SSR1 Tuner (F10055138) Installation - PowerPoint Presentation

SSR1 Tuner (F10055138) Installation Pre-assembled Tuner Parts: 1) x2 Main Tuner Arm pre-assembly (F10055138_B) 2) x1 Actuator Frame pre-assembly (F10055140_B) 3) x1 Wired Motor pre-assembly (FC0022079) 4) x2 Wired Piezo (FC0046546)NB: Parts pre-assembled by the vendor need to be re-torqued.

Torque Values for Screws #4-40 SB socket head cap screw : 10 in- lb#6-32 brass pan head cap screws Philips head : 10 in-lb#8-32 brass set screws : 15 in-lb --- apply glue “Loctite 243” before inserting #8-32 brass pan head cap screws Philips head : 20 in-lb#10-32 SB socket head cap screw : 30 in-lb1/4 : 80 in-lb5/16 : 120 in-lb 3/8 : 180 in- lb --- except the actuation system mounting screws (80 in- lb ) : this is to make removal of the unit not too difficult.

Fig 1) Piezo Assembly 4 pin connector & Shorting cap PI Encapsulated Piezo: 2 independent piezo stacks

Tuner Arm Pre-assembly The tuner main arm are attached with main flexure joint with mounting screws by the vendor. The fasteners should be checked for the applied torque values. The threaded rods on this surface and the knurled knob at the center should be fully recessed. Also the piezo adjustment screw is recessed. “Connector” to be Removed after the arm installation

Actuator System pre-assembly 1) Install 2 Piezos into the bellow 2) Remove motor mounting pivot

Fig 2) Installing Piezos on the Actuation System

Tuner Actuation System Assembly Ready for Installation Fig 3) Actuation System Assembly. Piezos are already installed. Motor mounting pivots and screws are removed.

Motor Pre-assembly 1) Align the Switch Clamp and Base (Fig. 5) 2) Assemble Pivoting Lever assembly (Fig. 6) 3) Place the Pivoting Lever on the motor shaft (Fig. 7)

Fig 4) Phytron Motor with wiring 4pin connector for RTD Limit Switch Box RTD 8pin connector: #1-4 : motor #5-8 : limit switch

Switches Collar Base pointing in the same direction as the heat sink copper tab. Torque the 2 socket head screws with 20 in-lb. Figure 5) Using the flat surface of the motor block to align the limit switch mounting bracket. Remove the switches holder plate after torqueing

Figure 6) Showing installation of the Pivoting Lever to the Travelling Nut: Put the travelling nut on the shaft then put on the 2 brass bushings on the traveling nut. Then install the Pivot Lever as shown in the picture. Torque the 4 screws with 15 in-lb. Remove the Pivoting Lever assembly. The insert on the travelling nut facing against the motor block.

Figure 7) Set the Pivoting Lever assembly such a way the 2 balls facing to the motor block. Turn the Pivoting Lever assembly 28 turns after initial engagement with the threaded shaft. Apply Stycast on the thread before tightening Trigger Switch Screw

Installation of the Main Arms onto the Cavity This is two person task. Let’s do the upper arm first. Upper arms’ aluminum side plates will facing up and lower arms’ side plates will facing down after they are installed. The person on the arm mounting side pick up the flexure side of the arm and bring up over toward the person at the other side of the string. The other person pick up the ‘Connector’ attached on the arm. When bring down (or bring up for the lower arm) the arm, simultaneously rotate the arm so that the main adjustment screw is always pointing toward the homing position of the ball tip. Make sure the arm touches the string or cavity on the way. Make the arm horizontal and the adjustment is pointing near the homing position. Slide flexure slot over the lug to engages into the lug. Bring it down (or bring up for the lower arm) until it hits stop. Engage one of the main screws and finger tighten it. Then do the same for the other screw then tighten them with Allen wrench. Do the same for the lower arm. Remove both Connectors.

