ZAPF PANEL SYSTEM ASSEMBLY INSTRUCTIONS - Marvel … · MARVEL 6 NOTES Panel Preparation continued Begin at a 90o connection, and note which side of the panels have a wedge block

ZAPF PANEL SYSTEM

ASSEMBLYINSTRUCTIONS

O F F I C E F U R N I T U R E F O R T H E I N F O R M A T I O N A G E

✔ It is recommended that the components be installedin the sequence of this assembly manual.

3 M A R V E L

INSTALLATION PREPARATIONTools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Panel Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Installation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PANEL CONNECTIONSCorner Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7In-line Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Leveling Glides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Variable Height In-line Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Variable Height Corner Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Panel-Mount-to-Wall Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Wall Hanger Strips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Top Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Panel End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

ELECTRICAL COMPONENTS INSTALLATIONOff Panel Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Power Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Harness Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Harness Jumpers with Power Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Worksurface Power Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-22Power Poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Ceiling Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25Receptacles and Single Raceway Receptacle Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PANEL MOUNTED COMPONENTSStandard Shelves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Half-height Shelves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Flipper Door Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Task Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Tackboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

PANEL-MOUNTED WORK SURFACE INSTALLATIONFull End Panel Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Shared Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Worksurface Bracket Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Cantilevers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Rectangular, Corner, and Extended Corner Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33D-Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Peninsula Surface and P-shaped Peninsula Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Peninsula Leg for Freestanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

COUNTER-TOP INSTALLATIONCounter-Tops and Counter-Top Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

WORK SURFACE MOUNTED COMPONENTSKeyboard Arms/Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Pencil Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

FREESTANDING WORK SURFACE INSTALLATIONMobile Desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Desk/Credenza . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Freestanding Shared Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Freestanding Corner Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Modesty Panel-to-Panel Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Bridge Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Wire Management Trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Freestanding Open Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Freestanding Flipper Door Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Tackboard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

LATERAL PEDESTAL AND LATERAL FILESPedestal Drawer Removal, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Pedestal to Freestanding Pedestal Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

CONFERENCE TABLEConference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Table of Contents

Tools Required

1/4” allen wrench

#2 Phillips screwdriver

#2 flathead screwdriver

non-marring rubber mallet

level

packing knife

Additional Recommended Equipment

Panel cart

Drill-driver with charger

Drill bit set

Tape measure

Pliers

Touch-up paint

Layout preparation1. Become familiar with the plan view and elevation layout.

Be aware of physical obstructions which affect the installation, such as building columns.

2. As material is delivered develop an inventory. Use the packing listenclosed in the hardware box to verify components received.Group components by installation sequence.

3. Plot the layout on the floor, using white chalk or tape.

4. Check the levelness of the floor and locate the highest point. Begin the installation at this high point.

5. Remove packaging and protective wrapping from components onlyas they are assembled.

If you have any questions regarding Zapf installation, callCustomer Service at 800-621-8846.

Installation Preparation

✔ It is recommended that the components be installed in the sequence of this assembly manual.

M A R V E L 4

5 M A R V E L

N O T E S

HardwareRubber Mallet

Flat Head Screwdriver

Panel Preparation

After unpacking the panels, remove the top cap assemblies and racewaycovers.

When moving the panels, always grasp the outer channels or the internalframe of the panels. Never use the center or internal material to carry.

Rotate the top caps out of the frame top channel.

To assemble, remove the raceway covers by tapping with rubber malletand screwdriver at a 45° to the bottom.

PP01

Top Cap Assembly

Raceway

M A R V E L 6

N O T E SPanel Preparation continued

Begin at a 90o connection, and note which side of the panels have awedge block and foam lightblock strip applied (See page 7 for illustra-tion of wedge block and light block). Panel sides with wedge blocksare attached to the panel sides without wedge blocks.

Begin the installation at the highest point on the floor.

Note that if 3-Way or 4-Way Power Poles are to be used, proper connec-tors are used in corresponding connections (See page 20).

Installation Sequence (Panel Mounted Surfaces)

1) Remove top caps and raceway covers from panels.2) Begin first pair of panels at 90 degrees at highest point in floor.3) Assemble remaining panels, leveling each pair as they are attached.4) Panel Mount to Wall Kits (2 and 4 are interchangeable).5) Wall Hanger strips.6) Power blocks, harness jumpers, and power blocks with harness

jumper.7) Power poles and power feeds.8) Receptacles.9) Tackboard(s).10) Task Lights.11) Shelves and Flipper Doors.12) End caps for end of run.13) Raceway covers.14) Top caps and transition trim.15) Worksurface supports and brackets.16) Worksurface-mounted components.17) Counter Tops.18) Worksurfaces.

