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VST-TRE-TOM-22300-2128-2.0 SupSys - VSTceN Portal

1. 19 a2 LC atr 19 2 Mirror Dummy Removal 23 MATERIAL SPARES EQUIPMENT INSTRUMENTS AND TOOLS eeeeeeeee 25 3 1 REIS an EET 25 3 2 DAMS AN E E O A 25 3 2 1 25 3 2 2 E E 23 3 3 UI OILD AEE E EA E E A E E E E E E UR ates 27 3 4 Instruments ANT OOIS 33 3 4 1 General Purpose Tools and 33 3 4 2 Special Tools and Instruments 33 A SUPPORT SYSTEM DESCRIPTION 6 sssscisscssssavaveedsandichadatvasiasduaanssaawaveedsandshadatvariascduacassaavaxeedeadchieh 35 4 1 AXIAL FORCE ACTUATORS ccccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeesseeeseeeeeeeeeeeeeeseeeesess 35 4 1 1 How to Mount the Axial Force nnne enne 41 4 1 2 How to Remove the Axial Force Actuators nennen 42 4 1 3 How to Verify the Height of the Axial Force Actuators cccccccceccccceeeaessssesseseeeeeeeees 44 4 1 4 Disassembly of an Axial Force nnns 46 AD AXIAL PAED POINT 9482022409993 2891
2. 46 4 2 1 How to Mount an Axial Fixed 1 48 4 2 2 How to Verify the Height of an Axial Fixed 1 48 4 2 3 How to Remove an Axial Fixed 48 4 2 4 Disassembly of an Axial Fixed 1 49 4 3 LATERAL FIXED POINTS eene nenne 50 4 3 1 How to Mount the Lateral Fixed 1 51 4 3 2 How to Remove the Lateral Fixed Points 32 4 3 3 Disassembly of a Lateral Fixed 1 22 4 3 4 How to Adjust the Lateral Fixed Points 02 ASTATIC LEVI RS 54 4 4 How to Remove an Astatic Levet ecce duo E Ca des bu eed S PER 395 4 4 1 1 Removing the Supports of Astatic Levers nr 1 2 3 4 9 10 11 12 13 14 15 16 21 PALAIS ITUR A AEE A 55 4 4 1 2 Demounting the support of astatic levers 5 6 7 8 17 18 19 and 20 57 4 4 2 How to Mount an A STATIC LEVET cs a aaia a 58 4 4 2 How to Mount the suppots of astatic levers 1 2 3 4 9 10 11 12 13 14 15 16 21 22 23 and
3. eene nnne enn 26 Figure 9 Spacers for gap adjusting safety 29 Figure 10 Test Bench for the static tests and of the axial force actuators cesses 29 Figure 11 Test Equipment for the dynamic test T2 of the axial force actuators cesses 30 Figure 12 5Kg IOKg and 20Kg reference weights eese eene 30 Figure 13 high accuracy 50kg full scale Load Cell esses eene 31 Figure 14 220 full scale Load 31 Figure 15 3000kg full scale Load 32 Figure 16 Support Rod for the axial force actuators and axial fixed points sss 33 Figure 17 Shaft Extension bottom and Key Extension top for safety devices 0501 and 0515 34 Figure 18 Axial Force Actuators and Axial Fixed Points arrangement top VICW ccccceeeseseeeeeceeees 35 Figure 19 Axial Force Actuators and Axial Fixed Points AFP position cessere 37 Figure 20 Axial Force Actuator to be mounted on ring nr 1 cross section 3 Figure 21 Axial Force Actuator to be mounted on rings nr 2 and nr 3 cross section view 39 Figure 22 Axial Force Actuator to be mounted on ring nr 4 cross section 40 Figure 23 Axial Force Actuator cross section view and top vlew seeeee
4. 100 7 6 SIUS AVE Devices Pad PRI 101 EXTRA ORDINARY nennen nnne nennen 102 8 1 Failure of an Axial Force Act ator eub ue PH ela 103 8 2 How to replace an Axial Force Actuator or an Axial Fixed Point eueessssee 104 8 3 How to Replace a Lateral Fixed 105 8 4 to Replace an Amplifier of the Lateral Fixed Points c ccccccceccccceeceesssseseeeeeeeeeeees 106 8 5 How to Replace a PDB sanseenaaaeatenegednedsccabddabesenersaanahedenoenss 107 8 6 to replace a Cable m 108 9 Attachement CONFORMITY DECLARATION enn 109 Qr Issue 2 0 Date 2009 03 04 Pag 9 of 109 Code VST TRE VST PROJECT VST M1 SUPPORT SYSTEM USE AND MAINTENANCE MANUAL TOM 22300 2128 TABLE INDEX Table 1 Data Sheets Instructions and Certificates eese eese nnne enses nnns 12 Table 2 Symbols likely to be used in the manual eese eese nnne enne nennen 13 Table 5 Symbols related to dangers danger prevention and instructions eaae 15 Table 4 Reference information to order commercial ar Table 5 axial force actuators and axial fixed points reference height 44 Table 6 axial force actua
5. 49 4 E AN B 1 t T 2 v ee p Ez Figure 19 Axial Force Actuators and Axial Fixed Points AFP position For ease of reference the cross section views of the three different types of axial force actuator are reported in the next pages the total height of each type is shown so to ease the identification VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 38 of 109 Qr c Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 co Cl F wE 7 cn E up E ge a li C E Pm o 2 ud m C ER ce i Figure 20 Axial Force Actuator to be mounted on ring 1 cross section view Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 39 of 109 6 Ice e Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 i tg LL 1 TTE A reference height 227 total height 258 Figure 21 Axial Force Actuator to be mounted on rings nr 2 and nr 3 cross section View VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 40 of 109 Qr and Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 reference height 261 total height 294 s P Figure 22 Axial Force Actuator to be mounted on ring nr 4 cross section view Issue 2 0 6 VST PROJECT Date 2009 03 04
6. Beware of electrical connections and parts at high voltage The operators carrying out all ordinary maintenance operations must wear the appropriate safety equipment helmet protection shoes gloves glasses and so on as by the norms in force and as described in the use and maintenance manual of the telescope as a whole system Do not touch the screws marked with a red dot they can be released only for extra ordinary maintenance reasons Qr VST PROJECT VST M1 SUPPORT SYSTEM USE AND MAINTENANCE MANUAL Issue 2 0 Date 2009 03 04 Pag 94 of 109 Code VST TRE TOM 22300 2128 Ordinary maintenance is summarised in the table below that gives in an eye glance all information necessary to prevent failures of the M1 Support System MAINTENANCE TABLE every mirror removal Axial Force Actuators and Axial fixed Points verification with mirror mirror removal Lateral Fixed Points zero adjusting with mirror removed Lateral Supports astatic levers verification with mirror removed T3 7 4 7 6 every mirror removal every mirror removal every 5 years Safety Devices gap verification with mirror mounted back in the cell Axial Force Actuators and Axial Fixed Points re greasing with the mirror removed Safety Devices verification of the pad personnel instruments amp tools or mechanical grease technician or electronics multi meter technician
7. Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 7 4 Safety Devices Gap every Safety Devices gap nr 1 mirror verification with mirror mechanical removal mounted back 1n the cell technician special spacer hour After mirror has been removed and then set back in the mirror cell it 1s time to check the gap between the safety devices and the mirror The operation consists of checking how much gap is there between the safety devices and the mirror it should be within 0 8mm and 1 0 mm along the radial direction within 0 4mm and 0 5 mm along the axial direction for both the top and bottom arms of the safety devices MISSING PICTURE spacer being produced Figure 63 Safety Devices verifying the gap The safety devices nr 0501 and 0515 that 1s those placed at he very East and at the very West sides of the cell can be reached with the special spacer realised on purpose MISSING PICTURE spacer being produced Figure 64 Safety Devices 0501 and 0515 verifying the gap Issue 2 0 bee Date 2009 03 04 Qr VST M1 SUPPORT SYSTEM Pag 100 of 109 USE AND MAINTENANCE MANUAL Code VST TRE TOM 22300 2128 WARNING Pay attention and do not touch the top surface of the mirror apart from the areas strictly below and above the axial safety devices 7 5 Axial Force Actuators and Axial Fixed Points Greasing ver Axial Force Actuators el mand y and Axial Fixed Points
8. 6 4 2 Lifting the Mirror Dummy Ne Mount the Hydra Set to the crane hook mount the handling to the Hydra Set ring mount the tripod to the Dummy verifying that the numbers of the three connections is correct move the hook right on top of the centre of the dummy slowly lift the dummy while the dummy is still in contact with the columns moving the crane laterally in order to share the load among all tie rods lift the dummy about 100 mm over the supports verify that it is horizontal within 2 mm 6 4 3 Integrating The Mirror Dummy in the Mirror Cell l Lift the dummy 500 mm over its final height in the mirror cell move the dummy horizontally until it is about on top of its final position in the mirror cell verify that the dummy orientation around the z axis is correct lower the dummy down to 100 mm over any possible contact point with the safety devices of the support system move the dummy horizontally until it is about on top of its final position in the mirror cell lower the dummy down to 8 mm over any possible contact point with the safety devices of the support system move the dummy horizontally until it is about on top of its final position in the mirror cell move the dummy horizontally in the two directions until it has backlash within 5mm and 15mm in relation to the lateral safety devices VST PROJECT Issue 2 0 USE AND MAINTENANCE MANUAL Code VST TRE Date 2009 03 04 VST M1 SUPPORT SYSTEM 92
