IAC INDUSTRIES DIMENSION 4 User manual

INDUSTRIES
Rev. 042318P65)
IAC INDUSTRIES
3831 S BULLARD AVE., GOODYEAR, AZ 85338
Phone (714) 990
-
8997 Fax (714) 990
-
0557
www.iacindustries.com
DIMENSION 4
Assembly Instructions

2
DIMENSION 4
ASSEMBLY INSTRUCTIONS
Page #
3 Attention Notes
4 - 9 D4 Single Sided Starter & Adder
10 -16 D4 Double Sided Starter & Adder
17 SES Standard Electrical System
18-22 PDS-II Power Distribution System
23-24 Corner Worksurface Radius/Square
25-35 Corner Shelf Worksurface Radius/Square
36-37 Drawer/Cabinet
38-40 Light Fixtures
41 Electrical Channels
42-43 Shelves
Cautionary Notes and Warnings:
IAC strongly recommends care must be taken during the lifting and positioning of
all workstation components as they can be heavy and awkward to lift, move and
install. Only qualified installation personnel using the proper Personal Protective
Equipment should be allowed to lift any of these components into place. Failure
to use proper lifting techniques and proper Personal Protective Equipment could
result in injury individuals, the workstation and/or surrounding property. IAC
Industries is not responsible for any injuries sustained or damage to the
workstation and its contents and/or damage to surrounding property caused
during the proper or improper installation of the workstation.
WARNING:
ALL PARTICLE BOARD USED IN IAC INDUSTRIES PRODUCTS ARE SOURCED ONLY FROM
VENDORS THAT ARE CARB ATCM PHASE 2 AND TSCA TITLE VI COMPLIANT WITH VALID
CERTIFICATES.Drilling, Sawing, Sanding or Machining Wood products can expose you to wood dust, a substance
known to the state of California to cause cancer. Avoid inhaling dust generated from wood products or use a dust mask
to other safeguards for personal protection. This product can expose you to chemicals, including formaldehyde, which is
known to the state of California to cause cancer, and methanol, which is known to the state of California to cause birth
defects or other reproductive harm. For more information please visit, www.P65WARNINGS.CA.GOV/WOOD. COPY OF
VENDOR CERTIFICATE AVAILABLE UPON REQUEST.

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ATTENTION:
IAC Industries takes great care in the packing of it’s products, however damage
can occur during shipment. Check all packages and parts for any signs of
damage. If damage is evident STOP and contact the carrier that delivered your
order. Request a freight claim inspector to document the damage and begin the
freight claim process.
Tools required:
Wrenches 7/16” and 1/2”, socket with ratchet or open end wrench
Phillips screwdriver 8” long
Utility knife
Safety glasses and light duty protective gloves
NOTE: Power tools are NOT recommended unless they are equipped with a torque limiting
device which can limit the torque to 10 foot lbs maximum at aluminum attachment points,
and 15 foot lbs for all other attachment points.
Unpack your order and separate like parts into separate areas. Be careful not to
damage parts as they are being moved around and put into position. Also be
sure all parts are removed from the packing materials before these materials are
thrown away.
Locate the hardware kits and keep them in a central area. If the assembly is
going to take more than one day, all individual hardware pieces should be
returned to a central location.
Check all parts and hardware kits against the itemized packing list found with the
assembly instructions. If you believe there are parts missing from your order
please contact IAC Industries customer service HOTLINE at 800-989-1422.
If your order has the Standard Electrical System (SES) or the Power Distribution
System II (PDS-II) please review pages 17 through 22 for cautions and
restrictions before you begin assembling the workstations.
If your order has ESD worksurfaces or accessories please review pages 85 and
86 for cautions and helpful suggestions before you begin assembling the
workstations.
If your order has adjustable height system, please review the D4 Adjustable
Height Assembly Instructions for suggestions and warnings.