7 M A R V E L

N O T E S

Hardware (2-4) 5/16"-18" x 3/4" long bolts

Tools1/4" hex bit

Power driver recommended

PANEL CONNECTIONS

Corner Connections

Install the wedge block to the side of one corner panel that does nothave a foam light block or wedge block. Therefore, one corner panel willhave two wedge blocks, allowing the panels to be assembled onto theblocks in both directions. Otherwise, the installed panels will have to belifted to rest on the block of the next panel. Make sure there is always astrip of foam light block between each set of panels.

The Corner Post has one wedge block pre-installed, which can berelocated if necessary place the post over the wedge block of the cornerpanel. Place the other corner panel onto the wedge block assembledon the post.

FoamLight Block

Wedge Block

2-Way

3-Way

M A R V E L 8

N O T E S


Tools1/4" hex bit


Use the 2-Way, the 3-Way or the 4-Way Bracket and mount with connector bolts to the tops of the panels.

In-line Connectors

Hook the side of one panel without a wedge block over the wedgeblock connection (low end of hanger frame) of the adjacent panel.

Use the in-line connector bracket and mount with connector bolts to thetops of the panels.

N O T E S


Tools1/4" hex socket bit


Hack saw with fine

tooth blade

Leveling Glides

As each panel is connected, use a level and adjust the leveling glides asneeded.

In-line Variable Height Connector

Lower panel attachment is the same as the standard panel-to-panel in-line connection.

To complete the connection, place the two hooks on the variable heightconnector into the rails of the taller panel and use a bolt to secure the connector to the top end of the lower panel.

Attach the transition trim piece to the top cap of the lower panel andinstall the top cap. The lower panel top cap must be cut by 1 3/4”to attach to the trim piece.

9 M A R V E L

Cut 1-3/4”

N O T E S




Use the provided clip to fasten the upper end of the vertical trim pieceto the exposed side of the higher panel.

Attach the upper transition trim piece to the top cap of the higher paneland install the top cap so that the plastic tab is inside the vertical trimpiece.

M A R V E L 10

11 M A R V E L

N O T E S




Hack saw with fine tooth

blade

Variable Height Corner ConnectorsThe Lower panel attachment is the same as the standard corner post connection.

For panels which are the same height as the corner post (highest height),post-to-panel connection, uses an end cap attachment bracket(s).

To complete the connection, place the tab of the corner post variableheight connector into the hole in the corner post and then use the pro-vided bolt(s) to secure the connector to top of lower panel(s).

PC12a

Note:Cut back the lower top cap by 1 3/4” to attach to the transition trim piece.

Lower Top Cap

12 M A R V E L

N O T E S




PC12b

Attach transition trim piece(s) to the top cap(s) of the lowerpanel(s) and install the top cap(s). Use the provided clips(s) tofasten the upper end of the vertical trim pieces(s) to th exposedside of the corner posts(s)

Attach the upper corner post trim piece over the top of the cornerpost, panel ends of the same height, and vertical trim piece(s), sothat the plastic tab(s) is inside the vertical trim piece(s).

Install top caps of any panels, which are the same height as thecorner post.

M A R V E L 13

N O T E S

Hardware (1) 5/16”-18”x3/4” long bolts

(12) -#8 x 2-7/16” Flat head

(1) End Cap Connector

Tools1/4" hex bit

#2 Phillips bit

Panel Mount-to-Wall Kit

The installer/user must determine the type of existing wallconstruction and must apply accepted installation standardsfor safe use. Marvel assumes no responsibility for providedfasteners or installation of the Panel Mount-to-Wall Kit topermanent structures.

Required Conditions:1. Bottom of Panel Mount-to-Wall Kit must contact solid flooring.2. Proper fasteners (for dry-wall or concrete) must be used

properly to attach kit.3. If fastening to dry-wall, dry wall must be at least 5/8” thick and

proper fasteners are required.

M A R V E L 14

N O T E S




Wall Hanger Strips

The installer/user must determine the type of existing wallconstruction and must apply accepted installation standards forsafe use. Marvel assumes no responsibility for provided fastenersor installation of the Panel Mount-to-Wall Kit to permanentstructures.

Attach Wall Hanger Strips to the wall with fasteners, using a level and atape measure to insure proper alignment. Marvel Zapf panel-mountedcomponents will mount on wall hanger strips in the same fashion as theydo to the panels.

M A R V E L 15

N O T E STOP CAP INSTALLATION

Before installing the top caps, the 2-Way, 3-Way, 4-Way and in-linetransition pieces must be snapped into place.

M A R V E L 16

N O T E S

ToolsPower driver recommended

#2 Phillips bit

Hook the “L” Bracket over the end cap and screw to the panel with#5/16 -18 bolt.

Install the top cap with the plastic tab on the end of the transition trimpiece inside the end cap.

PC07

Panel End Cap - (Install before raceway covers are installed)

Make sure the wedge block is attached to the end of the panel for panelend attachment. Verify that the panel is oriented so the End Cap sidehas a foam Lightblock.

Place the panel end cap over the wedge block at the end of the panel.