9. Issue 2 0 Date 2009 03 04 VST M1 PPORT SYSTEM Pag 1 of 10 Qr 5 SUPPORT SYS ag 1 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 VST Project MI SUPPORT SYSTEM USE AND MAINTENANCE MANUAL VS T MAN TOM 22300 2128 Date 2009 03 04 Issue 2 0 Name Date Signature Written by 2009 03 04 Checked by AT Mm jf Le 1 Released by R Tomelleri 2009 03 04 2 LUI Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 SUPPORT SYSTEM Pas 2 of 109 Qr ag 20 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Change Record Issue Date SectionsAffected Reason Remarks 1 0 2000 00 16 al firstiswe OOO 2 0 2009 03 04 all added pictures and reviewed Applicable Documents ADs Document code Title Date VST SPE OAC 22000 1311 Frimary Mirror Support System 2008 01 17 Technical Specification 2 VST TRE OAC 22300 2009 Primary Mirror System Design 2008 02 29 Description Primary Mirror Active Optics 3 VST TRE OAC 22000 1305 Control System Hardware 2008 05 30 1 1 Electronics Design Report 1 Actuators Control Board Description Manual 5 VST MAN OAC 24300 2122 Ml AO PDB Electronic Board 4005 99 99 1 0 Description Manual Motor Control Handset Description Manual M1 Handling Integration of Primary Mirror in the Cell 6 VST MAN OAC 24303 2131 7 VST TRE OAC 20000 1111 VST
10. zs from the cell interface from any three actuators 5 with the astatic levers of ring nr 2 1 5 3 0 15 16 9 0 15 2 11 6 0 15 0 0 15 3 35 5 0 15 23 9 0 15 EM 65 6 0 15 54 0 0 15 Table 6 axial force actuators and axial fixed points functional height table Issue 2 0 wr lena Date 2009 03 04 VST M1 PPORT SYSTEM Pag 46 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 1 4 Disassembly of an Axial Force Actuator In case of any intervention that requires to open and disassemble an axial force actuator more information is necessary which can be easily found in the Design Description VST TRE TOM 22303 2010 2 1 in the Assembly Procedure VST TRE TOM 22303 2081 2 0 or derived from the Drawing OACNOI 01 000 0 4 2 AXIAL FIXED POINTS The Axial Fixed Point can be mounted onto the mirror cell or removed from it no matter whether the mirror is integrated in the cell or not In the case of mirror integrated in the cell it 1s allowed to remove just one axial fixed point at a time This means that you have to restore the one axial fixed point back onto the mirror cell before removing the next one If the mirror is not integrated in the cell all three axial fixed points can be removed but they must be all placed back before integrating back the mirror in the cell The 3 axial fixed points are mounted as shown in the figures that follow in three
11. 10 11 12 13 14 15 16 21 22 23 and 24 Inorder to mo mount the support of any of these astatic levers it is necessary to have demounted the mirror because it is not possible to have the adequate accessibility from the outside of the mirror cell conversely accessibility is assured if working from the area where the axial actuators are It is necessary to discern among the astatic levers of this group because the shape of the counterweight obliges to proceed in two different ways e astatic levers number 1 3 10 12 13 15 22 and 24 a rotate the support of the astatic lever towards the center of the mirror cell so to be able to insert the counterweight into the hole of the seat 1n which the support has to be mounted Let the counterweight move down in the hole and when the encumbrance of the centrepiece allows it straighten up the support so to centre it in its own seat b rotate the support around the vertical axis so to position it with the right orientation just like the arm must be repositioned C screw in the M8 screws that fix the support to the mirror cell d position the arm fork on the pivot shaft and fix 1t with the five M5 screws e now it 1s possible to reposition the safety devices that have been removed to allow the removal of the support of the astatic lever e astatic levers number 2 4 9 11 14 16 21 and 23 a rotate the support of the astatic lever towards the center of the mirror cell so to be
12. Date 2009 03 04 VST M1 SUPPORT SYSTEM Pas 102 of 109 Qr SONNO Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 8 EXTRA ORDINARY MAINTENANCE The present section describes the extra ordinary maintenance operations and warns against the main risks for the operator Anyway all general safety prescriptions must be followed as best specified by the safety responsible with reference made to the telescope as a whole system WARNINGS If the Mirror Cell is placed at or above 2m height it is mandatory to set up a suitable staircase and a gangway as by the norms in force Beware of machine parts in motion Beware of electrical connections and parts at high voltage The operators carrying out all extra ordinary maintenance operations must wear the appropriate safety equipment helmet protection shoes gloves glasses and so on as by the norms in force and as described in the use and maintenance manual of the telescope as a whole system Do not touch the screws marked with a red dot they can be released only for extra ordinary maintenance reasons Issue 2 0 VST PROJECT Date 2009 03 04 Qr VST M1 SUPPORT SYSTEM Pag 103 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 8 1 Failure of an Axial Force Actuator Equipment Motor Control Handset Personnel nr 1 electronics technician In case of failure of the electronics or of the load cell the electric motor
13. Figure 40 Safety Devices 0501 and 0515 position adjusting with the Shaft Extension Figure 41 Safety Devices 0501 and 0515 top arm adjusting with the Key Extension VST PROJECT uc Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 67 of 109 ISTce ag 670 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 6 ABSOLUTE TRANSDUCERS To measure the dummy or the mirror position during the integration phase five position transducers are applied to the Mirror Cell three along the axial direction and two along the radial direction The three axial transducers are positioned close to the three axial fixed points in the room available between the third and the fourth ring where the axial force actuators are assembled The two radial transducers are so positioned one at South Eastern and one at South Western sector of the mirror cell on the plane where the safety devices are applied making an angle with the North South axis of 45 Their electrical connectors have to be connected with their own electrical cables that come out of the holes obtained on the top plane of the mirror cell gt y ARAS a E Ko Figure 43 Radial Absolute Transducer apart and integrated VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pas 68 of 109 Qr Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 5 OPERATIONAL CONDITIONS AND PERFORMANCE OF TH
14. Figure 54 Safety Devices adjusting the Bottom Radial Pads esee 86 Figure 55 Safety Devices adjusting the Top Pads 87 Figure 56 Safety Devices 0501 and 0515 position adjusting elements eec 5S Figure 57 Shaft Extension bottom and Key Extension top for safety devices 0501 and 0515 89 Figure 56 Safety Devices 0501 and 0515 Plastic Feeler Gauge with Extension cesses 90 Figure 59 Axial Force Actuator top side view with sphere and spacer 95 Figure 60 Lateral Fixed Point multi meter connected to the load cell amplifier 96 Figure 61 Lateral Fixed Point supported by means of a string sss enne 97 Figure 62 Checking the movements of the four joints of the Lateral Supports the right hand thumb is parallel O A EEE E 98 Figure 63 Safety Devices verifying the gap cccccccssseccccccccccnesseseccccececessseccceeesaasseeeeceeeesaaeseeeeeeessuaaeseeeees 99 Figure 64 Safety Devices 0501 and 0515 verifying the gap sss enne 99 Figure 65 Greasing with the PUMp cccccccccccccccccccccnssseeessssseeeeeeeeeeeeeeeeaaeeeesssssseeeeeeeeeeeeeaaaaaasaassseseseeess 100 Figure 66 Test Bench to be used for the Pad of the Safety Devices as well eese 101 Figure 67 Motor