Figure 8) Lugs for Main Arm Mount (NB: hole pattern is horizontal)

Side Plate on top for the upper Arm Slide down the upper Arm from top to bottom and slide up the lower Arm from bottom to top ,along these sliding edges while keeping the arms horizontal, until the Side Plates hit the other edge. Side Plate on bottom for the lower Arm 2 Main Screws X4 adjustment screws Figure 9)

Installation of the Actuation System A) The cavity Lug for the tuner Actuation System mount is shown in Fig. 10) B) Put the unit on top of the lug with piezos pointing toward the tip of the tuner arm then make the slot engage with the lug C) Get started the 6 mounting screws very loosely (Fig. 11). Tighten the 2set screws to align edges and to provide hard stop (Fig. 12).D) Torque the mounting screws with 80 in-lb.

Figure 10) Lugs for Actuation System mount (NB: hole pattern is circular)

6 Mounting screws for the Actuator Figure 11)

Tighten these set screws to align edges and to provide hard stop. Figure 12)

Figure 13) Attach the Connector back to the tip of the tuner arm. Align the connector with the tip of the tuner arm then start the screws loosely. Then torque two screws with 120 in-lb B) Glue & torque the set screws (15 in-lb)

Adjustment of the tuner arms to align the piezos with the Connector. 1) Align according to the criteria shown in Fig. 14), using following tricks: *) Screw in 2 upper brass screws to bring up the arm. *) Screw in these 2 lower brass screws to lower down the arm. *) Screw in 2 inner brass screws to bring in the arm. *) Screw in 2 outer brass screws to bring out the arm. *) After adjustments torque the 2 main screws with 180 in-lb . *) Torque all 4 brass screws with 20 in-lb. 2) Check the piezo alignment if it satisfies the requirement. If not repeat the process 1) - 2)3) Also check the piezo alignment by screw in the piezo adjustment screw to make full contact with the V cone. Then dis-engage the piezo by unscrewing the piezo adjustment screw. 4) If alignment is good, lock the brass screws by gluing and torqueing all the #8-32 screws with 15 in-lb. Finger tighten the piezo adjustment screw until the ball is fully contacting the cup.

Gap C = 8(?) < +- 1 Gap B Gap A |Gap A – Gap B| < 1.0 Figure 14) Alignment using the brass screws as shown in Fig 15).

Upper Screws : screw in to bring the arm up Inner Screws : screw in to bring the arm in Outer Screws : screw in to bring the arm out Lower Screws : screw in to bring the arm low Figure 15)

Installation of the Motors *) Mount motor by inserting the motor pivots (do not screw in) as shown on the picture -- the copper tap and the plastic pin facing away of the cavity. *) Check the distance between the balls and the V groove. *) Remove the motor pivots and pull out the motor and turn in the pivoting lever – each turn reduces the distance by 1 mm since the pitch of the screw is 1mm. *) Re-mount the motor but without inserting the motor pivots and pull out the motor to make the both balls fully contact to the V groove barely – N.B. make sure the balls are not compressing the V groove which will cause bending of the flexure. Keep flexure bending as small as possible so the flexure won’t be bent permanently. Remove the motor and turn the lever one turn at a time and check with the motor with pivot pins inserted. Repeat this until both balls are in full contact with the V groove – initial full contact position.*) Pull out the motor and screw in 2 turns and install motor and insert the pivots and torque the 6 brass screws on the pivots – we call this location: position 0 .

Figure 16) Finding initial full contact position. Initial full contact position is where for the first time balls V-grooves are in full contact on both sides. During this process do not tighten the #8 brass screws

Limit Switch Pin pointing Away from Cavity Copper Tab pointing Away from Cavity Figure 17)

The Main Adjustment Screw Setting Softly turn in the knob of the main adjustment screw until it contact the cavity surface. Then turn out the main adjustment screw by 300 degrees. Then lock all 4 brass #8 screws by gluing and torqueing with 15 in-lb. Figure 18)

Limit Switch Setting Refer to Fig. 19) & Fig. 20):Attach the Switches Holding PlateAttach the Switches Mounting BracketsAttach the Limit Switches : * Switch #1 (wire #1#2) --away from motor body * Switch #2 (wire #3#4) – close to motor body * Longer leaf contacts are away from the Trigger Switch Screw , shorter leaf contacts are closer to the Trigger Switch Screw.

Switches Mounting Bracket Limit Switch Trigger Switch Screw Switches Holder Plate Figure 19)

#4 9.0 mm (switch opening distance) 1.0 mm (switch opening distance) #2 #1 #3 Figure 20) Limit Switch Setting (switch opening distance : Travel distance of the nut when the switch opens)