M A R V E L 17

N O T E SThe panel top caps consist of an aluminum extrusion part and a plasticextrusion part. These two parts are shipped assembled and should beinstalled that way. The plastic extrusion fits into the top channel of thepanel. Do not try to force the top cap straight down. The plasticextrusion has two legs, start with one leg inside the top channel at anangle. Then rotate the other leg inside the channel, it should snap inplace locking the top cap.

After top caps are installed you will notice a black gap between thepanel and its top cap and between adjoining top caps. To give the pan-els a cleaner look all these gaps should be consistent with each other.This requires either lifting the top caps up with a driver or tapping themdown. There is play in the tolerances of the top caps because of theplastic connection method, therefore obtaining the black reveal consis-tency should not be difficult.

PC09

M A R V E L 18

N O T E S

Hardware (per raceway connecting to corner)

(1) 8/32” x 1/2” machine screw

(1) #8 x 1-1/2” wood screw

(1) 7 ft. x 1-1/2” felt

(1) 7’ ft. x 3/4” open cell foam

(1) wedge block

Off Panel Door

Very Important! Read This First!This door comes factory semi installed to swing/open 2 styles. To obtain theother 2 styles, read option phase!

Depending on which style, before you slide the door in place as shownin phase 2, attach the 3/4” felt adhesive on the side of the door frameslotted channel that doesn’t come in contact with the adjacent panelthat already has the felt adhesive. (see existing panels for felt attachment)

Steps To Follow1) Remove both the adjustment panel top caps. See Detail 12) Position the threshold in the middle between the panels(Note: Do not fasten it to the floor yet). See Detail 23) Make sure both panels’ lower sides at the slotted channel have the

connecting wedge blocks facing each other. The hardware bagincludes one wedge block. See Detail 3 for illustration.

Steps To Follow4) Slide in the door frame assembly between the panels. See Detail 45) Be sure the lower frame snugly fits over the threshold brackets. See Detail 5 6) Screw in the two 5/16-18 cap screws (one on each side) to finish the

upper panel to panel connection of each side of door frame. After thissnap the top caps back into place. See Detail 6 Use standard connectorsin any configuration.

DETAIL 1

PHASE 1

DETAIL 2

DETAIL 3

PANELWEDGEBLOCK

DOORTHRESHOLD

8-32x 1/2TCS SCREW

DETAIL 1

DETAIL 6PHASE 2

DETAIL 5sLEFT SIDE SHOWN

LEFT SIDE SHOWN

GROUND

PANELWEDGEBLOCK

THRESHOLDBRACKET

5/16-18 CAP SCREW2 PIECES

DETAIL 4

19 M A R V E L

N O T E S

Hardware (1) 8/32” x 1/2” machine screw

(1) #8 x 1-1/2” wood screw

(1) 7 ft. x 1-1/2” felt

(1) 7’ ft. x 3/4” open cell foam

(1) wedge block

Tools(1) 3/8” hex socket wrenchPower driver recommended

utility knife

#2 Phillips bit

Steps To Follow1) Remove all screws that hold the slotted channel on both sides of thedoor frame.2) Remove the slotted channels and this will expose the hinge bolt and nutassembly. Using a 3/8” socket wrench remove all nuts and bolts that hold thehinges and re-attach it on the other side of the frame the same way youremoved them.3) Reattach the slotted channels the same way you removed them. Now youhave the other 2 swing configurations!

Steps To Follow7) Once door frame is in place and aligned correctly, Fasten the threshold to

the ground. You might need to use custom screws depending on the floorcondition. See Detail 7

8) Mount the door with the #8 x 1.5 screws provide. See Detail 8 9) Attach the door lock provided on the door. 10) Optional: Attach the 1.5” W felt adhesive to cover the screw holes on the

frame side. Cut out a small hole in the felt for the lock hole See Detail 10

DETAIL 7

DETAIL 8

PHASE3

DETAIL10

10-32 NUTS6PCS

FOR THE OTHER TWO SWINGCONFIGURATION

OPTION PHASEZAPF DOORFRAME ASSEMBLY

LIGHT BLOCKER

SLOTTED CHANNEL

COUNTERSINKHINGE BOLT6 PCS

HINGE

9

N O T E SELECTRICAL COMPONENTS

Risk of fire or electric shock. Do not electrically connect any powerblock to more than one supply source. Always determine that a powerblock is connected to one and only one source of supply.

Hardwiring between any power entry harness and the building supply isto be completed by a qualified electrician following all electrical codes.

Only those installers familiar with 8 wire/4 circuit power systems used inoffice furnishings should perform installation of any electrical compo-nents.

Electrical wiring is only permitted between the panels, if those panelsare mechanically connected.

To properly install the electrical components, determine the location ofthe power entries and which direction power will “run,” since eachpower block has a “pigtail” which must be attached to the blockassembly of the adjacent panel.