15. Pag 41 of 1 STce VST M1 SUPPORT SYSTEM ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 An interface flange is placed inside each seat with the purpose of supporting the axial force actuators as well as the axial fixed points The interface flanges are marked on the top with the same number as the seat they are in The height of each single flange has been adjusted therefore it is not possible to move it to a different seat or to replace it with a different one WARNING The Axial Force Actuators can be mounted and removed in both cases when the mirror is integrated in the cell and when the mirror is removed In case the mirror is integrated in the cell it is allowed to remove just one axial force actuator So before removing a second actuator it is mandatory that the previous one has been restored in the mirror cell In case the mirror is not integrated it is no problem to remove no matter how many actuators but they must be mounted back in the mirror cell before the next mirror integration 4 1 1 How to Mount the Axial Force Actuators A special tool referred to as Support Rod has been realised to make it easier to mount the axial force actuators in their seat in the mirror cell it helps keeping the actuator centered in the seat It is available in two units of different lengths to bets accommodate the operator position Anyway the operation must be carried out by two mechanical technicians together
16. axial support system b Test Bench static tests of the axial force actuators c Reference Weights axial force actuators load cell verification d Reference Load Cells axial force actuators safety devices integrated cell e Test Equipment dynamic tests of the axial force actuators f Lateral Support Calibration Box Chiave tagliata Spacers calibration of the safety devices In the intent of making it easier for the operator the different tools and instruments have been gathered in different boxes as hereafter better detailed The Calibration Box is foreseen to carry out the calibration of the Lateral Supports astatic levers Besides power and conditioning electronics it includes the four load cells necessary for the calibration of the astatic levers whose design does not include any load cell VST PROJECT Date 2009 03 04 ecT VST M1 SUPPORT SYSTEM Pag 28 of 109 ceN Ec Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Figure 7 Calibration Box with load cells and cables Together with the calibration box a modified key in included which helps access the screws of the delrin spacer of the arm of the astatic levers The modified key in is contained in a coffer referred to as coffer nr 1 The Motor Control Handset can be found in the wooden box of the axial support system together with the spares of the axial force actuators and axial fixed points Figure 8 Motor Control Handse
17. by a square and spirit level 3 in the following two tables the theoretical values are shown that should be read from the load cells for each astatic lever at different angles at 0 the voltage measured from each amplifier is reported in the column 0 4 PO NM HAH AH AH AH AH AK st 2 Qr Fx 101 0580799 276 0958089 377 1538889 377 1538889 276 0958089 101 0580799 101 0580799 276 0958089 377 1538889 377 1538889 276 0958089 101 0580799 101 0580799 276 0958089 377 1538889 377 1538889 276 0958089 101 0580799 101 0580799 276 0958089 377 1538889 377 1538889 276 0958089 101 0580799 SdSozogl2 ooudonsow Zz ho MDW no no RWND Fy 1158 070764 1057 012684 881 9749549 679 8587951 504 8210661 403 7629861 403 7629861 504 8210661 679 8587951 881 9749549 1057 012684 1158 070764 1158 070764 1057 012684 881 9749549 679 8587951 504 8210661 403 7629861 403 7629861 504 8210661 679 8587951 881 9749549 1057 012684 1158 070764 VST PROJECT VST M1 SUPPORT SYSTEM USE AND MAINTENANCE MANUAL Fz Ft Arm weight Angle lever arm V 75 6 347207 1162 4891 12 29 0 087043666 0 760108 18 609069 1092 63489 11 27 0 255495374 0 714042 29 602755 959 688074 6 42 0 404091319 0 624783 38 579061 778 422367 6 42 0 506485227 0 507309 44 926268 577 140862 6 42 0 500474037 0 377082 48
18. fig 25 have their own base fixed to the mirror cell on which base the main structure slides Figure 38 Safety Devices type T B To assemble safety devices type T B a position the main structure by their own threaded holes done on the upper surface of the mirror cell b slide the main structure along the slots until the distance in the radial direction between the external corners of the top pad and the lateral surface of the dummy 1s more than 4mm VST PROJECT uc USE AND MAINTENANCE MANUAL Code VST TRE Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 65 of 109 Qv ag 650 c TOM 22300 2128 fix the main structure with the six M10 screws tighten them with a torque of about 70 Nm d verify that the rotation around the pivot pin of the top arm locking allow the e f opening of the top arm verify that the rotation of the top arm is free from any encumbrance verify accessibility to adjust backlash and lock the forward position toward the mirror Sliding main structure Bridge MS screws for bridge M10 screws for sliding structure M10 screws for base Base Figure 39 Safety Devices type T B L or just L To assemble the safety devices type T B L or only L a b c d e f g h position the base with their own threaded holes done on the upper surface of the mirror cell and fix it with the M10 screws foreseen tighten them with a torque of abou
19. positions Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 PPORT SYSTEM Pag 61 of 10 Qe S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 5 1 Safety Devices Identification The safety devices are divided in two groups axial amp radial safety devices just radial safety devices The first group is identified by the first two numbers of the code being equal to 05 the second one is identified by the first two numbers of the code being equal to 06 The numbering that defines all safety devices starts from the east point of the mirror cell and increases proceeding in anticlockwise direction Figure 35 Safety Devices North West section positions VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 62 of 109 Qr NM Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 0517 0618 0519 Figure 36 Safety Devices South West section positions Bussi aa a E gt ms i wy gn Y 4 gt j Fs we 24 3 D ri O 0923 0624 0525 0 0826 Figure 37 Safety Devices South East section positions Issue 2 0 Vo ERREGI Date 2009 03 04 VST M1 PPORT SYSTEM Pag 63 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 In the following list for each code are reported all letters T B and L that indicate the presence of th
20. respect to the mirror cell axis at their mechanical end of stroke equal to 8 mm back v 5 Verify that the special safety devices 1 and 15 are moved in the rear position external with respect to the mirror cell axis at their mechanical end of stroke 100 mm back Verify that all invar pads are locked with the spring to their own hook fixed on the top plane of the mirror cell v 7 Verify that the cardanic joint of the arm of the astatic levers 1 12 13 and 24 lay on their own supports and that the interface with invar pads are locked with the spring to their own hook fixed on the top plane of the v 6 Issue 2 0 VST PROJECT Date 2009 03 04 Qr VST M1 SUPPORT SYSTEM Pag 75 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TONS OT mirror cell v 8 verify that the interface with invar pad of the arm of astatic levers 2 11 14 and 23 are locked with the spring to their own hook fixed on the top plane of the mirror cell v 9 verify that the three lateral fixed points lay on their own supports v 10 verify that the load cells of both Axial Force Actuators and Axial Fixed Points are read by the LCU v 11 verify that the load cells of the Lateral Fixed Points are read by the LCU v 12 verify that all Axial Force Actuators are at the lower end of stroke v 13 verify that the axial position of the three axial fixed points are read by the LCU verify that the lateral absolute transducers are locked in the rear positio
21. 0 id Document code Title Axial Force Actuator Assembly 1 ring Axial Force Actuator Assembly 4 ring Axial Fixed Point Assembly Lateral Fixed Point South East and South West Assembly Lateral Fixed Point North Assembly Astatic Lever Nr 01 amp Nr 13 Astatic Lever Nr 02 amp Nr 14 Astatic Lever Nr 03 Astatic Lever Nr 04 amp Nr 16 Astatic Lever Nr 05 amp Nr 17 Astatic Lever Nr 06 Astatic Lever Nr 10 Astatic Lever Nr 15 Astatic Lever Nr 18 Astatic Lever Nr 07 amp Nr 19 Astatic Lever Nr 08 amp Nr 20 Astatic Lever Nr 09 amp Nr 21 Astatic Lever Nr 22 Astatic Lever Nr 11 amp Nr 23 Astatic Lever Nr 12 amp Nr 24 safety Device 0501 and 0515 Safety Device 0508 Safety Device 0522 Qr 76 QACNO1 0503 000 0 77 OACNO1 0509 000 0 78 OACNO1 0523 000 0 79 OACNO1 0507 000 0 80 OACNO1 0516 000 0 81 OACNO1 0528 000 0 82 OACNO01 0602 000 0 OACN01 0610 000 0 83 84 OACNOI 0604 000 0 8 5 OACNO1 0612 000 0 86 OACN01 0606 000 0 Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 5 of 109 VST PROJECT Code VST TRE TOM 22300 2128 USE AND MAINTENANCE MANUAL Safety Device 0503 0505 0511 0513 0517 0519 0525 and 0527 Safety Device 0509 Safety Device 0523 Safety Device 0507 and 0521 Safety Device 0516 Safety Device 0528 Safety Device 0602 Safety Device 0610 and 0624 Safety Device 0604