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D4 Single Sided Workstation Starter & Adder
ITEM DESCRIPTION QTY
1 D4 Back Panel 1
2 D4 Top Support Bracket LT 1
3 D4 Top Support Bracket RT 1
HARDWARE KIT HWR214
ITEM DESCRIPTION QTY
A Bolt 5/16-18 x .75 SQH 8
B Washer 5/16 Flat 8
C Nut 5/16-18 Hex Keps 8
Please read Caution and Warning Notices found on page 2.
Step 1:
Install 5/16-18 x .75 square head bolts item A, 5/16 flat washer item B, and 5/16-18 hex head
keps nuts item C into each end of all back panels item 1 and into all top support brackets items 2
and 3 as shown below. Do not tighten this hardware.
Step 2:
Make small pencil marks on the uprights approximately 1 1/4” lower than the desired working
height. It is a good idea to make these marks all the uprights at the same time. Install the back
panel and top support bracket by leaning an upright against a wall or have a second person hold it
and install the square head bolts into the milled slots in the nut channels of the upright. Gently
slide the back panel and top support brackets to the pencil marks and tighten the hex head keps
nuts to hold them in place. Do not tighten this hardware to more than 10 foot lbs of torque. Doing
so will cause scoring to the aluminum of the upright.

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Step 3:
Attach the back panel to the second upright by having one person hold the back panel in place
while another person lifts the upright so that the square head bolts can be installed into the milled
slots in the upright nut channel and gently sliding the upright down to the floor. Gently slide the
back panel to the pencil marks on the upright and tighten the hex head keps nuts to hold it in
place. Do not tighten this hardware to more than 10 foot lbs of torque. Attach the top support
bracket by aligning the square head bolts with the milled slots in the upright nut channel and
gently sliding it to the pencil marks and tighten this hardware to a maximum of 10 foot lbs of
torque. Do not over tighten the hardware.
Step 4:
Attach the add-on back panels and top support brackets to the starter uprights by repeating Step
2 above. Be sure to maintain the same back panel and top support bracket height so that the
worksurface heights will be the same.
Step 5:
Attach the next add-on upright to the back panel and top support bracket to by repeating Step 3
above. Be sure to maintain the same back panel and top support bracket height so that the
worksurface heights will be the same.

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ITEM DESCRIPTION QTY
4 D4 S/S Worksurface 1
5 D4Hat Section 2
HARDWARE KIT HWR214
ITEM DESCRIPTION QTY
B Washer 1/4 Flat Black 16
D Bolt 1/4-20 Hex Head Black 16
Note: At this point in the assembly of your benches it may be easier to install options such
as footrests, shelves, lights, parts cut stringers and electrical channels to the uprights
before the worksurfaces are installed.
If your order includes Heavy Duty Frames please see page 9 before proceeding. If your
order includes PDS-II please see page 18 before installing the worksurfaces.
Step 6:
Lay the worksurface upside down on a clean padded surface. Position the worksurface hat
sections over the threaded inserts in the front and middle portion of the worksurface and center
them left to right of the worksurface. Attach each hat section with 8 sets of Item # D and B.
Tighten hardware only when all bolts are started by hand. Do not tighten this hardware to more
than 10 foot lbs of torque. Do not over tighten. If this is an ESD worksurface attach the ESD
Coupler Nut found in hardware kit HWR014. See page 85 for installation caution notes.
Note:
If your order includes 3”, 6” or 12” single drawers units you can assemble the drawer cases onto
the worksurface hat sections at this time. This makes the attachment of the drawer cases easier
but also makes the worksurfaces heavier and therefore more difficult to turn over and place into
position. Caution must be taken during this process to insure that assemblers are not injured
during and that the worksurfaces and the surrounding areas are not damaged. If you choose to
assembly the drawer cases to the worksurface at this time IAC Industries recommends that all
assemblers are wearing proper safety equipment. Refer to page 36 for drawer assembly
instructions.