The panel raceway covers have knockouts to access both the upper andlower slots of the raceway for receptacles and data/communication.When power receptacles are to be placed in the upper portion of theraceway but no data receptacle in the lower portion, knock out only theupper piece.

Refer to the electrical plan or plan view layout to determine properplacement of the power block assemblies, harness jumpers, powerentries and receptacles.

Power Blocks for Raceways

Use power block widths that are the same as the widths for the panelsto which they are to be attached. Snap the heavy plastic clips on eachblock assembly onto the brackets attached underneath the upper por-tion of the raceway. When block the assemblies are snapped into place,there is an audible “click” that generally occurs. Insure that the “pigtail”ofthe power block does not interfere with replacement of the racewaycovers.

M A R V E L 20

21 M A R V E L

N O T E S Harness Jumpers for Raceways

Harness jumpers merely pass power through the raceway of a panel.Use the harness jumper widths that are the same as the widths for thepanels to which they are to be attached.

Harness Jumpers with Power Block for Raceways

Attach harness jumpers with a power block in the same fashion as thepower blocks; these have only one block assembly.

Harness Jumpers with Power Block for WorksurfaceElectrical Access Panels

Remove the single receptacle covers from the access cover at work levelheight.

Leave any covers on where no receptacles are to be mounted.

M A R V E L 22

N O T E SA 48” Harness jumper with Power Block should be specified to carrypower from the raceway of the adjacent panel to the bracket 33” H inthe worksurface Electrical Access Panel. If using different power sourcesfor each of the block assemblies on the left and the right of the panel,refer to the figure 1. If continuing power through the access panel andinto the raceway of the adjacent panel, refer to figure 2.

48” HarnessJumper withPower Block

Figure 1

Figure 2


Using PowerInfeeds fromBoth Directions



Using PowerInfeeds fromOne Directionand ContinuingPower


23 M A R V E L

N O T E S

Hardware(2-4) 5/16"-18" x 3/4" long bolts

(3) 1/4”-20 x 1.000” long bolts

(1) 1/4” washer

(3) 1/4” lock nuts

(6) 10-32 KEPS lock nuts

(6) 10-32 x 3/8” PHMS



#2 Phillips bit

Power Entries

Base End Power Entry

No receptacles are displaced when using a base end power entry. Plugthe end of the “whip” assembly into either a power block or harnessjumper attached in a raceway.

A certified electrician must attach the other end of the base powerentry to the building power.

Power Pole – End of Run

Make sure a wedge block is attached to the end of the panel run. Attachthe raceway cover plate to the bottom of the power pole with hardwareprovided. Place the cutout in the bottom of the power pole over thewedge block.

Ceiling Attachment1) Cut a 2 1/2” x 3 1/2 ” access hole in the ceiling tile directly above the

ceiling power entry outside the footprint attachment point.

2) Cut the pole to size: top of pole should be about 4” above top ofceiling tile.

3) Push the top of the pole through the access hole in the ceiling tile.

4) Feed the base power entry through the cover and into the opening onthe raceway frame end. Use the septum when running wires insidethe pole.

5) Attach the power entry to the junction block. Match the curved termi-nal on the power entry to the curved terminal on the junction block.(See jumpers)

6) Install hanger strip: To gain access to the area, remove a ceiling tileadjacent to the location of the pole. Twist the hanger strip to lie flatagainst the pole. Use the provided 1/4-10” bolt, washer, and 1/4” nutto fasten the hanger strip to the pole. Drill 5/16” clearance holesthrough the ceiling grid. Fasten the hanger strip to the ceiling grid withthe provided 1/4-20” bolt and 1/4” nuts. Tighten with a socket wrench.Insert the provided foam plug into top of the pole.

7) Install the mounting box assembly: Fit the halves of the mountingbracket together. Insert the provided #10-32 screws into the bracketholes to hold the halves together. Loosely thread nuts onto screws.Remove the center knockout from the electrical box (electrical box issupplied locally). Fit the assembly over the top of the pole. Onceassembly is in position tighten nuts onto screws.

8) Install the trim bezel: Position the trim bezel halves around the pole.Snap the provided retaining clips through the holes in both trim bezelthe halves. Push trim bezel up against the ceiling tile. Replace the adja-cent ceiling tile.

N O T E S


(3) 1/4”- 20 x 1.000” long bolts

(3) 1/4”- 20 x KEPS nuts

(1) 1/4” flat washer

(6) 10-32 x 3/8” Phillips screws

(6) 10-32 KEPS nuts



#2 Phillips bitPower Pole – 3-Way or 4-Way Post Entry

Lower post-to-panel connection is similar as the standard post-to-panelconnection. However there can be no wedge blocks assembled insidethe post itself as it impedes the base power feed from entering the race-ways. All wedge blocks must be assembled onto the connectingpanels. The top post connection uses 4 variable height connectionbrackets instead of the standard post connection bracket. Use the 3-Wayor 4-Way trim cap to transition the connector post to the power pole.

