Installation difficulty with NXB-GEN-611-016 Perimeter Guard Panel alignment

Description

We are expanding a safety cell for our R-100 series robot and have purchased five NXB-GEN-611-016 Perimeter Guard Panels. During installation, we are finding that the integrated mounting tabs on the panels do not align correctly with the pre-drilled holes on our existing 80mm square profile posts. The horizontal spacing between posts is exactly 2040mm center-to-center as per our original drawings, and the panel width is confirmed at 2000mm. However, when we attempt to mount a panel, the bolt holes are vertically offset by approximately 5-6mm. We have tried multiple panels and posts with the same result. We cannot complete the installation and need to know if we have received a defective batch of panels or if there is an incompatibility with our existing post system that was not documented.

Symptoms

• Panel mounting holes do not align with existing fence post holes.
• A vertical offset of 5-6mm is observed when trying to attach the panel.
• Standard mounting hardware cannot be inserted.
• Installation of the safety cell expansion is halted.

Resolution

Investigation determined that the customer's existing 80mm posts are a legacy model from a previous installation. These posts have a different hole pattern than the current NexBot standard posts. The NXB-GEN-611-016 panel is manufactured to current specifications and is not defective. The correct installation procedure for this mixed-generation hardware requires the use of an adapter bracket, part number NXB-FNC-BRK-008. These brackets bolt to the legacy posts and provide the correct mounting points for the new panels. The customer was provided with the part number to order the necessary brackets to complete their installation.

Resolution Steps

1. Verified the customer's post profile dimensions (80mm x 80mm) and hole spacing via submitted photographs.
2. Identified the customer's posts as a legacy design incompatible with the direct mounting tabs of the NXB-GEN-611-016 panel.
3. Confirmed that the panel dimensions are within manufacturing tolerance and the product is not defective.
4. Specified the required adapter bracket, SKU NXB-FNC-BRK-008, which is designed to bridge legacy posts and current-generation panels.
5. Provided the customer with ordering information for 20 units of NXB-FNC-BRK-008 (4 per panel).
6. Advised the customer on the correct installation procedure: attach brackets to posts first, then mount the panel to the brackets.
7. Case closed after customer confirmed the adapter brackets resolved the alignment issue and the installation was successful.