KI WireWorks User manual

Assembly Instructions
WireWorks® Panel System
January 2020

A

WireWorks® Panel System - Table of Contents
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Required Tools ...........................................2
Overview ....................................................3
Frame Assembly.........................................4
Enhanced Horizontals Rails......................10
Tile Hook Installation ...............................14
Electrical Installation................................15
Receptacle/Bezel Installation....................18
Base Trim Installation...............................20
Power Infeed Installation..........................22
Data Cable Management .........................27
Tile Installation.........................................34
Trim Installation .......................................37
Reconfiguration .......................................41
Specification Guidelines...........................43

2
WireWorks®Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Required Tools for Assembly
The following tools are required
to assemble panels:
• Dead blow mallet (soft rubber
mallet filled with shock absorbing
material such as sand or lead
shot)
•3/8” large, flat blade screwdriver
•3/16” allen wrench
•9/16” open end wrench
• #3 Phillips head screwdriver
• Diagonal pliers
• Utility knife

WireWorks® Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
3
Scope of Manual
This installation manual is
organized in the same order as
a typical installation would be
conducted.
- Starting with frame members
and ending with connection of
electrical infeeds.
This manual is confined to the
assembly and installation of the
panel and its electrical components.
Assembly instructions for other
components, such as worksurfaces,
overhead storage and doors are
provided separately.

4
WireWorks®Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Overview
WireWorks Panel System uses
four basic parts to build the
framework for the panels:
• full (width) vertical post
• half (width) vertical post
• horizontal rail
• connector block
Full vertical posts are used at
straight in-line conditions and
at end-of-runs. Half vertical
posts are used along with the
90° connector block to make
90°, 3-way and 4-way panel
intersections.
Note: Half vertical posts are
approximately one half the width
of a full post.

WireWorks® Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
5
Highest Point of Floor
Prior to erecting the system,
locate the highest point of the
floor and position the first corner
of the workstation at that point.
Assembling Intersections
Note: Refer to the
space-planning layout to
determine the necessary
intersection specifications.
1. Assemble intersections by
bolting two, three, or four half
posts together using a connector
block, shoulder bolts and
washers with a 3/16” allen wrench
(Figure 1). Refer to page 7 for
the correct number of connector
blocks per intersection.
Note: The plastic inserts at
the bottom of the vertical posts
must be oriented such that the
recessed cut out is positioned
under the slots (Detail A).
Note: All half posts get one
connector block in the lowest
hole and one connector block in
the highest hole, with taller posts
requiring additional connectors.
See Planning Guide for more
detailed information. Position
connector blocks at heights that
avoid obstructing power and data
cabling. Refer to the
space-planning layout for power
and data locations.

6
WireWorks®Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Assembling Intersections
(continued)
2. Install height-change connector
block (if required) to the frame
using, shoulder bolts and
washers with a 3/16” allen wrench
(Figure 2). Refer to the table on
next page for the correct number
of connector blocks.
Note: Height-change connector
blocks have a wire management
channel that allows cables
to be routed between two different
height panels (Detail B).
Note: Face the opening of all
height-change connector blocks
toward the shortest panel to
allow for lay-in wire management
(Detail C).

WireWorks® Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
7
Rules for Building
Intersections
1. Determine quantity of connector
blocks by referring to
Number of Height-Change
Connectors chart.
2. Determine quantity of connector
blocks by identifying the shortest
panel in your intersection. Refer
to corresponding chart.
3. Determine quantity of
height-change connector blocks
by subtracting heights of the
two shortest panels. Refer to the
chart for order quantity. If your
intersection includes more than
two different heights, repeat this
process for all heights.
Hint: Start with shortest panel.
Use height difference between
shortest and next tallest, etc.
Sample
You Need (Refer to Figure 3)
Shortest panel
30” = 2 connector blocks
Second shortest panel
54”-30” = 24” or 2 height-change
connectors
Third shortest panel
66”-54” = 12” or 1 height-change
connectors
Tallest panel
84”-66” = 18” or 2 height-change
connectors
Total
2 connector blocks
5 height-change connector blocks

