depths 300mm and above. Static Stacks Static and mobile stacks share similar runners and crosstie components. Static stacks are achieved by fitting lock brackets and static pins on each runner of each stack. Double Entry Stacks Double entry mobile units are permitted in all bay depths from 300mm and bay heights to 2400mm. Page 3.5
Section 3 Designers Reference LATERAL CONFIGURATIONS Compactus Side2Side (Lateral) Lateral installations are limited to single bay mobile assemblies. These bays can be 750, 900, or 1200mm nominal width, with 300, 400, 450, or 600mm deep shelves. Lateral units are available in frame heights up to 2400mm. Note: For all lateral units the rear track must be securely anchored to the floor at regular intervals to prevent bays being accidentally tipped forward. Page 3.6
Section 3 Designers Reference TYPICAL FLOOR PLANS Typical Floor Plans - Conventional Units Typical Single Bay Unit Typical Tandem Bay Unit Note: Generally, unit overall length should not exceed 9,000mm Unit depth configurations are possible from a 750mm wide single bay up to 3x900mm (2700mm) wide triple bay unit. Bay heights - 1875 and 2175 and 2400mm Bay depths - 300, 400, 450 and 600mm Page 3.7
Section 3 Designers Reference Typical Floor Plans Side2Side (Lateral) Units Lateral movement units are used in limited space situations, such as narrow rooms or corridors. The static bays comprise standard Ultima CI-80 static shelving, which sits on the floor, generally against a wall. The mobile units consist of individual 750, 900 or 1200mm wide bays, which move side ways on tracks and runners (trolley assemblies) in front of the static bays. Note: In lateral installations, all mobile bays are individual single bays. The recommended clearance between front of the static unit roll posts and back panel or corner cover strip of mobile unit is 50mm. Configuration - 900mm Static Bays and 750mm Mobile Bays Number of 900mm static bays 2 3 4 5 6 7 8 Number of 750mm mobile bays 1 2 3 4 5 6 7 Configuration Common Bay Widths If common bay widths are used in the static and mobile bays, then the track length must be greater than the total length of the static bays to allow full access to picking faces in the static bays. The track will extend an equal distance (X) on each end of the static bays. X X Track extension distance (X) is calculated as follows: Ensure full bay width is revealed X = 76mm for each mobile bay + 8mm for each bumper (used between mobile bays) + 28mm for the end stop The total track length is calculated using the following formula: Track length = length of static bays + 2 times track extension (X) Page 3.8
Section 3 Designers Reference TRACK DESIGN The standard and Mekdrive track extrusions are supplied in 3 metre lengths and, when necessary, are cut to length. Track lengths are joined together where the length required is greater than 3 metres, or to extend an existing unit. Generally track lengths should not exceed 9 metres. Where floor levels are uneven track lengths may need to be reduced so that packing height of the levelling plates does not exceed 50mm. The Mekdrive track extrusion is used as the front (drive) track for mechanically assisted Freetrack units and is readily distinguishable from the standard track, as it features a side extension wing which faces outward to provide a flat drive surface for the spring loaded drive wheel. Standard tracks are used for the remaining tracks. Note: The crinolin strip must be cut to the exact full length of the installed aluminium track. Track Length Add the runner lengths (including end caps) together, plus the aisle width Then add 56mm to the total for track end stops (this allows for the two track end stops) The track extrusion should be cut 16mm shorter than the overall track length required to allow for the two track end stops. A 8mm 20mm Page 3.9
Section 3 Designers Reference LEFT AND RIGHT HANDED UNITS In a typical Freetrack installation, the finishing panels (manual or mekdrive) are the only handed components. The handing convention used for Finishing Panels is based on the side of the manual handle or Mekdrive handwheel on the double sided stack. Single entry mobile stacks generally have the same hand as the double entry stacks; therefore this determines the handing of the manual or Mekdrive finishing panels for the unit. See below for more detail. Side2Side (lateral movement) units are not handed. Plain Finishing Panels are not handed. Manual Note: 1875mm and 2175mm high manual finishing panels are not handed as the handle is positioned centrally on the panel. Mekdrive Note: All Mekdrive finishing panels are handed. Page 3.10
Section 3 Designers Reference FLOOR COVERING Carpeted areas with unusually thick pile and/or under lay, should be carefully assessed onsite, to determine suitability in terms of: Clearance the clear height from the underside of the track to the underside of the cross tie is approximately 35mm Unit stability. Note that tracks should be anchored at one end on smooth or slippery floor surfaces. HEAVY ITEMS Heavier items should be stacked on the lower shelves and the lighter items on the upper shelves. This lowers the centre of gravity of a loaded shelving bay and improves stability. Page 3.11
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Section 4 Load Information SECTION 4 LOAD INFORMATION GENERAL The following load information show the maximum allowable shelf loads, the maximum allowable bay loads, and a method for calculating the point loads exerted by the wheels. SHELF LOADS Ultima CI-80 standard un-braced shelves have the following maximum load rating. These ratings are based on a uniformly distributed load. Plain shelves Shelf Width (mm) Shelf depth (mm) 300 400 450 600 750 130kg 115kg 115kg 115kg 900 130kg 115kg 115kg 115kg 1200 80kg 80kg 80kg 100kg Mat. Thickness 0.75 0.75 0.75 0.95 If the shelving is being used for paper filing the figures below may be used as a guide to the actual load of the contents. Shelf Width (mm) Average Weight Max. Weight 750mm 25kg 37.5kg 900mm 30kg 45kg 1200mm 40kg 60kg BAY LOADS The maximum allowable bay loads when the bays are mounted on freetrack2 are: Single entry - 500kg Double entry - 1,000kg Page 4.1
Section 4 Load Information WHEEL LOADS The diagrams below show how to calculate the point loads exerted by the wheels onto the tracks. This information can be required when advising clients on floor loading implications. Maximum Load The maximum load figure should be calculated using either: maximum allowable shelf load x number of storage levels or maximum bay load (which ever is less) Empty Weight The empty weight is the weight of the Freetrack and shelving components. This is best obtained by configuring the unit in the DDP design programme. Actual Load For floor loading calculations it is best to substitute the maximum load with the actual load when possible. This is obtained by defining what will physically be stored in the unit. If the unit is to be utilised for lateral paper filing the figures provided on the previous page may be used to determine a realistic actual load that will be exerted onto the floor. Wheel Loads - Single Bay, Single Entry Stacks Wheel Loads - Single Bay, Double Entry Stacks Page 4.2
Section 4 Load Information Wheel Loads - Double Bay, Single Entry Stacks Wheel Loads Double Bay, Double Entry Stacks Page 4.3
Section 4 Load Information Wheel Loads Triple Bay, Single Entry Stacks Wheel Loads Triple Bay, Double Entry Stacks Page 4.4
Section 4 Load Information BLOCK LOAD LIMITATIONS The block load is the weight of the number of stacks which may be moved together. This figure is important in determining the size of the system and the method of movement, manual or mechanically assisted. To calculate the block load multiply the stack weight (empty weight + proposed load) by the number of mobile stacks which may be moved together. For ease of movement the block load should generally not exceed 1000kg for manually operated units. For mechanically assisted units (Mekdrive2) the block load should not exceed 5000kg. These figures are given as a guide only. Designers should take account of any specific client occupational health and safety requirements. Page 4.5