Quantum Scalar i6000 User manual

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Scalar i6000
Installing a Multi-Module Library – Gen 2 Dual
Robot Configuration
This is an excerpt from the Scalar i6000 Installation Guide (6-66881-03 Rev
A), enhanced with notes, extra images, and video links.
This is a training document and is not meant to be used in place of the
current Installation Guide.

2Introduction
Introduction
Training Introduction
Caution: This document is intended to be reviewed before an installation, it is not intended
to substitute for the relevant technical publications.
This is a training document. It is not intended to take the place of the Installation Guide, its
purpose is to provide additional information about a Gen 2 Dual Robot installation for service
personnel who have installed Gen 1 systems, but who have not yet installed a Gen 2 system.
This training document is based on an excerpt from the Installation Guide. In addition to the
steps and images in the installation guide, there are some added comments, photographic
images, and links to short videos. This additional information is provided to assist your first Gen
2 installation.
Please review this document and watch the short video excerpts linked to it.
In addition to a Gen 2 Dual Robot installation, there are also Gen 2 Single Robot installation
procedures. Those procedures are not included here because all of those individual tasks are
included in the Gen 2 Dual Robot installation procedures.
This chapter describes how to install a new multi-module Gen 2 dual-robot library, and how to add
expansion modules to an existing Gen 2 dual-robot library.
Parts List
The modules are shipped from the factory with everything pre-installed except for the few items that cross
over frame boundaries. These items come in separate parts kits as noted below.
PM Kit
• Catch tray
• Power rail bridge clamps (1 set of 2 clamps)
• X-axis gear rack, full, right load position (3)
• Screws needed for the above parts
CM Kit
• X-axis gear rack, full, standard (3)
• Screws needed for above parts
Note
The factory does not ship a frame called the “right parking module.” The factory
just calls it an “expansion module” or EM. You will know it is the right parking
module because it is the last numbered frame, and also because it has a right
side cover installed.
Note
The left parking module is simply called the “parking module,” or PM, at the
factory. The PM kit below is the parts kit for the left and right parking modules.

Scalar i6000 Installation Guide Super Doc 3
EM Kit
• Power rail bridge clamps (1 set of 2 clamps)
• X-axis gear rack, full, standard (3)
• Catch tray
• Screws needed for the above parts
Required Tools
• ESD wrist strap
• 2.5 mm hex wrench
•3mmhexwrench
•6mmhexwrench
• 13 mm open end wrench
• 16 mm open end wrench
• 24 mm open end wrench
• T10 Torx wrench
• digital level
• laptop with current library firmware loaded
Step 1: Installing the System Unit (First Four Frames)
Training Note: The installation procedure assumes that the system has been unpacked
according to the Scalar i6000 Unpacking and Removal Instructions. The robots are shipped in
the modules. The robots and the modules must be unpacked and prepared according to the
instructions to ensure the installation goes smoothly.
Perform this section you are installing a completely new library.
Many of the sub-procedures are the same for a Gen 1 or Gen 2 installation. These are pointed
out for you here.
If you are installing four or fewer frames, you can bolt the frames together while the frames are on their
casters, and then raise and level the frames as one system unit.
The system unit consists of the left parking module, control module, and the next two modules.
•Aligning and Bolting the Frames (Same as Gen 1 Task) on page 4
•Positioning the System Unit (Same as Gen 1 Task) on page 5
•Lowering the System Unit Leveling Legs (Same as Gen 1 Task) on page 6
•Raising the System Unit Off the Casters (Same as Gen 1 Task) on page 6
•Verifying the System is Level (Same as Gen 1 Task) on page 7
•Verifying the Frames are Aligned Using Alignment Marks on page 10
•Setting the Leg Lock Nuts (Same as Gen 1 Task) on page 11

4Introduction
Aligning and Bolting the Frames (Same as Gen 1 Task)
1Using the corner edges of the frames as a rough alignment, position the frames together so the
attachment bolt holes are aligned.
Verify that the attachment holes are aligned. If necessary, adjust the frame legs to better align the
attachment bolt holes.
2Repeat the following steps for the front lowerbolt, front upper bolt, back lower bolt, and back upperbolt,
in that order:
a. Insert the attachment bolt from right to left into the attachment hole
b. If the bolts do not slide smoothly into the holes, raise the appropriate leveling legs until they do.
c. Once the bolts are inserted, loosely thread the nuts onto the bolts.
front upper bolt
front lower bolt