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HARDWARE KIT HWR214
ITEM DESCRIPTION QTY
D Bolt 1/4-20 Hex Head Black 8
B Washer 1/4 Flat Black 8
Note: If your order includes accessories such as shelves, light fixtures, parts cup stringers, flipper
door cabinets, footrests and electrical channels IAC Industries recommends that they be
assembled to the uprights before you install the worksurfaces. This reduces the reach distances
for installing these items making assembly much easier and safer.
Step: 7
Turn the worksurface sub assembly over and carefully place the rear of the worksurface onto the
top support brackets. Align the side cutouts of the worksurface between the uprights and gently
slide it into position. There should be approximately a 1/16” gap between the front of the upright
and the cutout in the worksurface, and approximately a 1/8” gap between the side of the uprights
and the side of the cutouts.
Step: 8
Align the threaded inserts in the bottom of the worksurface with the slots in the back panel and top
support brackets. Install 4 each item # D and B into the slots in the back panel, and 2 each item #
D and B in the slots in each top support brackets by hand. When all hardware is installed and the
worksurface is aligned, squared and leveled with the uprights, tighten all worksurface hardware.
Do not over tighten.
Note: If you are assembling starters and adders it is best not to tighten any of the worksurface
attachment hardware until all the worksurfaces are installed. Then align, square and level all the
worksurfaces and tighten attachment hardware. Do not over tighten.
Please read Caution and Warning Notices found on page 2.

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HARDWARE KIT HWR214
ITEM DESCRIPTION QTY
5 Bolt 1/4-20 Hex Head Black 2
6 Washer 1/4 Flat Black 2
Step: 9
Attach adder worksurfaces the same as starter worksurfaces. When all hardware is installed and
the worksurface is aligned, squared and leveled with the uprights, tighten all worksurface
hardware. Do not over tighten. Tie plates are used to secure each starter and adder worksurface
to the next. Position the tie plate over the threaded inserts in the bottom of the worksurface and
attach it using 2 each of hardware item # 5 and 6. Double-check the worksurface alignment
before tightening this hardware. Do not over tighten.
Please read Caution and Warning Notices found on page 2.

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D4 Single Sided Workstation Heavy Duty Frame
ITEM DESCRIPTION QTY
4 D4 S/S Worksurface 1
6 D4 S/S Heavy Duty Frame 1
HARDWARE KIT HWR214
ITEM DESCRIPTION QTY
B Washer 1/4 Flat Black 16
D Bolt 1/4-20 Hex Head Black 16
Note: If this order includes PDS-II please see page 18 before installing work surface.
Step 10:
Lay the worksurface upside down on a clean padded surface. Position the heavy-duty frame over
the threaded inserts in the worksurface. Attach the frame using Item #’s D and B. Tighten
hardware only when all bolts are started by hand. Do not over tighten. If this is an ESD
worksurface attach the ESD Coupler Nut found in hardware kit HWR014. See page 85 for
installation caution notes.
Note:
If your order includes 3”, 6” or 12” single drawers units you can assemble the drawer cases onto
the worksurface hat sections at this time. This makes the attachment of the drawer cases easier
but also makes the worksurfaces heavier and therefore more difficult to turn over and place into
position. Caution must be taken during this process to insure that assemblers are not injured
during and that the worksurfaces and the surrounding areas are not damaged. If you choose to
assembly the drawer cases to the worksurface at this time IAC Industries recommends that all
assemblers are wearing proper safety equipment. Refer to page 36 for drawer assembly
instructions.

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D4 Double Sided Workstation Starter & Adder
ATTENTION: If you have ordered Standard Electrical System (SES) or the Power Distribution
System (PDS II) options, please see details on upright configurations, restrictions and warnings
found on pages 17 through 22.
ITEM DESCRIPTION QTY
2 D4 D/S Top support bracket LT 2
3 D4 D/S Top support bracket RT 2
HARDWARE KIT HWR267
ITEM DESCRIPTION QTY
A Bolt 5/16-18 x .75 SQH 16
B Washer 5/16 Flat 16
C Nut 5/16-18 Hex Keps 16
Step: 1
Install 5/16-18 x .75 square head bolts item A, 5/16 flat washer item B, and 5/16-18 hex head
keps nuts item # C into all D/S top support brackets items 2 and 3 as shown below. Do not tighten
this hardware.
Step: 2
Make small pencil marks on the uprights approximately 1 1/4” lower than the desired working
height. It is a good idea to make these marks all the uprights at the same time. Install the D/S top
support brackets by leaning an upright against a wall or having a second person hold it and install
the square head bolts into the milled slots in the nut channels of the upright. Gently slide the D/S
top support brackets to the pencil marks and tighten the hex head keps nuts to hold them in
place. Do not tighten this hardware to more than 10 foot lbs of torque. Doing so will cause scoring
to the aluminum of the upright. Attach the second D/S top support bracket to the opposite upright
in the same manner. Do not over tighten.