22. 211824 419 000793 6 42 0 24525215 0 275143 48 211824 419 000793 6 42 0 24525215 0 275143 44 926268 577 140862 6 42 0 500474037 0 377082 38 579061 778 422367 6 42 0 506485227 0 507309 29 602755 959 688074 6 42 0 404091319 0 624783 18 609069 1092 63489 11 27 0 255495374 0 714042 6 347207 1162 4891 12 29 0 087043666 0 760108 6 347207 1162 4891 12 29 0 087043666 0 760108 18 609069 1092 63489 11 27 0 255495374 0 714042 29 602755 959 688074 6 42 0 404091319 0 624783 38 579061 778 422367 6 42 0 506485227 0 507309 44 926268 577 140862 6 42 0 500474037 0 377082 48 211824 419 000793 6 42 0 24525215 0 275143 48 211824 419 000793 6 42 0 24525215 0 275143 44 926268 577 140862 6 42 0 500474037 0 377082 38 579061 778 422367 6 42 0 506485227 0 507309 29 602755 959 688074 6 42 0 404091319 0 624783 18 609069 1092 63489 11 27 0 255495374 0 714042 6 347207 1162 4891 12 29 0 087043666 0 760108 V 60 1 468416 1 379424 1 206989 0 980045 0 728467 0 531536 0 531536 0 728467 0 980045 1 206989 1 379424 1 468416 1 468416 1 379424 1 206989 0 980045 0 728467 0 531536 0 531536 0 728467 0 980045 1 206989 1 379424 1 468416 V 455 2 076653 1 9508 1 70694 1 385994 1 030208 0 751705 0 751705 1 030208 1 385994 1 70694 1 9508 2 076653 2 076653 1 9508 1 70694 1 385994 1 030208 0 751705 0 751705 1 030208 1 385994 1 70694 1 9508 2 076653 Table 11 Lateral Supports force data V 759 0 760108 0 714042 0 6
23. 24 58 4 4 2 2 How to Mount the suppots of astatic levers 5 6 7 8 17 18 19 and 20 59 4 4 3 Lateral Support Assembly Oo hans va zu asd dU eux Saa Res pu Educ UA 59 4 5 SAP LIY ee ee ee er IM UE 60 4 5 1 Safety Devices IdentiTI EEEE 61 4 5 2 Inteeraldomotr the Satety COVICES Eta ndu ves Rus tu S 64 4 5 3 Integration of the safety devices 0501 and 0515 66 46 ABSOLUTE TRANSDUCERS eere eene t aaa hn nnne annee eene eee nete erra 67 5 6 VST PROJECT ue Date 2009 03 04 ecT N VST M1 SUPPORT SYSTEM Pag 8 of 109 USE AND MAINTENANCE MANUAL a TOM 22300 2128 OPERATIONAL CONDITIONS AND PERFORMANCE OF THE SUPPORT SYSTEM 68 DUMMY MIRROR INTEGRATION 70 6 1 First Integration of the Mirror Dummy in the Mirror 70 6 2 Removing the Mirror DUMMY seisoene eendi b Qu OR Deu said Eua apud quera AEA CORR LuU UNUS Cod pa tied nu OE NEU UNE 70 6 2 1 Before Lifting the Mirror Dummy seco sesasersscincenaveiccduesuadswilapedoswsancaeceetesedsswves ton Rua ov dap EE EEUU 70 6 2 2 Lif ne the Mirror d OUH ANY 73 6 3 First Integration of the Dummy in the Mirror Cell ccccccccecccccecceeeeeeeeeeeeseeeeceeeeeeeeeeeeaaas 74 6 3 1 NN ON TT 7
24. 30m supply cable Sabix 8x0 75mm2 25m can bus Belden 2x0 5mm2 shielded nr 10 DB9 male connectors for the Axial Force Actuators and the Axial Fixed Points nr 10 DB9 female connectors for the Axial Force Actuators and the Axial Fixed Points nr 10 100 mA fuses for the Power Distribution Boxes 3 2 Spares 3 2 Spare Sub Systems The following spare sub systems are available nr 6 Axial Force Actuators o belongs to the first ring and has a blue cover o three belong to either the second or the third ring and have red covers o two belong to the fourth ring and have black covers nr 1 Axial Fixed Point Lateral Fixed Point 3 2 2 Spare Parts The following spare parts are available 3 Load Cells for the Axial Force Actuators nr 5 Motors for the Axial Force Actuators 6 Pads for the Safety Devices nr 10 Helical Springs for the Axial Force Actuators nr 10 Spiral Springs for the Axial Force Actuators nr 10 Flexible Plates for the Axial Force Actuators nr 2 Sets of Bearings for the Astatic Levers 2 type NTN 6000 ZZ 2 type NTN 6007 ZZ and 2 type NTN 6010 ZZ nr 2 Universal Joints for the Astatic Levers as by drawing OACNO1 0424 022 0 In case one or more spare parts have been used it is recommended to restore the stock so to always have spare parts and material available VST PROJECT iud Date 2009 03 04 VST M1 PPORT SYSTEM Pag 26 of 10 Qr SUPPORT SY
25. 31 250 Ibs esi career cali bration Installation instructions Honeywell Load Cell model 31 500 Ibs Certificate of calibration Installation instructions Honeywell Load Cell model 31 1000 Ibs NC M CR Burster Amplifier Module model 9243 Test certificate D S Europe Load Cell model LTS 3000kg Table 1 Data Sheets Instructions and Certificates VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 PPORT SYSTEM Pag 13 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 1 5 Safety All operations described in the present manual both use or maintenance related must be carried out according to the general safety rules in force and following the instructions of the safety responsible who must have clear knowledge of the telescope as a whole system If the Mirror Cell is placed at or above 2m height it is mandatory to set up a suitable staircase and a gangway as by the norms in force Beware of machine parts in motion and electrical connections as well as parts at high voltage The operators must wear the appropriate safety equipment helmet protection shoes gloves glasses and so on as by the norms in force and as best specified by the safety responsible who must have clear knowledge of the telescope as a whole system In the present manual a set of symbols will be used some of which are also reported on the Support System supplied In the next table each sym
26. Control Handset plugged in the PDB sees enne nnne 103 Figure 68 Motor Control Handset plugged in the PDB detail sess 105 Figure 69 Mounting an Axial Force Actuator with the Support Rod eese 104 Figure 70 Lateral Fixed Point adjusting the length and checking the gaps eeeeeesess 105 Figure 71 Lateral Fixed Points Box of the Load Cell Amplifiers ccccccccssseccccccccceneeeseecceeesaaaseseseees 106 Figure 72 PDB changing the fuse essei eee eeee nennen es senea nnn nree 107 Figure 73 overall picture of the cabling for traceability example essen 108 VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 PPORT SYSTEM Pag 11 of 109 Qr ens Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 1 INTRODUCTION 1 4 Scope The VST VLT Survey Telescope is an Alt Az telescope designed by INAF Osservatorio Astronomico di Capodimonte within a collaboration with ESO responsible for the civil infrastructures The telescope has a primary mirror of 2 6m diameter supported by a mirror cell and equipped with an active optics system The purpose of this document is to give all useful information and necessary instructions for the use and the maintenance of the Support System of the Main Mirror of the VST 1 2 Warning The use and maintenance operations described in the
27. M1 SUPPORT SYSTEM Pag 50 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 3 LATERAL FIXED POINTS As shown in the figure below the three Lateral Fixed Points are mounted onto the top side of the mirror cell with three supports and are applied to the lateral surface of the mirror along the tangent direction through three lateral special invar pads They are all identified by code as follows OACNO1 03 001 0 Lateral Fixed Point to be mounted at the North position OACNO1 03 002 0 Lateral Fixed Point to be mounted at the South West position OACNO1 03 003 0 Lateral Fixed Point to be mounted at the South East position SOUTH WEST SOUTH EAST Figure 27 Lateral Fixed Points positions The Lateral Fixed Points foreseen for the South West and South East positions are interchangeable while the Lateral Fixed Point at North 1s different so it cannot replace any of the first two and vice versa The purpose of the three Lateral Fixed Points 1s to constrain the position of the mirror along the X Y axes and around the Z axis as well as to allow repositioning the mirror in Issue 2 0 6 VST PROJECT Date 2009 03 04 Pag 51 of 1 STce VST M1 SUPPORT SYSTEM ag 51 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 the mirror cell during the integration phase This is the reason why the Lateral Fixed Points must be fixed to the cell before integrating the mirror The three Lateral Fixed Point
28. The actuators must be mounted onto the mirror cell from the bottom side preferably with an altitude rotation of 90 cell pointing to zenith as this gives no extra difficulties to the operators Follow these steps to mount an actuator a verify that the axial force actuator 1s completely assembled don t forget to check the two brackets at the top of the actuator and that the actuator height corresponds to colour of the bottom cover and it 1s within tolerance b place and center the body of the actuator inside the hole of the flange c turn the body of the actuator taking the electrical connectors as reference d plug and fix with the appropriate screws the two electrical connectors of the cell harness to the base of the actuator e choose either support rod and push the actuator up to make the interface surface of the actuator touch the bottom surface of the interface flange f in case the mirror is integrated the Axial Force Actuator should be in contact with the flange without exerting any force this proves that the actuator has the right height g otherwise in case the mirror is not integrated verify the actuator height by inspection using the actuator next by as reference h while the one technician holds the actuator in contact with the interface flange the other one fits the M5 screws and locks the actuator on the interface flange four screws are necessary The same procedure holds for the Axial Fixed Points VST PRO