Ceiling Attachment

��

3 way or 4 way trim cap

M A R V E L 24

25 M A R V E L

N O T E S

Hardware(3) 1/4”-20 x 1.00” bolts

(3) 1/4” KEPS lock nut

(1) 1/4” flat washer

(6) 10-32 x 3/8” Phillips screws

(6) 10-32 KEPS lock nut


#2 Phillips bit

1) Cut a 2 1/2” x 2 1/2” access hole in the ceiling tile directly above theceiling power entry outside the footprint attachment point.

2) Cut pole to size: the top of the pole should be about 4” above thetop of the ceiling tile.

3) Push the top of pole through the access hole in the ceiling tile.

4) Feed the base power entry through the pole and connector post andinto the opening on the raceway frame end.

5) Attach the power entry to the junction block. Match the curved termi-nal on the power entry to the curved terminal on the junction block.(See jumpers)

6) Install hanger strip: To gain access to the area, remove a ceiling tileadjacent to the location of the pole. Twist the hanger strip to lie flatagainst the pole. Use the provided 1/4-10” bolt, washer, and 1/4” nutto fasten the hanger strip to the pole. Drill 5/16” clearance holesthrough the ceiling grid. Fasten the hanger strip to the ceiling grid withthe provided 1/4-20” bolt and 1/4” nuts. Tighten with socket wrench.Insert the provided foam plug into the top of the pole.

7) Install mounting box assembly: Fit the halves of the mounting brackettogether. Insert the provided #10-32 screws into the bracket holes tohold the halves together. Loosely thread nuts onto screws. Remove thecenter knockout from the electrical box (electrical box is suppliedlocally). Fit the assembly over the top of the pole. Once the assemblyis in position, tighten nuts onto screws.

8) Install trim bezel: Position the trim bezel halves around the pole. Snapthe provided retaining clips through the holes in both of the trimbezel halves. Push the trim bezel up against the ceiling tile. Replacethe adjacent ceiling tile.

Receptacles

Electrical Box

Foam Plug

#10-32 Screwand Nut

1/4”-20 Bolt,Washer and Nut

Ceiling Grid

Retaining Clip

Trim Bezel Halves

Mounting Bracket

Hanger Strip

M A R V E L 26

N O T E SReceptacles are labeled in Roman numerals to distinguish circuits; allpower blocks carry all of the four circuits. Receptacles snap into placeinto power blocks.

Roman numeral number IV is the dedicated line in a 3 and 1 set-up.

(Refer to Electrical In-Feed for schematic)

N O T E S

Hardware(4) 10-24 x 1/2” Thread Cutting

Screws

Tools#2 Phillips bit


Half Height/Standard Shelves

Shelves are shipped knocked-down. Insert the end panels for the shelvesinto the rails of the panels. Place the shelf, with the lip at the back, overthe bottom of the end panels and insert the screws provided. Note: If installing a tackboard underneath, tackboard must beinstalled first.

27 M A R V E L

M A R V E L 28

N O T E S


Screws


#2 Phillips bit

Flipper Door Units

Flipper Door Units are shipped knocked down. Insert the end panels forthe shelves into the rails of the panels. Place the door assembly coverover the top set of lips, insert the screws provided. Place the shelf, withthe lip at the back, over the bottom of the end panels and insert thescrews provided. Be sure to engage the attached locking clips on lowerpart of each side of the Flipper Door Unit side panel to make sure it staysengaged into the panel. Note: If installing a tackboard underneath aFlipper Door Unit, tackboard must be installed first.

N O T E S Task LightsMarvel provides several different hanger bars for task lights to provide“universal” installation to most furniture. Select the proper length hangerbars and slide them through the notches on each side of the task light.Place each hanger bar over the lip on the front end of the shelf or flipperdoor unit; bend the hanger bars as necessary to place them over the lipat the back end of the shelf or flipper door unit, and release into place.

Tackboards

Tackboards are shipped without their hook brackets assembled for easeof installation. The brackets are universal. Slide brackets on to the boardwhere screws are pre-assembled. Tighten screws. Center the board onthe panel and align the hooks at the desired height. Note: Tackboardsmay only be used on matching panel widths. Slide the hooks into theslots on the side of the panel and drop it into place. Note: If installingunderneath an Open Shelf or a Flipper Door Unit, tackboard mustbe installed first.

PMC05

PMC04, a

PMC04, a

29 M A R V E L

M A R V E L 30

N O T E S


Screws

(3) #10 x 5/8” wood screws


#2 Phillips bit

PANEL-MOUNTED WORKSURFACE INSTALLATION

Full End Panel LegsThe panel attachment bracket is assembled onto the panel at the correctheight which aligns with the threaded holes in the leg. Attach with (4)10-24 x 1/2” TCS screws. Right hand configuration shown. For Left handconfiguration, turn leg around and turn bracket upside-down.