8
WireWorks®Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Attaching Horizontals To
Verticals
Horizontals are used at the top
and bottom of a panel to space
the vertical posts apart the
appropriate distance for the panel
width you are building. One rail is
used at the top of the panel with
the opening facing upward and
one rail is used at the bottom
facing downward. Panels that
are made up of more than one
tile also use horizontals at
intermediate heights (with the
opening facing up).
Note: Refer to the
space-planning layout and start
with a panel corner intersection,
building out in two directions so
the panel frame is able to stand
on its own.
1. Slide a horizontal into the top of
a vertical half post with the rivets
above the pocket on the post.
Making sure all four rivets are
lined up with the corresponding
embosses, tap the horizontal into
place with a dead-blow style
mallet (Figure 4)
2. Referring again to the
space-planning layout, position
the appropriate vertical post
(full or half post) relative to
the horizontals and tap the
horizontals into place (Figure 5).
3. Repeat the above instructions,
building out in a direction
perpendicular to the first
horizontals from the corner post.
When this step is completed you
should have a partially assembled
90° corner that can support itself
(Figure 6).

WireWorks® Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
9
4. Position the lower horizontals
relative to the lowest set of
pockets on the vertical posts with
the opening facing downward and
tap into place with a dead-blow
style mallet. Continue to add
horizontals as required by the
style of panel (Figure 7).
Note: Remember, only the
bottom horizontal rails are
installed with the opening
facing downward. All other rails
openings should face upward.
Warning: Use care when tapping
the horizontals in place to ensure
that all rivets are sliding into
the embossed areas of the post.
Failure to engage all rivets into
the post will compromise the
strength of the frame and could
possibly result in product failure.

10
WireWorks®Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Recognizing Enhanced
Horizontal Rails
Each Enhanced Horizontal Rail
can be identified by the unique
labels that appear on both sides
of the horizontal rail (Figures 8
and 9).

WireWorks® Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
11
Attaching Enhanced
Horizontals To Verticals
Enhanced Horizontals are used at
the top and bottom of a panel to
space the vertical posts apart
the appropriate distance for the
panel width you are building.
One rail is used at the top of the
panel with the opening facing
upward and one rail is used at
the bottom facing downward.
Panels that are made up of more
than one tile use additional
standard construction horizontals
at intermediate heights (with the
opening facing up).
Note: Refer to the
space-planning layout to
determine which panels receive
enhanced horizontals.
1. Slide an enhanced horizontal into
the top of a vertical half post with
the rivets above the embossed
area on the post. Making sure all
four rivets are lined up with the
corresponding embosses, tap the
horizontal into place with a
dead-blow style mallet
(Figure 10).
2. Referring again to the
space-planning layout, position
the appropriate vertical post
(full or half post) relative to
the horizontals and tap the
horizontals into place (Figure 11).
3. Repeat the above instructions,
building out in a direction
perpendicular to the first
horizontals from the corner post.
When this step is completed you
should have a partially assembled
90° corner that can support itself.
(Figure 12).

12
WireWorks®Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Attaching Enhanced
Horizontals To Verticals
(continued)
4. Position the lower enhanced
horizontals relative to the lowest
set of embossed areas on the
vertical posts with the opening
downward and tap into place
with a dead-blow style mallet.
Continue to add standard
horizontals as required by the
style of panel (Figure 13).
Note: Remember, only the
bottom horizontal rails are
installed with the opening
facing downward. All other rails
openings should face upward.
Warning: Use care when
tapping the horizontals in place to
ensure that all rivets are sliding
into the embossed areas of the
post. Failure to engage all rivets
into the post will compromise the
strength of the frame and could
possibly result in product failure.