29. VST TRE TOM 22300 2128 USE AND MAINTENANCE MANUAL Here below follow the performances given by the Lateral Fixed Points expected to be verified measured calculated value Ssl passive stroke measured along the push aoe 5mm direction Ssl passive stroke measured along the pull 5 mm direction Ssl passive stroke along any lateral direction 5mm maximum axial force measured along the lt 1300 N push direction maximum axial force measured along the lt 1300 N pull direction KI axial stiffness measured along the push gt 20000 direction N mm KI axial stiffness measured along the pull gt 20000 direction N mm PI preload measured along the push direction 600 800 N PI preload measured along the pull direction 600 800 N Table 10 Lateral Fixed Points main parameters measured value 5 10 mm 5 40 mm 255 mm 1200 1250 1100 1150 27000 N mm 25000 N mm 650 VST PROJECT iud Date 2009 03 04 Pag 70 of 1 STce VST M1 SUPPORT SYSTEM ag 70 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 6 DUMMY MIRROR INTEGRATION 6 1 First Integration of the Mirror Dummy in the Mirror Cell All subsystems that performed the mirror support and safety have been already calibrated on the dummy mirror dimensions that are very similar to those of the real mirror so it 1s not necessary to check all the positioning that the ax
30. and 0618 Safety Device 0612 and 0626 Safety Device 0606 and 0620 Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 SUPPORT SYSTEM Pas 6 of 109 Qr ore SN RM Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 IMPORTANT The use and maintenance operations described in the present manual shall not be carried out without having clear knowledge of the telescope as a whole system Before starting with any kind of operation related to the M1 Support System it is mandatory that the present Instruction and Maintenance Manual has been completely read and understood VST PROJECT iud Date 2009 03 04 Qr VST M1 SUPPORT SYSTEM Pag 7 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 CONTENT INDEX RECO cc RU 11 1 1 O pss cea 1 AMM 11 1 3 General Tie OBI TN AON ores etui eres n VHC d eine te 11 12 1 5 csc ee ui 13 L5 and CIAO ING bentes tb mU beets 16 1 6 1 Coordinate Sy SCSI 16 1 6 2 wis MIA EN ER aan tweddesdsneubeaeductsendelivonecbucndes 17 1 6 3 Abbreviations and 18 2 MIRROR CEC cn 19 24 ric OT
31. axial fixed point is removed and assembled back then the height should be checked with the help of Johnson blocks and a gauge just like shown in the case of the axial force actuators 4 2 3 How to Remove an Axial Fixed Point Just like the mounting operation either Support Rod must be used by two mechanical technicians for the removal operation of an axial fixed point Once again the axial fixed points must be removed from the bottom of the mirror cell when the azimuth angle is 90 cell pointing to zenith Proceed as follows a as the one operator holds the axial fixed point in contact with the interface flange the second one will release the M5 screws so to free the axial fixed point from the interface flange b lower down the axial fixed point out of the interface flange c release the screws that fix the electrical connectors and unplug them from the base of the axial fixed point Issue 2 0 Date 2009 03 04 VST M1 PPORT SYSTEM Pag 49 of 109 Qr Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 2 4 Disassembly of an Axial Fixed Point In case of any intervention that requires to open and disassemble an axial fixed point more information is necessary which can be easily found in the Design Description VST TRE TOM 22304 2011 3 1 in the Assembly Procedure VST TRE TOM 22300 2123 1 0 or derived from the Drawing OACNOI 02 000 0 Issue 2 0 VST PROJECT Date 2009 03 04 Qe VST
32. directed from M1 to M2 Qr 1 6 2 Specific Terms Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 17 of 109 VST PROJECT Code VST TRE TOM 22300 2128 USE AND MAINTENANCE MANUAL In this document several specific terms are used these have been gathered in the table that follows AXIAL ACTUATORS AA AXIAL FIXED POINTS AFP LATERAL SUPPORTS LS OR ASTATIC LEVERS LATERAL FIXED POINTS LFP SAFETY DEVICES SD ACTIVE STROKE PASSIVE STROKE The 81 force controlled axial supports They are used to support the weight along the z axis and to change the shape of the mirror The 3 axial supports defining the Z position and orientation of the primary mirror around the x and y axes and are 120 spaced They are equipped with a motorized position control to adjust their height They are purely passive during normal telescope operation The 24 astatic lever based lateral supports purely passive The 3 tangential fixed points defining the position of the primary mirror in the XY plane and the orientation around the Z axis The axial and lateral devices to prevent mirror damages in case of an earthquake The internal stroke in the axial actuator in up direction of the piston obtained by the motor The external stroke in the axial actuator in down direction by pushing down the sphere Qr Issue 2 0 Date 2009 03 04 Pag 18 of 109 Code VST TRE TOM 22300 2128 VST PROJECT
33. europe com Tel 39 0292276400 Fax 39 0292276409 Ref Mr Simone Sacco e mail simone delta line it DS EUROPE S R L Via F Russoli 6 20143 Milano MI ITALY www dseurope com e mail dseurope dseurope com Tel 39 028910142 Fax 39 0289124848 ref Mr Corbetta Mr Piardi BOSCH REXROTH S P A S S Padana Superiore 11 N 41 20093 Cernusco sul Naviglio MI ITALY http www boschrexroth it e mail info 9 boschrexroth it SKF Honeywell NTN Burster Omnitrack INA Portescap DS Europe Bosch Rexroth Issue 2 0 Vo ERREGI Date 2009 03 04 VST M1 PPORT SYSTEM Pag 27 of 10 Qr SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Tek 39 02 92 365 1 Fax 390292365500 SCHNEIDER ELECTRIC S P A Via Circonvallazione Est 1 24040 STEZZANO BG ITALY T l m canige www schneiderelectric it Tel 39 035 415 11 11 Fax 39 035 415 28 66 FITA S R L Via Torricelli 12B 37135 Verona VR ITALY Motovario WW fita net e mail info fita net Tel 39 0458200955 Fax 39 0458200953 MONTESI PAOLO amp C S n c Viale N Baldini 51 53 48010 Cotignola RA ITALY Montesi http www montesi it Tel 0545 40162 Fax 0545 41621 Table 4 Reference information to order commercial parts 3 3 Equipment Here below is a list of the main tools and instruments made available with the shipping of the supply a Manual Remote Control
34. of 10 Qs SSS er UIS ag 92 of 109 10 11 12 13 14 15 16 17 18 19 20 2 22 23 24 25 TOM 22300 2128 lower the dummy down until the bottom of the dummy it is at the same height as the top of the lateral safety devices of the support system move the dummy horizontally in the two directions until it has backlash within 7mm and 13mm in relation to the lateral safety devices lower the dummy with the Hydra Set until it touches the three axial absolute transducers that are at 20mm height above the final position rotate the dummy around z in order to reach its final orientation within 5mm tangential distance between the pads of the dummy and the pads of the astatic levers disengage the lateral absolute transducers in order to read the lateral position of the dummy verify the lateral position of the dummy to be centered within 3mm lower the dummy with the crane step by step verifying its height by means of the axial absolute transducers until it is about 4mm above its final position mount the three lateral pads of the Lateral Fixed Points on the dummy centering them by means of their pins then insert the three invar bars and screw them to the lateral fixed points move the four main safety devices radially until they have 1mm gap from the lateral cylindrical surface of the dummy lock the position of the four safety devices lower the dummy with the Hydra Set step by step continuously verifying
35. or mechanical technician nr mechanical SP technician nr 1 pump and mechanical Lubcon technician grease or mechanical test bench technician Table 13 Ordinary Maintenance frequency sub system and resources time required 2 hours 1 2 hour 1 2 hour 1 hour 12 hours 1 2 hour Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 SUPPORT SYSTEM Pas 95 of 109 Qr Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 7 1 Axial Force Actuators and Axial Fixed Points Spheres Axial Force Actuators ever NS nr 1 y and Axial fixed Points mirror mechanical grease 2 hours verification with mirror un removal technician removed For all axial force actuators and the three axial fixed points verify by hand that each sphere is free to rotate and that each sphere block is still fixed to the actuator fixed point In case the sphere block is found to be loose than tighten it by hand In case the sphere doesn t rotate than grease it and try again to rotate it In case it 1s still malfunctioning than remove the sphere block and replace it with a spare one Figure 59 Axial Force Actuator top side view with sphere and spacer removed Note that the sphere of the axial fixed points is larger than that of the axial force actuators WARNING When replacing a sphere block pay attention and do not forget to set back the spacer plac