Scalar i6000 Installation Guide Super Doc 5
3Tighten the bolts using the 6 mm hex wrench and the 13 mm open end wrench.
4Once the frames are aligned and bolted properly together, proceed to Positioning the System Unit
(Same as Gen 1 Task) on page 5.
Positioning the System Unit (Same as Gen 1 Task)
For more information on location specifications, see the Scalar i6000 Planning Guide.
1Verify the placement of the system unit.
2Verify the following:
• There is an AC outlet within 10 feet (3.05 m) of the control module’s location.
• There is adequate clearance for the access and service doors.
• All raised floor tiles have been cut out accordingly to accommodate the power, SCSI, Fibre, and
Ethernet cables to any of the modules.
3Position the system unit in its intended location.
4Verify that the system unit is positioned correctly.
5Ensure that the leveling legs are not resting on tiles that will need to be raised to accommodate cables
after the system unit has been installed.
Note
Do not overtighten the bolts. Overtightening can damage the vertical frame
post structure.
Note
The left parking module is at the left end of a dual-robotics multi-module
library.
back upper bolt
back lower bolt

6Introduction
Lowering the System Unit Leveling Legs (Same as Gen 1 Task)
Required tools: 24 mm open end wrench, 6 mm hex wrench or 16 mm open end wrench.
1On only the four outer edge corner legs of the system unit, use the 24 mm open end wrench to loosen
the four locking nuts.
2Lower the four outer edge corner legs by hand until the legs touch the floor. You may need to use the
6 mm hex wrench or 16 mm open end wrench to turn the legs if the threads do not turn freely.
Raising the System Unit Off the Casters (Same as Gen 1 Task)
Required tools: 6 mm hex wrench or 16 mm open end wrench
1Using the 6 mm hex wrench or 16 mm open end wrench, raise the entire system unit by only the four
outer edge corner legs seven (7) half turns during the system raising process. If a leg is lifted off the
floor, give only that leg seven (7) half turns. This should raise the entire system unit off of the casters
seven (7) half turns.
Training Note: Some people find the phrase "seven half turns" confusing. Another way to think
of it is as 3 and 1/2 rotations.
2Check each corner leg to ensure that there is pressure on the foot and you cannot turn it by hand.
• If you have correctly given each outer edge corner leg seven (7) half turns you should not be able
to turn the feet by hand.
CAUTION
If you do not loosen the locking nuts, you may strip the threads on the
leveling legs during movement.
Note
To ensure even weight distribution on the legs, it is very important that the
lowered legs be brought into contact with the floor without lifting the system
unit. You can verify whether a leg is in contact with the floor by attempting
to slide a piece of paper underneath it.
Note
Making a mark on the top of the leg will help you keep track of the half
turns. It is important to track the total number of turns, especially if you are
installing additional expansion modules.
leveling foot
leveling leg
make mark here to keep
track of seven half turns

Scalar i6000 Installation Guide Super Doc 7
• If you can turn one or more of the feet by hand, lower the system unit back onto the casters and
restart this procedure at Raising the System Unit Off the Casters (Same as Gen 1 Task) on page
6. The goal is to have the system unit weight evenly distributed across all four outer edge leveling
legs when it is properly raised. The system unit may or may not be level at this time.
Verifying the System is Level (Same as Gen 1 Task)
Training Note: This sub-procedure is the same as for a Gen 1 installation, except the four
leveling steps have been placed under a section heading. This is for organization. The procedure
is performed the same way.
Verifying the system is level consists of the following steps:
1Testing the Digital Level on page 7
2Verifying Level Condition on page 8
3Additional Leveling on page 9
4Lowering All Other Leveling Legs and Checking Library Level on page 10
Testing the Digital Level
Required tools: digital level
Perform this test before each use of the digital level and any time the digital level has been dropped or is
being used in an environment that varies ±9°F from the environment in which it was last calibrated. If the
digital level fails the accuracy test, you must re-calibrate the level before use.
1Turn on the level by pushing the ON/OFF button. Position the level with the display facing you and the
text on the face of the level right-side up. Ensure that the level is on a clean, flat, and horizontal surface.
This surface does not have to be exactly level. Wait 10 seconds for the level to completely settle and
take note of the angle on the display.
2Rotate the level end-for-end so the display is facing away from you. The screw on the back of the level
should be on the left side. Be sure to set the level in the exact spot as in Step 1. Wait 10 seconds for
the level to completely settle and take note of the angle on the display.

