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updating tof mounting instructions based on installation at Nevis!! #208

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94 changes: 29 additions & 65 deletions docs/MEC/notes/UMB/installation.md
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Expand Up @@ -201,83 +201,47 @@ them below:

### Installation Instructions

**NOTE:** Currently we only have QTY 24 of the load spreaders `TOF-PAN-011`.
I have another QTY 24 in production and scheduled to be delivered on 10/31
([track](https://www.fedex.com/apps/fedextrack/?action=track&trackingnumber=785639662959)).
Until all the load spreaders arrive, reserve what we have for inboard mounts and
panel 7 mounts. It won't be difficult to replace outboard mounts before the
whole frame is lifted.

1. Place the UMB frame on the ground and in a position with enough clearance
around the gondola for staging panels. All sides should have 5-8ft of
clearance, and one of the RAD or SOL sides needs 8-10ft of clearance.
Leg legs of the gondola frame should be rested on a piece of wood, and not
directly on the concrete ground.
2. Before installing any panels, attach the mounting bars to the gondola.
Reference the assembly PDF's linked in [Assembly Schematics](#assembly-schematics).
* This needs to be done first, since some bars have never been mounted and we
need to ensure that all tapped holes are deep enough to accept the hardware.
* You don't need to torque the fasteners in this step, just make them hand
tight.
* If a tapped hole does NOT have enough threads, then it needs to be tapped
further. Take a BOTTOM/BUTT tap and cut a few more threads. A FLUTE tap
will likely not work for this step, but a PLUG tap might work.
* If tapping still does not work, then use either a
[5360N124][washer no 10 .354 OD 1x] or
[5360N125][washer no 10 .354 OD 2x], with the latter being the
thicker one. Use only one washer and side with using the thinner one.
3. For each panel to come, leave the shipping rails on the panel to help move
the panel into place for setup. The 06PP are stacked in their crates
in the order they should be mounted.
4. Starting with panels 10 and 13... Move the panel to a position near the
UMB frame and rest the panel on a stack of foam that is at least 2" tall.
Near the gondola should be right next to the panels final position, so
the panel can be slid directly under the UMB frame.
4. Remove the shipping rails and attach the mounting bars to panel using the
specified components and hardware. Refer to the
[assembly docs](#assembly-schematics) for components and torque specs.
5. For the shipping rails, place the removed hardware pack into the sliders
and place the rails in a safe place for future shipping.
6. With the mounting bars attach slowly raise the panel by adding addition
supporting layers of foam. At the same time slowly bring the panel under
the gondola and into position.
7. When in close enough position, you can have someone lift the panel and
have a second person insert hardware.
* If hardware does not thread nicely, then STOP AND RETHINK. Forcing the
0. General instructions:
* always be sure there is no pressure on the SiPMs when they are resting on a foam platform.
* always replace hardware in shipping/lifting rails, and store them in a safe place as soon as they are removed from the panels.
* If hardware does not thread nicely, then STOP AND RETHINK. Forcing the
fastener can damage threads and we DO NOT have spare components.
* If a fastener does not thread it's usually for two reason: (1) your holes
* If a fastener does not thread it's usually for two reason: (1) your holes
and fasteners are not aligned and/or (2) your fastener is at an angle to
the threads.
* Additionally, do not tighten any fasteners until all fasteners are in
* Additionally, do not tighten any fasteners until all fasteners are in
threaded. Doing so will restrict the parts freedom of movement and you'll
have a very difficult time getting the remaining fasteners in.
8. With all the fasteners hand tightened, you can start torquing. As always,
creep up on the torque spec.
10. If the RAT associated with the panel is not in place and would be in the way
for mounting the next panel, then strap the current panel cables out of the
way and repeat steps 4-9 for the next panel in the series. Remember, you
are mounting panels 10 and 13, then 8 and 11, and then 9 and 12. Panel 7
is the last panel to be mounted and is detailed further down.
11. If the panel's associated RAT is not mounted, then follow the
[RAT mounting instructions](#mounting-rats) to do so.
* At this point the panel cables should also be routed and attached to
the RAT.
* All cables should be strain relived to the gondola (preferable)
* For mounting panels with vertical bolts that have to be accessed through access holes, recommend pre-loading the bolts into the holes, and preparing the T-shaped hex keys inside the bolts prior to lifting the panel into place.
* Start with all of the mounting hardware for each panel assembled.
* All cables should be strain relived to the gondola (preferable)
or the Top Strap of the panel using zip ties. The TOF team has flight
zip ties that can be used.
* If you have never zip tied the cables to a Top Strap before, then please
* If you have never zip tied the cables to a Top Strap before, then please
ask some who has for instructions. You can also reference how the cables
were attached during shipping.
12. Now that you are done with Panels 8-13, all RATs should be mounted, all
RAT umbilical cables should be routed, all panel (8-13) cables should be
routed and connected, and all fasteners should be torqued.
13. Access for routing Panel 7 cables will be extremely restricted once Panel 7
* Use velcro for cabling. Only use zip ties after all cables are in place, for Antarctic flight only.