Insert tabs into slots and slide down.

Swing lock tab into place as shown.

31 M A R V E L

N O T E S

Hardware (10) #10 x 5/8” Phillips screws

(4) 10-24 x 1/2” Thread CuttingScrews



#2 Phillips bit

Shared Legs

The panel attachment brackets (LH & RH) are first assembled onto thepanel at the correct height which aligns with the threaded holes in theleg. Insert leg between bracket and attach with (4) 10-24 TCS.

PMWS 02b

N O T E S

Hardware(4) #10 x 3/4” wood screws


#2 Phillips bit

Worksurface Kit Brackets

Assemble the Kit Brackets into the panel slots on the front and back ofthe return panel at the corresponding heights to the other supports.Note: Kit Brackets may only be used on a return panel that supports thesame depth worksurface.

Cantilevers

Assemble the cantilever (LH or RH) into the panel slots at the corre-sponding heights to the other supports.

PMWS 04

M A R V E L 32

N O T E S

Hardware#10 x 5/8” wood screws


#2 Phillips bit

Rectangular, Corner, Extended Corner SurfacesAll supports should be securely attached to the panels and leveled atthe same height before the worksurface assembly. Mount surfaces ontothe supports; line-up with the corresponding panel(s) and adjoining sur-faces. Insert #10 x 5/8” wood screws where applicable to attach thesupports to the surfaces. Use wood screws in the remaining pilot holes.

Note: Worksurface edges should line up with panel edges.

D-Top Surfaces

All supports should be securely attached to the panels and leveled atthe same height before the worksurface assembly. Attach the Peninsularound leg using (4) 1/4-20 machine screws, into the threaded metalinserts. Mount the surface onto the supports; line-up the cutout with thecorresponding panel(s) and adjoining surfaces. Insert wood screws intothe pilot holes to attach the D-top to the panel supports.

CornerSurface

RectangularSurface

Shared Leg

Full Leg LH Full Leg RH

RectangularSurface

ExtendedCornerSurface

Shared Leg

33 M A R V E L

M A R V E L 34

N O T E S

Hardware1/4”- 20 x 5/8” long bolts

#10 x 5/8” wood screws


#2 Phillips bit

Peninsula and P-Shaped Surfaces

All supports should be securely attached to the panels and leveled atthe same height before the worksurface assembly. Attach the Peninsularound leg using (4) 1/4-20 machine screws, into the threaded metalinserts. Mount the surface onto the supports; line-up with correspondingpanel(s) and adjoining surfaces. Insert wood screws into the pilot holesto attach it to the panel supports.

Shared Leg

RectangularSurface

P-ShapedSurface

PeninsulaSurface

Peninsula Leg

Determine which side your peninsula is to be located on. Connectmodesty panel to leg using (4) 10 x 1/2" TCS screws.

Hardware Screws are included with Modesty Panel which attaches to leg

35 M A R V E L

N O T E S

Hardware(8) 1/4"-20 x 5/8" long bolts





Hardware(4) #10 x 5/8” wood screws



COUNTER TOP INSTALLATION

Counter Tops and Counter Top Brackets

Counter Tops should be installed over the panel top caps. The surfacescome with 2 LH and 2 RH brackets which are installed by inserting thehooks into the panel slots. Mount the surface onto the four brackets andattach with (8) 1/4-20 threaded metal inserts. The 72” Counter Topincludes two additional brackets which are installed at the panelconnection (the largest panel is 60”).

Note: When Counter Tops are used in conjunction with a variable heightconnector they will have a radius cutout. This cutout will compensatefor the 1” radius endcap, which would impede a regular Counter Top.

WORKSURFACE MOUNTED COMPONENTS

Keyboard Arms and Trays

Determine the location of the tray and draw a centerline on the worksur-face perpendicular to the front. Position the flat side of the mountingtrack so it aligns with the centerline and attach with wood screwsthrough the pilot holes. Note: For easier installation, attach the keyboardto the worksurface face down on a carpet or non-marring surface.

Pencil Drawer

Align the surface pilot holes and attachment holes on the drawer. Attach with wood screws through the pilot holes. Note: For easier installation, attach pencil drawer to the worksurface face down on a carpet or non-marring surface.

M A R V E L 36

N O T E S

Hardware(4) 1/4” -20 x 5/8” long bolts


(8) 10 -24 x1/2” ThreadCutting Screws


#2Phillips bit

FREESTANDING WORKSURFACE INSTALLATION

Mobile Desk

Legs and components should be assembled to the worksurface facedown on carpet or a non-marring surface. Align the top bracket on theLH and RH legs to the pilot holes in the worksurface; attach usingwood screws. The modesty panel is attached by 10-24 x 1/2” TCS intothreaded holes in the legs. To attach the modesty panel to the work-surface, use wood screws into the pilot holes. Wire Management channelmay be assembled on the inside or outside of the modesty panel priorto tightening screws from modesty panel to worksurface.