8Introduction
3Roll the level toward you so that the display is facing you, but the lettering on the face of the unit is
upside down. Be sure to set the level in the exact spot as in Step 1. Wait 10 seconds for the level to
completely settle and take note of the angle on the display.
4Rotate the level end-for-end so the display is facing away from you. The screw on the back of the level
should be on the right side. Be sure to set the level in the exact spot as in Step 1. Wait 10 seconds for
the level to completely settle and take note of the angle on the display.
5Compare the level display readings that you captured from Steps 1 through 4. Ifany of the four readings
vary from one another more than0.1 degree, you must re-calibrate the level. For more information, see
"Calibrating the Digital Level" in the Scalar i6000 Installation Guide. If the variance between the
readings are within the 0.1 degree limit, the level is within compliance and is ready to be used.
Verifying Level Condition
Required tools: digital level
1In the control module only, verify the system unit is level front to back and left to right by placing the
digital level at the following locations:
a. Inside the access door
b. On the left side inside the access door
A reading on the digital level that is 0.00 +/- 0.30 is to be considered level.

Scalar i6000 Installation Guide Super Doc 9
If the module does not meet the 0.00 +/- 0.30 leveling requirement, go to Additional Leveling on page 9.
If the module is sufficiently level, go to Lowering All Other Leveling Legs and Checking Library Level on
page 10.
Additional Leveling
Customerfloorsmay besuch that furtherleveling is required.The goal in leveling the system unit is toadjust
the leveling legs to achieve a digital level reading that is 0.00 +/- 0.30.
1Place the digital level inside the control module access door (positions 1). Use the following rules when
leveling from left to right:
• Rule 1: Always make your leveling adjustments to raise the system unit (turn the legs clockwise
looking from the top).
• Rule 2: Since the frames are very stiff, adjust the appropriate left or right leg pair the same amount
when leveling left to right.
• Rule 3: Use small adjustment increments; no more than one half (½) turn at a time.
• Rule 4: If the leveling adjustment has raised any of the other leveling legs off the floor, take out the
adjustment and work on the opposite end of the system unit (front to back).
• Rule 5: Wait at least 10 seconds for the digital level to settle between adjustments.
Note
Make sure the digital level is not resting on any frame welds or debris that
would cause an inaccurate reading. To find the small circular frame welds,
run your finger tips over the spot where you are going to place the level
Note
Make sure the digital level is not resting on any frame welds or debris that
would cause an inaccurate reading. To find the small circular frame welds,
run your finger tips over the spot where you are going to place the level.
placements of level

10 Introduction
2Placethe level onthe left side inside the control moduleaccessdoor (position 2). Use the followingrules
when leveling from front to back:
• Rule 1: Always make your leveling adjustments to raise the system unit (turn the legs clockwise
looking from the top).
• Rule 2: Since the frames are very stiff, adjust the appropriate front or rear leg pair the same amount
when leveling front to back.
• Rule 3: Use small adjustment increments; no more than one half (½) turn at a time.
• Rule 4: If the leveling adjustment has raised any of the other leveling legs, take out the adjustment
and work on the other side.
• Rule 5: Wait at least 10 seconds for the digital level to settle between adjustments.
Lowering All Other Leveling Legs and Checking Library Level
1Lower all remaining frame leveling legs until the legs touch the floor.
2To support the weight of the system, give each non-leveling leg 1/4 turn.
3Check all leveling legs to verify that all the legs are on the floor.
4Use the digital level to double-check the levelness of the library.
Verifying the Frames are Aligned Using Alignment Marks
Training Note: This procedure is different for a Gen 2 installation. You also verify alignment in
a Gen 1 install, but the method is different for Gen 2. In fact, it's a much simpler procedure. The
image in the manual shows it very well.
1Verify the frames are aligned by checking the alignment marks in the middle rack supports. The
alignment marks are on the right and left sides of each middle rack support and are 2 mm in height.
These alignment marks must overlap, which indicates that the frames are aligned within 2 mm.
access door
digital level position #1
service door
digital level position #2
front to back
left to right

Scalar i6000 Installation Guide Super Doc 11
If the alignment marks cannot be properly aligned, then the frame-to-frame alignment is incorrect.
You will need to unbolt and realign the frames so the alignment marks meet the specification.
Training Note: If the alignment marks are within the acceptable range, don't attempt to make
them perfect.
.
Setting the Leg Lock Nuts (Same as Gen 1 Task)
Required tools: 24 mm open end wrench
1Verify that all leveling legs are carrying load and that the system unit does not rock.
Alignment
marks
Best Acceptable Unacceptable

12 Introduction
2Use the 24 mm open end wrench to raise the leveling leg lock nuts to the top and tighten them against
the welded nut.
Step 2: Installing the Gen 2 Hardware
Once all the frames are bolted together and level, there are a few pieces of hardware to install. These parts
are the items that cross frame boundaries, some partially pre-installed cables, and the robots.
•Connecting and Securing the Power Rails on page 13
•Installing the Catch Trays on page 16
•Installing the X-Axis Gear Racks on page 19
•Removing the Control Module Cover Plates on page 28
•Removing the Left Parking Module Cover Plate on page 29
•Connecting the Door Switch Loop Cable on page 30
•Connecting the Aisle Cable Assembly on page 33
•Checking the Display Cable Connector on page 35
•Routing and Connecting Module Cables on page 35
•Installing the Gen 2 Robot on page 41
•Verifying Both Robots are Ready for IVT on page 55
•Running IVT and Troubleshooting on page 56
•Reinstalling the Cover Plates on page 58
Note
Ensure that you do not take the leveling legs out of adjustment during this
process.