WireWorks® Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
13
Return Panel Guidelines
Definition of Return: A panel or
combination of panels that has
one of its ends connected to a run
of panels while the other end is
unsupported.
• Cannot exceed a total length of 8’
• Cannot consist of more than two
panels
• Cannot support overhead storage
• Cannot support worksurfaces or
counter tops
Rules:
• Any return between 48” and 96”
in length requires enhanced
horizontals.
• Any return greater than 48”
requires enhanced horizontals
on both panels that make up the
return.
• Two enhanced horizontals are
required per panel, one at the top
and the other at the bottom.
54-96”
This
combination of two panels is
wider
than 48”, therefore both
panels
require Enhanced
Horizontals
This
single panel is wider than
48”,
therefore requires Enhanced
Horizontals
This
combination of two panels is
adjacent
toaworksurface, but still
requires
Enhanced Horizontals in
both
panels
This
combination of two panels
attaches
the adjacent worksurfaces
t
oapanel withaworksurface
suppor
t bracket (WSB), but still
requires
Enhanced Horizontals in
both
panels
54-60”
54-96”
54-96”
24-30”
24”
Examples: Where needed

14
WireWorks®Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Installing Tile Hooks
Tile hooks are used to lock the
horizontal rail in place relative
to the vertical post and provide
a mounting location for the tiles.
Four hooks need to be installed
for every acoustical and raceway
tile.
Note: Be sure the frame has been
correctly installed and aligned.
1. Insert tile hooks through the
cutout in the end of the horizontal
and into the cutout in the vertical
with the top of the hook pointing
to the left (rounded side of hook
faces up). Push the end of each
hook through the cut-out, then
rotate the hook one-quarter turn
to the right so the top of the hook
is pointing upward (Figure 14).
Hint: If the tile hook does not
turn properly, the horizontal has
not been installed properly. Check
to be sure the horizontal rivets are
fully seated into the vertical post
and that none of the rivets are
outside of the embosses. When
all of the hooks are properly
installed, there should be four
hooks for each tile you are going
to hang on the panel.
Note: On segmented tiled panels,
hooks are inserted in the cut-outs
in the verticals just above the
intermediate horizontals as well
as through the cut-outs in the
horizontal rails. See the diagram
on the right.
Leveling
1. After building the first corner,
level the panel frames by turning
the post glides the appropriate
direction with a 9/16” open end
wrench (Figure 15).
Note: Glides can be adjusted by
hand or by using a 9/16” open end
wrench.
2. Continue building panels in this
manner described in Attaching
Horizontals To Verticals
on page 8 until the frames are
complete, leveling each panel as
it is constructed.

WireWorks® Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
15
WARNING: Assembly of all
mechanical frame components
must be completed before
making any electrical
connections. All electrically
connected furnishings
must also be mechanically
connected.
Product Overview
KI’s “810” 10-wire electrical
system is available in two
versions: a six-circuit system
(622) and a four-circuit
system (442). They are not
interchangeable and are
differentiated by the color of the
UL label; 622 is green and 442
is blue.
Installing Rigid Wireway
Rigid wireways are installed
by first installing the plastic
clips into the appropriate slot
on the horizontal rail. Slide the
clips near side open saddles
(Figure 16) on to the frame until
a snap is heard. Then squeeze
frame until the far side saddles
engage the rail and affix in place
manually, or with a soft mallet.
Rigid wireways hang off the
lowest rail (base power)
(Figure 16) but sit on top of
the rails at other heights (ADA,
worksurface height and standing
height) (Figure 17).
1. Orient the wireway so the N
symbol points toward the top of
the panel (Figure 18). For base
power, position the rigid wireway
below the horizontal rail, insert
plastic clips as stated above.
Then, align the steel mounting
brackets to the two holes in the
plastic clips and insert one
#10-24 x 3/8” screw from each
side, on both ends (Detail D).
2. For power at other heights,
position the plastic clips on the
top of the horizontal rail
(Figure 17). Continue installing
rigid wireways as required.
Hint: To remove the wireway,
insert a screwdriver into the
mounting slot of the horizontal
rail until the clip can be pulled
free (Figure 18) or remove all
four screws

