Multiple Cassette Unit (MCU)

Before installing the MCU:

• the Trendsetter VLF must be correctly installed and aligned. See the Base Trendsetter VLF installation procedure.
• the track and picker must be correctly installed and aligned. See the Track/Picker Installation procedure.
• the picker must be safely parked over the table.
• the table fixture must be attached and aligned.

1. Roll the MCU into its final position.
   
2. Check that the plenum of the MCU is aligned to the system centerline laser.

1. Turn ON the laser plane
2. Check that the laser plane is aligned to the reference marks. The laser should touch both edges of the plenum centerline feature.
3. To adjust the alignment of the MCU:

• roll the MCU until the plenum feature is aligned to the system centerline laser.

3. Check the distance from the table edge to the plenum.

1. Open the picker door manually and use foam blocks to keep it open.
2. Measure from the inside edge of the plenum to the edge of the table, using a measuring tape. Check the distance at two points on the table, front and rear. The distance should be 660mm at each point.
3. Roll the MCU until the distance is 660 mm at both points.
4. Recheck the system centerline alignment.

4. Remove the castors.

1. Carefully slide the chariot until it is fully open. You must support the chariot as you open it, as the wheels will not touch the ground.
2. Remove the large rear access panel and place it safely out of the way.
3. Attach the two rear lifting fixtures (#92-0376A) to the lower rear frame.

Rear lifting fixtures

4. Attach the two front lifting fixtures (#92-0377A) to the front cross member.
5. Place the longer front fixture (#92-0374A) between the side frames.
6. Slide the lifting bars (#56-3266A) through the front lifting fixtures and into the other front fixture.
7. Insert the four lifting jacks (#92-0084A) into the 4 lifting fixtures.

Front lifting fixtures

8. Place two white plastic slide plates (#57-8573A) under each jack.
9. Carefully raise the jacks until all four are loaded. Continue to raise the jacks until the castors are 20mm above the floor.
10. Place wood safety blocks (#59-3808) under each corner of the MCU.
11. Remove the four screws holding the castors onto the MCU, using a ratchet handle, 450mm (18") extension and a 8mm hex key socket.
• Lay on the floor beside the MCU and reach underneath to remove the castors.
• Keep the castors and fasteners on site for future moves.

12. Lower the MCU until it rests on the four outside feet.
13. Do not remove the lifting jacks yet.

5. Check that the base of the MCU is level to 0° ± 0.2°.

1. With the chariot open, crawl inside the MCU.
2. Place a calibrated digital level along the rear cross member and then the side frame rails.
3. Place the level on the inside edge of the plenum. It is important that the plenum and the side frame have the same reading.
4. To adjust the levelness of the MCU:
• rotate the adjustable feet until the desired angle is achieved.

6. Attach the two plenum fixtures (#92-0393A) to the plenum (put tape on the plenum to prevent scratching the surface). The distance from the outside edge of the cassette door opening to the outer edge of each fixture is ± 320 mm (12.5").
   
7. Attach the cassette alignment fixture (#92-0370A).
   
   1. Check the calibration of the six sensors.

• Connect the sensor tester.
• Turn the power ON. All lights should be green. To adjust any sensors, loosen the two screws holding the sensor in place and use the adjusting screw to make any adjustments. Tighten the screws when done.

Calibrating the sensors

• Remove the calibration cover (the front brass cover).

2. Place the sensor end of the fixture through the cassette door opening and rest the fixture on the plenum.
3. Depress the sensors to allow the fixture to fit into position.
4. Connect the cassette fixture to the table fixture, using the two quick release pins.
5. Turn on the sensor readout.

9. Check the position of the MCU.
   
1. Check the alignment to the system centerline. (See Step 2 for instructions.)
2. Check the distance from the plenum to the table. Both sensors #1 and #2 should be green.
3. To adjust the position of the MCU:
   • raise the lifting jacks evenly until the four MCU feet are 2 mm above the floor.
   • push, pull or bump the MCU until the desired position is achieved.
   • lower the lifting jacks.

    

10. Check the height from the plenum to the picker.
    
    1. Move the picker into position over the plenum fixture. Both sensors #3 and #4 should be green.
    2. To adjust the height of the plenum:
    • raise the MCU by rotating the four adjustable feet
    • adjust the feet evenly until the sensor readouts are green
    • check that the MCU is still level
      
    3. Check that the #1 and #2 sensors are still green. Repeat steps 9 and 10 if necessary (to repeat step 9 you must lift and move the picker away from the table fixture).
    4. Lift and move the picker to the middle of the table.

     

11. Remove the following items and pack them back into the installation toolbox:
    • cassette alignment fixture
    • plenum fixtures
    • table fixture
    • lifting jacks, bars, fixtures and slide plates
    • wooden safety blocks

     

12. Remove the foam pads from the cassette door opening.
    
13. Lower the other two MCU feet inside the MCU.
    
14. Check the operation of the chariot. It should roll easily and should engage the MCU easily.
    

    To adjust the chariot ride height:

    • rotate the adjustment screws until the desired height is achieved.
      
15. Re-install the black safety guard in the MCU.
    
16. Connect the air and power lines.
    
    1. Turn the power switches on the MCU to OFF.
    2. Turn the AL air shutoff valve to OFF.
    3. Connect the umbilical cables from the MCU to the lower frame of the Trendsetter VLF.
    4. Remove the plug from the air fitting in the lower frame.
    5. Route and install the airline from the MCU lower frame to the Trendsetter.
    6. Connect the Trendsetter VLF AC power cable to the receptacle from the MCU.
    7. Connect the MCU power to the wall outlet.
       

    Do not install the cassettes yet!  Complete the rest of the Autoloader installation before loading the cassettes into the MCU.

Install the guard rail
Install the L-Conveyor or Straight Conveyor
Install the SSR

When the Autoloader is fully installed, follow these steps to install each cassette:

17. Installing the cassettes.

1. Turn the compressed air and power ON.
2. Open the chariot until it stops.
3. With 3 helpers, lift one cassette over the chariot.
4. Lower the rear edge of the cassette into the MCU until the front edge clears the chariot body.
5. Position the cassette on the rollers.
6. Push the cassette into the MCU until the latch engages (an audible double-latch).
7. Manually raise or lower the cassette until the next bay is in position. Turn the manual override switch to the left and use the up and down buttons to position the cassette bays.

MCU manual operation

8. Repeat the procedure for the other cassettes.
9. Close the chariot door.