36. present manual won t be carried out before reading the use and maintenance manual of the telescope as a whole system in full respect of the instructions therein Before starting with any kind of operation related to the M1 Support System it is mandatory that the present Instruction and Maintenance Manual has been completely read and understood All actions carried out on the M1 Support system must be in accordance with the instructions given in the present manual 1 3 General recommendations Before proceeding with any of the use operations or maintenance interventions described in the present Instruction and Maintenance Manual some general recommendations must be followed e the personnel required for the execution of the specific operation or intervention for maintenance has an adequate education has received the necessary training and has sufficient experience in the field of mechanics electric devices or electronics depending on the task e any use operation or maintenance intervention must be carried out in safety conditions using the appropriate tools and wearing appropriate protections according to the standard safety norms as better specified in the use and maintenance manual of the VST telescope as a whole e The present manual has been completely read and fully understood e The documents reported as reference documents and namely the Design Descriptions the Assembly Drawings the Assembly Manuals and the Integration Pro
37. s r l Via Orione 6 Sommacampagna VR Italy ia MANUFACTURER DECLARATION ATTACHEMENT II B Machine Directive 98 37 CE THE UNDERSIGNED TOMELLERI s r l viale del Lavoro 12 A Villafranca VR Italy DECLARES ON HIS OWN RESPONSABILITY THAT THE NEW MACHINE VST M1 SUPPORT SYSTEM MAY NOT BE RUN BEFORE THE MACHINE into which IT IS INCLUDED is DECLARED IN COMPLIANCE WITH THE INSTRUCTIONS OF DIRECTIVE 89 392 CE and following modifications as well as with the national instructions in force IS IN COMPLIANCE WITH THE INSTRUCTIONS OF DIRECTIVE 89 392 CE and following modifications as well as with the national instructions in force Raffaele Tomelleri Villafranca VR Italy March 2009 vf P 7 j A 1 FI 7 7 LA
38. seats that belong to the ring nr 3 namely at seats nrs 30 38 and 46 The axial fixed points are interchangeable even though each one 1s identified by a code as follows OACNO1 02 030 0 axial fixed point placed at position nr 30 in ring nr 3 OACNO1 02 038 0 axial fixed point placed at position nr 38 in ring nr 3 OACNO1 02 046 0 axial fixed point placed at position nr 46 in ring nr 3 The bottom cover of all axial fixed points 1s painted black so they can be recognised from the bottom of the mirror cell thanks to their BLACK PAINT COVER Date 2009 03 04 Pag 47 of 109 Code VST TRE TOM 22300 2128 Issue 2 0 dude ACCRUE E TY o C EO utu uuu inm I E VST PROJECT VST M1 SUPPORT SYSTEM USE AND MAINTENANCE MANUAL Nom OW M Nw a inr at T4 n ee m S E ay E s Rt M SN SS RN SUN LES LL LO E E E E Lu m d EM p EN r MS Figure 26 Axial Fixed Point cross section view Qr VST PROJECT iud Date 2009 03 04 Pag 48 of 1 STce VST M1 SUPPORT SYSTEM ag 48 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 2 1 How to Mount an Axial Fixed Point The same Support Rods are used as for the axial force actuators and two mechanical technicians are necessary for the mounting operation Just like the axial force actuators the axial fixed points must be mount
39. the arm and cannot be disconnected from the arm unless in case of damage These pads have to be fixed on invar pads glued on mirror lateral surface during the mirror integration Astatic levers nr 3 10 and 18 are connected on special invar pads the same that are used by the three lateral fixed points this 1s why these lateral supports will be the first ones to be connected to the mirror during integration All astatic lever supports are already mounted on the mirror cell and cannot be demounted unless in case of damage e g counterweight or bearings that support the shaft The only way to remove the supports of astatic levers nr 1 2 3 10 11 12 13 14 15 22 23 and 24 1s to first remove the mirror from the cell for accessibility reasons as for the supports of the other astatic levers it is possible to remove the support without removing the mirror The arms of all astatic levers can be installed or removed without removing the mirror 4 4 1 How to Remove an Astatic Lever In case of removal of an astatic lever refer to the identification number because two different procedures are foreseen as hereafter described 4 4 1 1 Removing the Supports of Astatic Levers nr 1 2 3 4 9 10 11 12 13 14 15 16 21 22 23 and 24 As mentioned before in order to remove the supports of these levers it is necessary to remove the mirror and operate from the area occupied by the axial force actuators Otherwise accessibility from out
40. the load on the three fixed points until the load read is between 200 N e 400 N each one adjust the position of all Lateral Safety Devices with Imm gap lock the position of all Lateral Safety devices slowly lower down the dummy with the Hydra Set until it lays on all axial force actuators and axial fixed points verifying that the force increases on the axial force actuators and verifying the axial displacement by means of the axial absolute transducers disengage the handling from the dummy and lift it switch on the Axial Force Actuators set the theoretical mean force and read the remaining loads on the three axial fixed points verify that the dummy is back to the previous height at all three absolute transducers move and lock the upper safety devices in their operational position VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 PPORT SYSTEM Pag 93 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 7 ORDINARY MAINTENANCE The present section describes the ordinary maintenance operations and warns against the main risks for the operator Anyway all general safety prescriptions must be followed as best specified by the safety responsible with reference made to the telescope as a whole system WARNINGS If the Mirror Cell is placed at or above 2m height it is mandatory to set up a suitable staircase and a gangway as by the norms in force Beware of machine parts in motion
41. 09 03 04 VST M1 SUPPORT SYSTEM Pag 34 of 109 Qe ag 340 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 L shaped MS allen spanner modified M8 allen spanner T haped 8 allen spanner Safety devices nr 0501 and 0515 are out of reach to the operator to adjust and fix the position of the pads therefore two special tools have been developed Because the radial position adjustment system is based on a commercial reducer a Shaft Extension has been designed having a shaft like end with key matching the motor reducer An additional Key Extension has been foreseen with a screw driver interface in order to turn screws and nuts of safety devices 0501 and 0515 and then tighten the nuts Figure 17 Shaft Extension bottom and Key Extension top for safety devices 0501 and 0515 The Shaft Extension and the Key Extension for safety devices 0501 and 0515 are also contained in coffer nr 2 Issue 2 0 Vo PERSEE Date 2009 03 04 h 17 VST M1 SUPPORT SYSTEM Pag 35 of 109 i STce Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 SUPPORT SYSTEM DESCRIPTION The entire Primary Mirror Support System consists of the following sub systems 81 Axial Force Actuators 3 Axial Fixed Points nr 24 Astatic Levers nr 3 Lateral Fixed Points nr 28 Safey Devices Harness Each mechanical sub system is applied onto the cell at the appropriate seat machined in the mirror cell as desc
42. 2008 10 11 1 1 2008 10 11 1 1 2008 10 11 1 1 2008 10 11 1 1 2008 10 06 1 1 2008 10 06 1 0 2009 01 20 1 0 2009 02 12 1 0 2009 02 12 1 0 Issue 2 0 Date 2009 03 04 Pag 4 of 109 Code VST TRE TOM 22300 2128 VST PROJECT VST M1 SUPPORT SYSTEM USE AND MAINTENANCE MANUAL Qr Reference Documents RDs Assembly and Integration Procedures 31 VST PRO TOM 22300 2090 Mirror Cell Integration Procedure M1 Axial Force Actuator VST TRE TOM 22303 2081 ssembly Procedure M1 Axial Fixed Point 2009 01 19 1 0 33 VST TRE TOM 22300 212 Assembly Procedure 34 VST TRE TOM 22300 2124 M1 Lateral Fixed Point Assembly Procedure M1 Lateral Support Assembly 2009 01 22 Procedure MI Safety Devices Assembly 2009 02 16 Procedure 2009 01 22 1 0 35 VST TRE TOM 22300 2125 36 VST TRE TOM 22300 2129 Reference Documents RDs Assembly Drawings OACNO1 0101 000 0 51 52 OACNOI 0102 000 0 53 OACNO1 0103 000 0 54 OACNOI 0104 000 0 6 55 OACNO1 02 000 0 E OACNO01 0301 000 0 57 OACNO1 0302 000 0 58 OACNOI 0401 000 0 59 OACNOI 0402 000 0 60 OACNO1 0403 000 0 61 OACNOI 0404 000 0 62 OACNO1 0405 000 0 63 OACNO01 0406 000 0 64 OACNO1 0410 000 0 69 OACNO1 0421 000 0 70 OACNO1 0422 000 0 71 OACNO1 0423 000 0 72 OACNO01 0424 000 0 73 OACNO1 0501 000 0 74 OACNO1 0508 000 0 75 OACNO1I 0522 000