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D4 Double Sided Workstation Starter & Adder
ITEM DESCRIPTION QTY
1 D/S Back Panel 2
HARDWARE KIT HWR276
ITEM DESCRIPTION QTY
B Washer 1/4 Flat Black 16
D Bolt 1/4-20 Hex Head Black 16
Step: 3
Attach the D/S back panel item 1 to the D/S top support bracket by placing it over the threaded
inserts in the bracket flange and installing 2 each items # B and D into the inserts. Attach a
second back panel to the opposite top support brackets flange in the same way. Do not tighten
the bolts at this time.
tep: 4
Attach the D/S back panels item 1 to the D/S top support bracket of the second upright by placing
it over the threaded inserts in the bracket flange and installing 2 each items # B and D into the
inserts. Do not tighten the bolts at this time.

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Step 5:
Attach the add-on top support brackets to the starter uprights by repeating Step 2 above. Be sure
to maintain the same top support bracket height so that the worksurface heights will be the same.
Attach the D/S back panels item 1 to the D/S top support bracket of the starter upright by placing it
over the threaded inserts in the bracket flange and installing 2 each items # B and D into the
inserts. Do not tighten the bolts at this time.
Step: 6
Attach the adder D/S back panels item 1 to the D/S top support brackets of the adder upright by
placing it over the threaded inserts in the bracket flange and installing 2 each items # B and D into
the inserts. Do not tighten the bolts at this time. Repeat this process for as many adder benches
ordered.

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ITEM DESCRIPTION QTY
4 D4 D/S Worksurface 2
5 D4 Hat Section 4
HARDWARE KIT HWR214
ITEM DESCRIPTION QTY
D Bolt 1/4-20 Hex Head Black 32
B Washer 1/4 Flat Black 32
Note: At this point in the assembly of your benches it may be easier to install options such
as footrests, shelves, lights, parts cut stringers and electrical channels to the uprights
before the worksurfaces are installed.
If your order includes Heavy Duty Frames please see page 16 before proceeding. If your
order includes PDS-II please see page 18 before installing the worksurfaces.
Step: 7
Lay the worksurfaces upside down on a clean padded surface. Position the worksurface hat
sections over the threaded inserts in the front and middle portion of the worksurface and center
them left to right of the worksurface. Attach each hat section with 8 sets of Item # D and B.
Tighten hardware only when all bolts are started by hand. Do not tighten this hardware to more
than 10 foot lbs of torque. Do not over tighten. If this is an ESD worksurfaces attach the ESD
Coupler Nuts found in hardware kit HWR014. See page 85 for installation caution notes.
Note:
If your order includes 3”, 6” or 12” single drawers units you can assemble the drawer cases onto
the worksurface hat sections at this time. This makes the attachment of the drawer cases easier
but also makes the worksurfaces heavier and therefore more difficult to turn over and place into
position. Caution must be taken during this process to insure that assemblers are not injured
during and that the worksurfaces and the surrounding areas are not damaged. If you choose to
assembly the drawer cases to the worksurface at this time IAC Industries recommends that all
assemblers are wearing proper safety equipment. Refer to page 36 for drawer assembly
instructions.