Scalar i6000 Installation Guide Super Doc 13
Connecting and Securing the Power Rails
The power rails are pre-installed. You need to secureadjacent power rails using bridge clamps and connect
adjacent rails via their connectors.
Required tools: 2.5 mm hex wrench
Required equipment:
• Two bridge clamps per pair of adjacent power rails
• Screw A, M4X10 socket head cap screws (low profile) — 2 per bridge clamp
1Secure adjacent power rails together with two bridge clamps, one on the upper edge of the rails and
one on the lower edge of the rails. Use the screw holes available on the power rails. Use a 2.5 mm hex
wrench to install two screws in each bridge clamp. See Figure 1 on 14.
2Connect the power connectors on all adjacent power rails. There are two power connectors on each
side of each rail — a 4-pin connector and a 3-pin connector. The right-most connectors in the right
parking module will not have anything plugged into them. See Figure 2 on 15.

14 Introduction
Figure 1 Power Rail Position in Module
Two bridge clamps connect adjacent rails

Scalar i6000 Installation Guide Super Doc 15
Figure 2 Power Rail, Front
4-pin and 3-pin
connectors

16 Introduction
Figure 3 Power Rails and Bridge Clamps
Installing the Catch Trays
Catch trays are installed on the floor of the library. Each tray straddles the junction between modules.
Training Note: These trays are to catch the carbon that wears off the collectors as they pass over
the gap between the power rail bridges. Please refer to the material as "stuff," not "debris" when
you're speaking to a customer.
Tools required: 2.5 mm hex wrench
Equipment required:
• Catch tray
• Screw B, M4X6 socket head cap screws (low profile) with attached M4 T-nut — 2 per catch tray
Bridge
Clamps
Power Rails
Power Rail Connectors

Scalar i6000 Installation Guide Super Doc 17
Figure 4 Catch Tray
1Place the catch tray on the floor of the library over the junction between modules, with the catch tray
screw holes over the holes in the bottom rack supports.
2Screw B screws and T-nuts should be pre-assembled. If they are not, install a T-nut on each screw in
the Screw B bag. Make sure the wider end of the T-nut faces toward the screw head.
M4X6
screw
M4 T-nut
Screw B

18 Introduction
3Install two T-nut screws through the catch tray into the bottom rack supports.
Install two T-nut
screws

Scalar i6000 Installation Guide Super Doc 19
Installing the X-Axis Gear Racks
The robot moves back and forth along black plastic X-axis gear racks that are installed on the bottom,
middle, andtop rack supports. There are several types ofx-axis gear racks, each used in a different position
on the rack supports.
.
Tools required: 2.5 mm hex wrench
Equipment required:
• X-axis gear racks (see Figure 5 for descriptions)
• Screw B, M4X6 socket head cap screws (low profile), with M4 T-nut attached — For middle and
bottom racks, 3 per half rack, 4 per full rack
• Screw C, M4X6 socket head cap screws (low profile) — For top racks, 3 per half rack, 4 per full rack
Note
The half-rack load position in the left parking module, and the half-rack end
position in the right parking module are pre-installed. If you are adding new
modules onto the right an pre-existing Gen 2 system, you should have already
removed the half-rack, end position, full rack, right load position, as well as the
loader bracket and locator.
CAUTION
Make sure to use the correct type of gear rack for each position. If you
don’t, you will have problems installing the robot and the robot may
become damaged during use.

20 Introduction
Figure 5 Types of X-axis Gear Racks
Half Rack, Left Load Position — First position on the left. Contains cutouts for the left robot’s wheels
to fit through during robot installation. These racks are pre-installed in the left parking module.
Full Rack, Standard — Covers all the space not taken by the other racks. Has no cutouts.
Full Rack, Right Load Position (dual robotics only) — Second position from right. Installed just to the
left of the Half Rack, End Position. Contains cutouts for the right-side robot’s wheels to fit through during
robot installation.
Half Rack, End Position — Last position on the right. Has no cutouts. These racks are pre-installed in
the right parking module.
cutouts
cutouts