43. 24783 0 507309 0 377082 0 275143 0 275143 0 377082 0 507309 0 624783 0 714042 0 760108 0 760108 0 714042 0 624783 0 507309 0 377082 0 275143 0 275143 0 377082 0 507309 0 624783 0 714042 0 760108 V 60 1 468416 1 379424 1 206989 0 980045 0 728467 0 531536 0 531536 0 728467 0 980045 1 206989 1 379424 1 468416 1 468416 1 379424 1 206989 0 980045 0 728467 0 531536 0 531536 0 728467 0 980045 1 206989 1 379424 1 468416 V 459 2 076653 1 9508 1 70694 1 385994 1 030208 0 751705 0 751705 1 030208 1 385994 1 70694 1 9508 2 076653 2 076653 1 9508 1 70694 1 385994 1 030208 0 751705 0 751705 1 030208 1 385994 1 70694 1 9508 2 076653 V 30 2 543371 2 389232 2 090566 1 697489 1 261742 0 920647 0 920647 1 261742 1 697489 2 090566 2 389232 2 543371 2 543371 2 389232 2 090566 1 697489 1 261742 0 920647 0 920647 1 261742 1 697489 2 090566 2 389232 2 543371 V 159 2 836761 2 664842 2 331723 1 893302 1 40729 1 026848 1 026848 1 40729 1 893302 2 331723 2 664842 2 836761 2 836761 2 664842 2 331723 1 893302 1 40729 1 026848 1 026848 1 40729 1 893302 2 331723 2 664842 2 836761 Issue 2 0 Date 2009 03 04 Pag 83 of 109 Code VST TRE TOM 22300 2128 V 30 2 543371 2 389232 2 090566 1 697489 1 261742 0 920647 0 920647 1 261742 1 697489 2 090566 2 389232 2 543371 2 543371 2 389232 2 090566 1 697489 159 2 836761 2 664842 2 331723 1
44. 4 6 3 2 Lowering the Mirror Dummy down in the Mirror Cell essere 79 6 3 3 Centering the Dummy Mirror in the Mirror Cell 17 6 3 4 Adjusting Arm Length of Astatic Levers ccccccccccceccceceeeeeeeeeseeeeeeeeeeeeeeeenaaas 78 6 3 5 Calibrating the Counter Weight of the Astatic Levers eseeeeee 82 6 3 6 Verifying the Safety Devices 86 6 3 7 Verifying Safety Devices 0501 and 0515 i eecesesssseeeeeeeeeeeeeeeeaaaaeeeseeeeeeeceeeeeeeeeeaaas 87 6 3 7 1 Special Tools for the Calibration of Safety Devices 0501 and 0515 89 6 4 Subsequent Integrations of the Mirror DUMMY sseeeeeessssseseseeeeeeeeeeeee nnne nennen 91 6 4 1 BMA SC 91 6 4 2 Lifting the Mirror 91 6 4 3 Integrating The Mirror Dummy in Mirror 91 ORDINARY MAINTENANCE 4 ee eeeeeee eee 93 7 1 Axial Force Actuators and Axial Fixed Points Spheres ccccccccccccccsesssseeeseeeeeeeeeeeeeeeeeeaaas 95 7 2 Lateral Fixed Points Load Cell Offset esses nene nemen eere reete ren 96 pps Lateral Supports 98 7 4 s NE ONT 99 7 5 Axial Force Actuators and Axial Fixed Points Greasing
45. 6s 447 m P kh P ve a DR E 8 nni i TAE EA ACTA RS PLAGE Issue 2 0 Date 2009 03 04 Pag 43 of 109 Code VST TRE TOM 22300 2128 AMAL LANE AAE FLAME ETC AGATUR Figure 23 Axial Force Actuator cross section view and top view VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 44 of 109 ceN NV Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Figure 24 Axial Force Actuator held with the Support Rod 4 1 3 How to Verify the Height of the Axial Force Actuators The axial force actuators have a given height by design and have been realised within the required tolerance The type of actuator is quickly identified by the color of the bottom cover this can be easily checked with the overall height as shown in the pictures before In this section it is not the matter of the overall actuator height but we refer to the height difference from the reference plane that couples with the interface flange to the top of the sphere So the height of the three different types of axial force actuators are give in the table that follows ring height mm 1 209 00 0 15 2 226 50 0 15 3 226 50 0 20 261 00 0 20 Table 5 axial force actuators and axial fixed points reference height table Issue 2 0 VST PROJECT Date 2009 03 04 ecT N VST M1 SUPPORT SYSTEM Pag 45 o
46. 893302 1 40729 1 026848 1 026848 1 40729 1 893302 2 331723 2 664842 2 836761 2 836761 2 664842 2 331723 1 893302 V 0 2 936831 2 758848 2 413978 1 960091 1 456934 1 063072 1 063072 1 456934 1 960091 2 413978 2 758848 2 936831 2 936831 2 758848 2 413978 1 960091 1 261742 0 920647 0 920647 1 261742 1 697489 2 090566 2 389232 2 543371 1 40729 1 026848 1 026848 1 40729 1 893302 2 331723 2 664842 2 836761 1 456934 1 063072 1 063072 1 456934 1 960091 2 413978 2 758848 2 936831 V 0 2 936831 2 758848 2 413978 1 960091 1 456934 1 063072 1 063072 1 456934 1 960091 2 413978 2 758848 2 936831 2 936831 2 758848 2 413978 1 960091 1 456934 1 063072 1 063072 1 456934 1 960091 2 413978 2 758848 2 936831 Table 12 Lateral Supports theoretical load cell reading at altitude angles read the force on the two astatic levers on which the load cells are always applied and on the four astatic levers to which the load cells have been applied VST PROJECT iud USE AND MAINTENANCE MANUAL Code VST TRE 6 Date 2009 03 04 Pag 84 of 1 STce VST M1 SUPPORT SYSTEM ag 84 of 109 a b c d e g e 10 TOM 22300 2128 adjust the distance of the counterweight in order to reach the theoretical value in the following way release the two headless screws just the necessary to radially unlock the bar that supports the counterweight unscrew the locking bar nut uns
47. ANCE MANUAL Code VST TRE TOM 22300 2128 8 4 How to Replace an Amplifier of the Lateral Fixed Points Spare amplifier temporarily borrowed from the Calibration Box Personnel nr 1 electronics technician In case the output voltage between nodes 5 and 7 of the amplifier of the lateral fixed points is quite different from 2 5 V 0 1 V proceed as follows switch power off and remove the amplifier take an amplifier from the Calibration Box setthe dip switches of the amplifier as required for the 1000 Lb Load Cells connect the amplifier to the lateral fixed point disconnected the lateral fixed point from the mirror keep the lateral fixed point in horizontal position switch power on and set the offset at 2 5 V replace the amplifier borrowed from the Calibration Box with a new one Figure 71 Lateral Fixed Points Box of the Load Cell Amplifiers Issue 2 0 VST PROJECT Date 2009 03 04 V Pag 107 of 1 Qr ST M1 SUPPORT SYSTEM ag 107 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 8 5 How to Replace a PDB fuse Spare 500 mA fuse 5x20mm F 10 537 1240 Personnel 1 electronics technician In case of absence of power supply to any axial force actuator or axial fixed point proceed as follows refer to the document VST TRE TOM 22300 2105 M1 Harness Description and see which PDB should supply that one axial force actuator or axial fixed point open that PDB and see w
48. ATIC LEVERS The 24 Lateral supports also referred to as Astatic Levers AL are located at the top side of the mirror cell as shown in the next picture They are connected to the lateral surface of the mirror through 24 lateral invar pads they are fixed on the mirror cell through their own supports mounted in the 24 seats worked on the top side of the mirror cell Each astatic lever has an identification number structured as follows from OACNO1 0401 to OACNO1 0424 increasing counter clockwise starting from the West position as highlighted in the following picture EAST Figure 30 Lateral Supports astatic levers positions VST PROJECT iud Date 2009 03 04 VST 1 PPORT SYSTEM Pag 55 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 The purpose of the 24 astatic levers is to counter balance the mirror weight component along the Y direction that shows when the telescope rotates around altitude axis To obtain this it is necessary to have already applied the 24 astatic lever supports in their seats on the mirror cell Astatic levers nr 1 2 11 12 13 14 23 and 24 have a special device at the end of the arm that will be connected to a removable lateral invar pad These pads are always fixed onto the invar pads glued on mirror lateral surface and cannot be demounted from the mirror All others have the removable lateral invar pad directly jointed to the end of
49. E SUPPORT SYSTEM Environment operational and survival conditions Telescope operating range O C to 15 C Functional temperature range 10 C to 30 C Dust environment in enclosure Class 30000 Maximum humidity 95 Earthquake Moderate earthquake Negligible system damage OBE Minor system damage repair time 3 weeks MLE Major system damage repair time 3 weeks Here below follow the performances given by the Axial Force Actuators from Reter to be verified measured calculated Espe tea MS spec value value st R14 Fma maximum force against the mirror R22 Ssa passive stroke mat Min R51 Ka axial stiffness 9000 N mm 12 000 N mm Ve ae pee a T y mad R53 Pa preload 580 700 N 700 N Table 8 Axial Force Actuators main parameters Here below follow the performances given by the Axial Fixed Points from Reter to be verified measured calculated Expected Meacnred ea EU value value i R14 Fma maximum force against the mirror lt 1500 N 1150 N mat R22 Ssa passive stroke 3 2 mm 3 2 mm iat R51 Ka axial stiffness gt 9000 N mm 12 000 N mm u R53 Pa preload 580 700 N mat Table 9 Axial Fixed Points main parameters Qr VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 69 of 109 Code