14
ITEM DESCRIPTION QTY
5 Bolt 1/4-20 Hex Head Black 16
6 Washer 1/4 Flat Black 16
Note: If your order includes accessories such as shelves, light fixtures, parts cup stringers, flipper
door cabinets, footrests and electrical channels IAC Industries recommends that they be
assembled to the uprights before you install the worksurfaces. This reduces the reach distances
for installing these items making assembly much easier and safer.
Please read Caution and Warning Notices found on page 2.
Step: 8
Turn each worksurface sub assembly over and carefully place the rear of the worksurface onto
the top support brackets. Align the side cutouts of the worksurface between the uprights and
gently slide it into position. There should be approximately a 1/16” gap between the front of the
upright and the cutout in the worksurface, and approximately a 1/8” gap between the side of the
uprights and the side of the cutouts.
Step: 9
Align the threaded inserts in the bottom of each worksurface with the slots in the back panels and
top support brackets. Install 4 sets per worksurface each of items # 5 and 6 into the slots in the
back panels, and 4 sets each of items # 5 and 6 in the slots in each top support bracket by hand.
When all hardware is installed and the worksurfaces are aligned, squared and leveled with the
uprights, tighten all worksurfaces hardware. Do not over tighten.
Note1: If you are assembling starters and adders it is best not to tighten any of the worksurface
attachment hardware until all the worksurfaces are installed. Then align, square and level all the
worksurfaces and tighten all attachment hardware. Do not over tighten.
Note 2: If you have 36” deep double-sided benches please see pages 83 and 84 of the
Dimension 4 Assembly Instructions Part 3.

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ITEM DESCRIPTION QTY
5 Bolt 1/4-20 Hex Head Black 2
6 Washer 1/4 Flat Black 2
Please read Caution and Warning Notices found on page 2.
Step: 10
Attach adder worksurfaces the same as starter worksurfaces. When all hardware is installed and
the worksurface is aligned, squared and leveled with the uprights, tighten all worksurface
hardware. Do not over tighten. Tie plates are used to secure each starter and adder worksurface
to the next. Position the tie plate over the threaded inserts in the bottom of the worksurface and
attach it using 2 each of hardware item # 5 and 6. Double-check the worksurface alignment
before tightening this hardware. Do not over tighten.

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ITEM DESCRIPTION QTY
4 D4 S/S Worksurface 2
6 D4 S/S Heavy Duty Frame 2
HARDWARE KIT HWR214
ITEM DESCRIPTION QTY
B Washer 1/4 Flat Black 16
D Bolt 1/4-20 Hex Head Black 16
If this order includes PDS-II please see page 18 before installing work surface.
Step 11:
Lay the worksurface upside down on a clean padded surface. Position the heavy-duty frame over
the threaded inserts in the worksurface. Attach the frame using Item #’s D and B. Tighten
hardware only when all bolts are started by hand. Do not over tighten. If this is an ESD
worksurface attach the ESD Coupler Nuts found in hardware kit HWR014. See page 85 for
installation caution notes.

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Standard Electrical System (SES)
The SES option has one 15 AMP 120 VAC circuit. There are a total of 4 outlets on benches with
48” and 60” tall uprights, and 8 outlets on benches with, 72”, and 84” tall uprights. It is the
customer’s responsibility to supply adequate power and circuit protection to the SES option.
Never use more than 15 Amp’s of power consumption at any one time.
Caution: Connect all interconnects before connecting power cords.
Please note the direction of the interconnect and power cord receptacles as shown below
on Double-sided Uprights before setting up Double-sided uprights.
Connecting the Interconnect Cord: (Make sure that the circuit breaker/pilot light switch is OFF.)
The interconnect cord is used to connect the pre-wired circuit of one upright of a bench to the pre-
wired circuit in the upright on other side of the bench. Identify the male and female ends of the
interconnect and plug the male end into the upper receptacle on the upright on the right side of
the bench and the female end into the receptacle on the upright on the left side of the bench.
Connecting the Power-Up Cord:
After all interconnect cords are installed connect the female end of the power cord into the lower
receptacle in the right side upright. Check to make sure all connections are secure before
plugging the male end of the power cord into the power source. Turn the circuit breaker/pilot light
switch on.
SES is not interconnected between workstations. Each bench, starter or adder has its own power
cord and requires a power source. Repeat the above process for add-on benches, being sure not
to connect the power to the power source before the interconnect cord is connected.
Note: Adder Uprights have outlets on both sides of the upright and should go between the single
sided outlet starter uprights as noticed above. Existing starters will need to place the adder upright
or any additional adder uprights between the two starter uprights as shown above.