16
WireWorks®Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Installing Horizontal Jumper
WARNING: Assembly of all
mechanical frame components
must be completed before
making any electrical
connections. All electrically
connected furnishings must also
be mechanically connected.
Power is passed from panel
to panel by using a horizontal
jumper (Figure 19). Horizontal
jumpers use a plastic mesh
sheathing and come in two
lengths (17” and 20”). The 17”
jumpers are used on inline
conditions, while 20” jumpers
are used to pass straight through
an intersection or around a 90°
corner. See examples A-E for
typical installations.
1. Jumpers plug into one of two
open sockets on each end of the
rigid wireway. Orient the jumper
so the Nsymbol is pointing up.
Slide the jumper into an open
socket until the end fully seats in
the metal wireway tab.
Removing Horizontal Jumper
1. To remove a jumper, pull slightly
on the steel tabs on the wireway
until the jumper can be pulled
from the socket.
Note: Horizontal jumpers will
pass behind raceway tiles,
but they will not pass behind
acoustical tiles.
Typical horizontal jumper
installations are shown in
examples A-E.

WireWorks® Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
17
Installing Vertical Jumper
WARNING: Assembly of all
mechanical frame components
must be completed before
making any electrical
connections. All electrically
connected furnishings must also
be mechanically connected.
Verticals jumpers are used to
run power within a single panel
between two different heights.
There are two lengths of vertical
jumpers: 20” and 56”. The 56”
long vertical jumper is capable of
running power from the base to
any other height within the panel.
The 20” short vertical jumper
is used to run power between
two adjacent heights (i. e. ADA
height to worksurface height or
worksurface height to standing
height) (Example F).
Note: The 56” vertical jumper
must be used to run power from
base to ADA height.
1. Install the vertical jumper in the
same manner as the horizontal
jumper, connecting the ends of
the jumper to rigid wireways at
two different heights of the same
panel (Detail E).
Typical rigid wireway and jumper
installation for “810” electrical
system is shown in example F.

18
WireWorks®Panel System
Assembly Instructions
Assemble units as described herein only. To do otherwise
may result in instability. All screws, nuts and bolts must be
tightened securely and must be checked periodically after
assembly. Failure to assemble properly, or to secure parts
may result in assembly failure and personal injury.
Installing in Base Raceway
WARNING: Assembly of all
mechanical frame components
must be completed before
making any electrical
connections. All electrically
connected furnishings must also
be mechanically connected.
1. Determine the position at which
the receptacle will be installed
and ensure a rigid wireway is
already mounted behind the base
raceway door.
2. Carefully remove the steel
knockout by pressing on the
edges until it snaps out of the
square opening.
3. Close the raceway door and snap
a bezel into the opening from
the front of the base (note “this
end up” orientation of bezel).
If data connection is required,
snap a data faceplate (supplied
by the customer) into the lower
opening in the bezel. Refer to
Planning Guide Data Cable
Management to additional
information. If data faceplates
are not being used, snap the
included bezel filler plate into the
unused bottom opening of the
bezel from the inside (Figure 20).
Note: The bezel filler plates
always occupy the lower of the
two openings on bezels in base
raceways. The bezel filler plate
can be snapped in place such
that it is flush with the bezel face
(Figure 20), or rotated to allow
data cables to exit (Detail F).
Installing Receptacles
WARNING: Assembly of all
mechanical frame components
must be completed before
making any electrical
connections. All electrically
connected furnishings must also
be mechanically connected.
1. Position the receptacle on either
end of the wireway as shown
(depending on location desired),
matching the Nsymbol to the
same orientation on both the
receptacle and wireway.
2. Align the receptacle so the end is
in line with the inner socket on
the wireway (Figure 21).
3. Push the receptacle back against
the mounting plate (Figure 21).
4. Slide the receptacle to the side so
the end terminals slide into the
wireway inner socket (Figure 22).
5. Receptacle is properly seated
when the catch clip on the
wireway is between the wedges
on the receptacle (Figure 23).
Removing Receptacle
1. Slightly lift the catch clips on the
top and bottom of the receptacle
(Figure 23) and slide the
receptacle away from the socket
on the wireway.
2. Pull the receptacle away from
the wireway once the end of the
receptacle clears the wireway
socket.