FS01b

FS02b

37 M A R V E L

N O T E S

Hardware(8) #10-5/8” wood screws

(8) #10 - 24 x 1/2” Thread cut-ting screws


#2 Phillips bit

Desk/Credenza

Place the work surface on a smooth clean surface (a carpet is fine). Use(8) silver screws (4/leg) to fasten the two non-handed legs to the work-surface as shown in the large diagram. Note the large notches in theback panel (they provide clearance for wires). Fasten the back panel tothe two legs using (8) black screws. Do not fasten the back to the worksurface yet. Slide the flange of the wire trough between the work sur-face and the top flange of the back panel, as shown in the small dia-gram. The wire trough can go on either the inside or the outside of theback panel. Locate the wire trough by sliding it to the left or right. Nowattach the back panel to the work surface using 5 silver screws. Tightenall of the screws. NOTE!! TWO PEOPLE ARE REQUIRED TO TURN THEDESK UPRIGHT!! Turn the desk right-side up. If grommets are specified,insert the plastic grommets into the grommet holes. Level desk using the(4) leveling glides. The desk may be cleaned with a soft cloth and milddetergent.

FS02c misc

M A R V E L 38

N O T E S

Hardware(10) 10-24 X 1/2’ Thread

Cutting Screws


(1) Shared Leg


#2 Phillips bit

Freestanding Shared Leg

Legs and components should be assembled to the worksurface facedown on carpet or a non-marring surface. Align the top bracket on theleg to the pilot holes on one side of the worksurface; attach using woodscrews. The modesty panel is attached by 10-24 x 1/2” TCS into thread-ed holes in the leg. After installing the Shared Leg to one side of theworksurface, flip upright to install the adjoining surface. This makes theleveling and the alignment of the surfaces much easier. Wire managementchannel may be assembled on the inside or outside of the modestypanel. Use worksurface connection bracket at front edge to level thesurfaces using #10 x 5/8” wood screws.

N O T E S

Hardware(4) #10 - 5/8” wood screws

(8) 10-24 x 1/2” Thread

Cutting Screws


#2 Phillips bit

Freestanding Corner Leg

The modesty panels are attached by 10-24 TCS into threaded holes inthe leg. Assemble modesty panel to legs prior to worksurface attachment. Align the top bracket on the leg to the pilot holes in theworksurface; attach using wood screws. To attach the modesty panelsto the worksurface, screw wood screws into the pilot holes. Note: Modesty Panel should be one size smaller than worksurfacesize (Example: 36” Corner would use 30” Modesty, 30” Cornerwould use 24” Modesty, etc.)

Modesty Panel-to-Panel Bracket

This bracket will allow a freestanding desk to attach perpendicular to apanel. The panel must be the same depth as the worksurface. This brack-et is assembled onto the panel at the back, corresponding to the work-surface. A standard Kit Bracket will support the front of the worksurface.Attach the freestanding support leg and modesty panel to the worksur-face (as above). Mount onto the two assembled brackets (on panel) andfasten into place. Attach the modesty panel to the Modesty Panel-to-Panel Bracket with 10-24 x 1/2” TCS into threaded holes in the brackets.

FS06a

39 M A R V E L

M A R V E L 40

N O T E S

Hardware(4) 10 x 1/2” thread CuttingScrews

(4) #10 x 3/4” Phillips screws


#2 Phillips screws

Bridge Connector

Position the two desks or the desk and credenza that will be connect-ed. They should be located where they will be used, and should beparallel to, and facing each other (note the diagrams below). Using (8)black screws (4/leg), fasten the two bridge brackets, one per desk, tothe front of the legs as shown.

Note the large notches in the back panel (they provide clearance forwires). Fasten the back panel to the two bridge brackets using (8) blackscrews. Attach worksurface connection bracket to the front of the backtable using silver wood screws.

Carefully lay the bridge work surface on the back panel and top plates.Using (2) silver screws per plate, fasten the work surface to the topplates. Do not fasten the work surface to the back panel yet. If grom-mets are specified, insert (2) plastic grommets into the grommet holes.

41 M A R V E L

N O T E S Wire Management Trough

Slide the flange of the wire trough between the work surface and thetop flange of the back panel, as shown in the diagram. The wire troughcan go on either the inside or the outside of the back panel. Locate thewire trough by sliding it to the left or right. Now attach the back panelto the work surface using (5) silver screws. Tighten all of the screws.

The desks may be cleaned with a soft cloth and mild detergent.

M A R V E L 42

N O T E SFreestanding Open Shelf

Set the left and right leg on their back edges as shown. Take (8) blackscrews and insert them 2-3 turns in the holes shown. Do not tighten thescrews yet.

Locate the back (The part with holes in all 4 flanges). Using (6) blackscrews, attach the back to the legs as shown. Make sure the opennotch is toward the bottom. Tighten screws “Finger Tight” only.