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PDS-II Power Distribution System II
Caution: Although the PDS-II system is UL Listed IAC Industries STRONGLY RECOMMENDS
that the PDS-II system be connected to or disconnected from the power source by a qualified
professional electrician ONLY. Incorrect or faulty installation of this system could cause severe
personal injury and property damage.
PDS-II Interconnect Cable Installation:
PLEASE NOTE: For proper installation of interconnect cable on D/S benches the orientation of
the uprights need to be the same as S/S uprights with the Number 1 and 3 Outlet blocks on the
upright facing your right side and the Number 2 and 4 Outlet blocks facing your left side on each
upright. The Number 2 and 4 Outlet blocks on one upright can not face each other for the
interconnect cable to installed properly.
HARDWARE KIT HWR278, HWR 279, HWR 280
ITEM DESCRIPTION QTY
A Screw, #10 x .625 PPH SMS Zinc 9
B Conduit, One Hole Strap Rigid 3/4 3
C PDS-II Duplex Trim Bezel 4
D PDS-II Duplex Trim Bezel Blank 1
E PDS-II Station Interconnect 48”, 60”, or 72” 1
Step 1:
Fit the interconnect cable end connector into the trim panel of the right side upright by tilting it in
and up into the trim panel cut out, pushing it flat against the distribution block and then pushing it
down into the connectors in the distribution block. Attach the end connector to the distribution
block with the screws supplied in the hardware kit.
Step 2:
Take two of the bezels from the above hardware kit and carefully fit them over the upright
interconnect cable.
Step 3:
Slide the bezel along the interconnect cable, fit it over the cutout in the trim panel of the upright
and gently snap it into place.

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Step 4:
Repeat steps 2 & 3 to connect the other end of the interconnect cable to the left side upright. For
starter adder application continue to repeat the interconnect cable installation for as many uprights
as are going to be powered by a single power up cable.
Step 5:
At this point return to the appropriate worksurface installation instructions and install the
worksurfaces.
Step 6:
Once the worksurface has been installed the upright interconnect cable is looped up to the
underside of the worksurface and is attached using three 1” conduit clamps and wood screws
included in the hardware kits.
PLEASE NOTE:
It is very important that the upright interconnect cables are secured to the underside of the
worksurface to avoid damage or failure of the PDS-II system. There should be a gentle radius at
the ends of the interconnect cables as shown above.
NOTE: For adjustable height benches the upright interconnect cables are attached to the
workstation back panel, NOT the underside of the worksurface.

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PDS-II Power up Cable:
The PDS-II Power-Up cable is attached to the outside of the right side upright at the top or at the
outside of the left side upright at the bottom. If the connection to the facility power is being made
from above the workstation the power-up cable will be attached to the outside of the right side
upright at the top as shown below left. If connection to the house power is being made at floor
level the power-up cable will be attached to the outside of the left side upright at the bottom as
shown below right.
Power from above
Power from below
Note: The following instructions are to be used if the Duplex Outlets need to be removing and
reinstalling to another location.
Step 1:
Gently remove the bezel from the trim panel on the duplex being removed.
Step 2:
Remove the two screws holding the duplex outlet in place.
Step 3:
Gently push down on the duplex outlet until it disconnects from the distribution block.
Next tilt the duplex out of the trim panel cut out.
Step 4:
Reinstall the removed duplex outlet by first tilting it down and into the trim panel cut out.
While pushing it flat against the distribution block, push it up into the distribution block to lock it in
place.
Step 5:
Secure the reinstalled duplex outlet by installing the two screws removed earlier and the then
installing the Duplex Trim Bezel.
Note: All attachment hardware must be installed to insure the outlets are secured to the
distribution blocks properly.
Please Note: The orientation of the duplex from right and left sides of the upright.