User:Jrkenti/TST-WI-061
AKR Flash Assembly Work Instruction explains the proper way to assemble a Flash reactor.
Materials
[edit]This section describes the tools and the consumables needed to execute this work.
Tools
[edit]
Consult with a lead or engineer if you are unsure of the proper tool for any particular step.
- Small Torque Screwdriver – 3 in-lbs (for control board screws)
- Medium Torque Screwdriver – 10 in-lbs (for single clamshell screw)
- Large Torque Screwdriver with 11/16” hex socket - 13 in-lbs (for NPT fittings)
Inputs
[edit]- Parts per DEV-BOM-005
Outputs
[edit]- Assembled Flash Reactor, ready for testing according to TST-WI-062
Process
[edit]Klaran WS (Flash) units can be assembled one at a time start to finish, or sub-assemblies can be made and each reactor can involve just assembling the completed sub-assemblies. If building sub-assemblies, build 20 of each sub-assembly before starting any final assembly.
Prepare
[edit]- Collect 20 AKR reactors from finished goods
A photograph of AKR box and barcode - Sit down at a computer work station with a label printer (loaded with white 0.75x2.25" stickers), and with ActiveBarcode properly installed.
- Open & log into Unipoint and download a new copy of the Flash traveler (TST-F-049) from Unipoint. A VBA macro should immediately begin, follow its instructions.
- SCAN AKR serial numbers onto log sheet
- SELECT the correct power adaptor in the dropdown on the traveler
- PRINT the log sheet & barcodes
NPT Fitting Sub-Assembly
[edit]- UNBOX the AKR, discard the bubble bag, recycle the box and set aside the ESD bag
A photograph of AKR box and barcode - Using a section of ¼” tubing with some print on it, WRAP ¼” wide Poly-Temp HD PTFE Tape around the tube 5 times by spinning the tube as shown. Use the print on the tubing as a guide to count the turns of the tubing.A photograph PolyTemp HD tapeA photograph of the tape wound around the tubing
- TEAR the tube and tape away from the roll with a quick tug.A pretty picture of gloved hands.
- APPLY the PTFE tape to the middle of the NPT threads on the AKR in a clockwise direction when viewing from the open end of the NPT fittings, as shown.
A picture of a person winding the tape around the NPT fitting.A photograph of the tape on the NPT fitting. - REPEAT the above steps for both NPT fittings on the AKR.
- Hand TIGHTEN two NPT to ¼” PTC fittings to the AKR portsNPT-to-PTC fittingsA photograph of the NPT fittings on the AKR.
- SNUG fittings using the large torque screwdriver with 11/16” socket set to 13 in-lbs. Continue turning the screwdriver slowly until it clicks several times in a row.
Tubing PTC Sub-Assembly
[edit]- PUSH one PTC coupler onto the end of the tubing
A PTC-to-PTC fiting
A piece of tubing
The assembled tubing and PTC fitting- The tubing must seat fully into the PTC fitting
- PUSH one PTC coupler onto the end of the flow sensor:
The PTC fitting on the flow sensor- The orientation is critical
- The PTC fitting must be on top, with the arrow on the flow sensor facing down
- The flow sensor must seat fully into the PTC fitting
- PUSH the tubing into the port closest to the metal end of the AKR:
The AKR with the tubing and flow sensor- The tubing must seat fully into the port
- PUSH the flow sensor into the port furthest from the metal end of the AKR
- The flow sensor must seat fully into the port
Housing and Control Board Sub-Assembly
[edit] | ESD REMINDER The steps described here require the user to be properly grounded to eliminate electrostatic discharges. Electrostatic discharges (ESD) can irreversibly damage electronic devices, including our LEDs. |
- PLACE one #4 x 5/16” self-tapping screw through the hole in each corner of the control board
Control board and four #4 screws - PLACE the control board with the black external port facing out of the rectangular opening in the housingControl board screwed into the clamshell housingPicture of the board with the screws numbered
- ENSURE the board sits flat before tightening screws
- TIGHTEN the screws in the order shown in the picture, using the small torque screwdriver set to 3 in-lb
Control Body Sub-Assembly
[edit]- ATTACH the AKR connector, making sure the tab locks.
AKR wire attached to control board
AKR wire attached to AKR and flow sensor - CONNECT the flow sensor wire
- BEND the wires as shown to accommodate cable lengthWires wrapped they they will fit in the box nicely.
- If the flow sensor is not in the same orientation as shown in the image to the right, it was installed backwards, and needs to be reversed.
- PLACE one #6 x 1/2” Long Type A/AB Tapping Screw into backside enclosure halfClamshell lid with one #6 screw.
Image of the sub assembly being screwed together. - PLACE the backside of the enclosure into a nested condition with the frontside of the enclosure
- TIGHTEN #6 screw using the medium torque screwdriver set to 10 in-lbs while holding the enclosure together with your other hand
- Be careful to avoid any cable pinches!
- PLACE the assembled Flash unit back in the AKR bag, PTC side down
- ISOLATE any failed components immediately. Do not discard.
- Any failed parts should be segregated into the non-conforming bin, and labeled with the date and non-conformance.
- Parts that fail may need to be investigated with the manufacturer by the area engineer.
- The content of the document, and every subsequent change, needs to be approved by the team shown below.
- The content should also be reviewed annually for accuracy and applicability.
- Records of reviews are stored and recorded on this Review Sub-Page.
- Training against this document should be preformed annually for relevant employees.
- Records of trainings are stored and recorded on this Training Sub-Page.