CAREFULLY PLACE ASSEMBLY UPRIGHT ON THE WORK SURFACE

Locate the shelf (The part with short flanges on the sides and a slot inthe front). Carefully slide it over the lower 2 pre-installed screws oneach leg. Tighten screws “Finger Tight” only.

Slot(66” & 72” modelshave2 slots)

Short flange

Hardware10 x 1/2” Thread Cutting Screws


#2 Phillips bit

43 M A R V E L

N O T E S Using 3 screws (5 for the 66” models), fasten the back to the shelf.

Locate the top. Carefully slide it over the 2 upper pre-installed screwson each leg.

Using 3 screws, (5 for the 66” models), fasten the back to the top.Tighten all screws. Carefully remove the backer from the tape on thebottoms of the legs. Use the tape to fasten the open shelf to the worksurface. This unit may be cleaned with a soft cloth and mild detergent.

M A R V E L 44

N O T E SFreestanding Flipper Door Kits

Remove the (3) screws (5 in the 66” and 72” wide models) that fastenthe back to the top cover. Loosen the (6) screws (3 on each side) thathold the top cover to the side panels.

CAREFULLY remove the top cover and set it aside. NOTE: if this is a 66”or a 72” top, note the two holes in the stiffener on the underside of thetop. They will be used later.

Make sure that the (4) screws in the side are loosened until they areabout halfway out. Look at the flipper door kit. Note the direction thatthe flipper door pulls out. Orienting the flipper door so that the doorpulls out in the correct direction, carefully slide the slots in the endsover the (4) screws in the side panels. DO NOT TIGHTEN THESCREWS YET!

Note location ofholes in

stiffeners (66” &72” model only)

45 M A R V E L

N O T E S Pick up the top cover. Carefully replace it so that the side flanges gobetween the side panels and the Flipper Door kit. Tighten the 4 screws,and re-insert the 2 screws previously removed from the sides. Removethe 3 screws (5 in the 66” and 72” models) that fasten the back to thetop cover.

(66” and 72” models only) Partially open the left door, as show at right.Carefully thread a screw though the front hole in the flipper door supportinto the hole in the stiffener under the top (the hole that was noted instep 1) and tighten. Repeat this for the right door.

M A R V E L 46

N O T E S

Hardware (6) 10 x 1/2" Thread Cutting Screws

Tools#2 Phillips Bit

Tackboard Assembly

Remove the fabric tackboard from the steel tackboard frame by slidingthe front UP, and removing it at the bottom edge. Thread the screwsthrough the ends of the tack board frame, and into the holes to the rearof the Uprights on the Open Shelf. Tighten all (6) screws. Re-insert thefabric tackboard front.

47 M A R V E L

N O T E S Pedestal Drawer Removal

Open drawer and press black tabs on center of slide inward

Pull drawer straight forward to release completely

Pedestal Drawer Assembly

Slide ball bearings to front of slide member

Align slide members on bottom of drawer with slides in cabinet andpush in. Slide will lock together when drawer is closed.

Right hand

Left hand

M A R V E L 48

N O T E S

Hardware (2) 10 x 1/2" Thread Cutting Screws

Tools#2 Phillips Bit

Pedestal Preparation for assembly to FreestandingPedestal Leg

Remove file drawers. (See drawer Removal instructions, page 48)Turn cabinet so back is facing up and locate indentations ON SIDE THATPEDESTAL LEG IS MOUNTED TO.

Knock indentations in with screwdriver and mallet.

Align holes on pedestal with threaded holes on pedestal leg.Side of leg should be flush with pedestal.

Attach pedestal to pedestal leg using screws and washers.

49 M A R V E L

N O T E S

Hardware (per raceway connecting to corner)

(12) #10 TCS

(24) #10 x 3/4” Phillips screws


#2 Phillips bit

Conference Table

Legs and components should be assembled to the worksurface facedown on carpet or a non-marring surface. The modesty panel isattached by 10 x 24 1/2” TCS into threaded holes in the legs. To attachthe modesty panel to the worksurface, use wood screws into thepilot holes.

Note: use 2 people to stand table upon its legs.

Attach tubular legs to Conference Table ends. Place ends over other halfof top plates. Fasten with #10 x 5/8” wood screws.

Level table.

O F F I C E F U R N I T U R E F O R T H E I N F O R M A T I O N A G E

®

3843 West 43rd Street

Chicago, Illinois 60632

Telephone 800-621-8846

Facsimile 800-237-0358

© 2004 MARVEL

SW 114rev904

Zapf and Marvel are registered trademarks of Marvel.

ZAPF PANEL SYSTEM ASSEMBLY INSTRUCTIONS - Marvel … · MARVEL 6 NOTES Panel Preparation continued Begin at a 90o connection, and note which side of the panels have a wedge block

Documents