1. Place the UMB frame on the ground and in a position with enough clearance
around the gondola for staging panels. All sides should have 5-8ft of
clearance, and one of the RAD or SOL sides needs 8-10ft of clearance.
Leg legs of the gondola frame should be rested on a piece of wood or foam, and not directly on the concrete ground.
2. Prepare a landing spot for 6PPs using the rolling lifty tables, by arranging tables with a piece of plywood on top (the 6PP lid workd well), and a piece of squishy TOF foam on top.
2. Install panel 10: Remove panel 10 from its crate using the mounting bars on which it is packed, and lay it on the lifty table assembly perpendicular to the plywood/foam, with the SiPMs pointing up. Remove the shipping bars and install the mounting bars according to [Panel 10 & 13 PDF]. Torque the inboard-side bolts, but leave the outboard bolts a bit loose for now. Use the lifty tables to roll and lift the panel into position and mount it onto the top frame. Torque down all remaining bolts.
3. Now it is time to parallelize! Deploy a team to start cabling panel 10. Try to route the cables to the edge of the top frame as directly as possible while still strain relieving them. They can continue to cabling panel 13 once they are finished with panel 10 (13 will probably be mounted before panel 10 is cabled.)
4. Meanwhile, extract and mount panel 13 as with panel 13.
5. Then, extract and mount panel 11. This cable needs to first land with SiPMs up. Cable the panel on the ground, routing them toward the outboard side, and securing the cables to the panel. Then, flip the panel over, being careful of the distribution of weight on the panel, in order to remove the lifting/shipping bars and apply the mounting bars. As with previous panels, torque down inboard bolts only before installing the panel. With this panel you will need to approach at an angle. The 91A corner will need to go up and in behind the mounting hardware first, and then the rest of the panel will be lifted into place. So, this cannot be done entirely with the lifting table, and manual lifting will also be required.
6. Repeat Step 5 with panel 8.
7. Meanwhile, if the cabling team has free hands, they can being installing RATs using the [RAT mounting instructions](#mounting-rats). RATs 4 and 2 can be installed after panel 11. RATs 1 and 3 can be installed after panel 8. This opens up a whole new range of cabling possibilities, as the cabling team can begin connecting panels to RATs after the RATs are installed and cabled. RATs 5 and 6 can go on after panel 12 and 9, respectively.
6. Repeat Step 5 for panels 9 and 12. The order here does not matter, and the application is actually much easier than for the other 6PPs.
7. Access for routing Panel 7 cables will be extremely restricted once Panel 7
is mounted. So, at this stage we'll route cables before attaching cables.
Annoying I know!
Annoying I know!
* Field note: these are Erik's original instructions. We actually cabled Panel 7 first, and then mounted it, and it seemed to be ok. We should discuss what to actually do next time.
* This step hasn't been done this way before, so you will need to adapt and
brainstorm a bit.
* [My suggestion] Start by attaching the cables to the RAT and routing the
cables along the gondola frame. Loosely zip-tie the cable along the way
cables along the gondola frame. Loosely velcro the cable along the way
for good housekeeping.
* Once the panel end of the cable is near where it connects to the paddle,
it needs to drop through the center opening of the gondola.
Expand All @@ -288,4 +252,4 @@ whole frame is lifted.
eventually connect, since the cable will need to make too tight of a bend
to get back to the SiPM. Instead, pass the cable past the panel a few
paddles before or after the cable's final destination.
14. Now mount Panel 7 repeating steps 4 - 11.
14. Now mount Panel 7 as in Step 5.