50. ELMET MANDATORY BP VST PROJECT iud Date 2009 03 04 VST 1 PPORT SYSTEM Pag 15 of 10 Qs S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 PROTECTION SHOES MANDATORY ACCESS FORBIDDEN TO NON AUTHORISED PERSONNEL IT IS FORBIDDEN TO CLEAN LUBRICATE GREASE REPAIR OR ADJUST BY HAND ANY MACHINE ELEMENT IN MOTION HOOKING POINT FOR LIFTING Table 3 Symbols related to dangers danger prevention and instructions VST PROJECT iud Date 2009 03 04 VST M1 PPORT SYSTEM Pag 16 of 109 EsTe Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 1 6 Definitions and Conventions 1 6 1 Coordinate System If the telescope is horizontal zenith angle 90 deg and the telescope is viewed from above the primary mirror coordinate system can be defined as follows The X axis 15 parallel to the altitude axis and pointing to the left The Y axis 1s perpendicular to the altitude axis and pointing downwards The Z axis optical axis follows the right hand rule and 1s directed from M1 to M2 The origin of the reference system is the mirror vertex N S The observer is looking from the secondary mirror to the surface of the primary mirror The NSWE notations are referred to the situation where the telescope points to South AZ 0 and to Zenith ALT 90 The altitude axis is along X direction The Z axis optical axis follows the right hand rule and is
51. How to Adjust the Lateral Fixed Points Positioning the Mirror in relation to the axis of the De Rotator can be achieved by changing the length of one or more Lateral Fixed Points by turning the four headless screws in the special mirror pad a remove the 8 screws that fix the flange of the invar extension to the mirror pad Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 PPORT SYSTEM Pag 53 of 10 Qr SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 b then drive the 4 headless screws to move the theoretical plane to the right position c only then fix the invar extension back to the mirror pad with the 8 screws just removed d verify whether the required position has been reached Remark that this 1s an iterative procedure so it 1s likely that more than one positioning is necessary Figure 26 Lateral Fixed Point adjusting the length After completion of the adjusting operation length of the three lateral fixed points it is mandatory to verify the gap of the flexible joints both flexible plates at both sides of all lateral fixed points For each flexible plate the gap is given by two head less screws locked by the related counter screws and is less than the available room it should be around 0 5mm Issue 2 0 Date 2009 03 04 oN VST M1 SUPPORT SYSTEM Pag 54 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 4 AST
52. JECT iud 6 Date 2009 03 04 Pag 42 of 1 STce VST M1 SUPPORT SYSTEM ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 WARNING pay attention and mount the axial force actuators on the right ring 4 1 2 How to Remove the Axial Force Actuators The same Support Rods as in the previous sub section are to be used for the purpose of removing the axial force actuators from the mirror cell As for the integration two mechanical technicians must be employed to remove the actuators The actuators must be removed from the bottom side of the mirror cell keeping the cell horizontal that 15 at an altitude angle of 90 as follows a as the one operator holds the actuator in contact with the interface flange the second one will release the M5 screws so to free the actuator from the interface flange b lower down the actuator out of the interface flange c release the screws that fix the electrical connectors and unplug them from the base of the actuator The same procedure holds for the Axial Fixed Points VST PROJECT Qr VST M1 SUPPORT SYSTEM USE AND MAINTENANCE MANUAL d Lb TAA ee ee SOS X FI Pa a 2 T SU d d m x L ob LM Mx xb F Ux FIC oC SCIMUS s SEM n oT F wow ow n a a i QU QU ee SS oh n s a SS jp som m k a m EP a a 2 uS Pe ee ee er x x us c S qv eventurum un a cmo So
53. PROJECT VST M1 SUPPORT SYSTEM Qs Issue 2 0 Date 2009 03 04 Pag 3 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Reference Documents RDs Design Descriptions id Document code Title Date Issue M1 Axial Force Actuator 1 VST TRE TOM 22303 2010 An Design Description M1 Axial Fixed Point Design Description Design Description MI Lateral Support Design Description Safety Devices Design Description 4 VST TER TOM 22304 2012 5 VST TRE TOM 22300 2092 12 VST TOM E 001 a Block Diagram 13 VST TOM E 001 b Block Diagram 14 VST TOM E 002 Power Cable Lay Out 15 VST TOM E 003 Power Supply Cable 16 VST TOM E 004 Bus Cable Lay Out 17 VST TOM E 005 CAN Bus Cable 18 VST TOM E 006 Power Supply Cable 19 VST TOM E 007 CAN Bus Cable 20 VST TOM E 008 Cable List 21 VST TOM E 010 Sensing Cable 22 VST TOM FE 011 CAN Bus Cable 23 VST TOM E 012 PDB Lateral Fixed Point EM Cable 24 VST TOM E 013 PDB Absolute Transducer Cable 25 VST TOM E 014 26 VST TOM E 015 PDB Power Supply Cable Connections Axial Fixed Point Internal Connections Axial Force Actuator with Potentiometer Interface Internal Connections 27 VST TOM E 016 28 VST TOM E 017 Axial Force Actuator Internal 2009 02 12 1 0 2008 06 09 3 1 2008 07 16 3 3 2008 12 21 1 4 2008 10 11 1 1 2008 10 11 1 1 2008 10 11 1 1
54. RT SYSTEM Pag 85 of 109 hin USE AND MAINTENANCE MANUAL E TOM 22300 2128 Bar f Fork Pivot shaft v H d Special nut AS lever support Astatic Arm adjustment M8 screws headless shaft screws seat Figure 53 Lateral Supports adjusting the position of the counter weight Issue 2 0 VST PROJECT Date 2009 03 04 USE AND MAINTENANCE MANUAL Qs VST M1 SUPPORT SYSTEM Pag 86 of 109 Code VST TRE TOM 22300 2128 6 3 6 Verifying the Safety Devices a b c d e g Bottom arm mechanical reference radial adjustmen Radial pad mechanical reference Bottom arm mechanical adiustment Figure 54 Safety Devices adjusting the Bottom and Radial Pads Acting on the radial adjustment see picture above move the sliding structure against the lateral surface of the dummy at this point the radial adjustment has to be unscrewed of about 2mm and needs to act on the two radial mechanical references to have a gap between the dummy lateral surface and the radial pad within 0 8mm and Imm This must be verified with a plastic feeler gauge at all four corners of the radial pad tighten the two MIO nuts that lock the rotation of the two radial mechanical references from this moment on these two mechanical references must not be touched because they have become the references for the next radial repos
55. S ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 The supplier of the parts or material can be found in the Assembly Drawings Here follows just the reference data for each company supplier reference and contact data SCHAEFFLER ITALIA S R L FAG Strada Provinciale 229 Km 17 28015 MOMO NO ITALY http www schaeffler it Tel 39 0321929211 Fax 39 0321929300 SKF ITALIA Via A Kuliscioff 37 20152 Milano MI ITALY http www skf com e mail luca baruffi skf com Tel 39 0248327202 Fax 39 024159563 BURSTER ITALIA S R L Via Cesare Battisti 25 24035 Curno BG ITALY WW burster it e mail burster burster it Tel 4 39 035618120 Fax 4 39 035618250 ref Mr Acquati NTN WALZLAGER EUROPA Via Maestri del Lavoro 3 40138 Bologna www ntn europe com sales it ntn europe com Tel 39 0 051 53 51 74 Fax 39 0 051 53 84 92 BURSTER ITALIA S R L Via Cesare Battisti 25 24035 Curno BG ITALY WWW burster it e mail burster burster it Tel 39035618120 Fax 39035618250 ref Mr Acquati FITA S R L Via Torricelli 12B 37135 Verona VR ITALY WW fita net e mail info fita net Tel 39 0458200955 Fax 39 0458200953 SCHAEFFLER ITALIA S R L Strada Provinciale 229 Km 17 28015 MOMO NO ITALY http www schaeffler it Tel 39 0321929211 Fax 39 0321929300 DELTA LINE S R L Via Ludovico il Moro 4 B Palazzolo Pitagora MI3 City 20080 Basiglio Milano ITALY www deltaline
56. VST M1 SUPPORT SYSTEM USE AND MAINTENANCE MANUAL 1 6 3 Abbreviations and Acronyms Here follow a list of the abbreviations and acronyms that the reader may encounter while using the present manual AD AFA AFPA AL ASD CCS CDT CIT DB DOF ESO GUI HCU HW ICD I F INAF LAN LCC LCU LFP LSD 1 1 2 MLE MTBF OAC OBE SW TCS VLT VST VSTceN WS Applicable Document Axial Force Actuator Axial Fixed Point Actuator Astatic Lever Axial Safety Device Central Control Software Command Definition Table Command Interpreter Table Database Degree of freedom European Southern Observatory Graphical User Interface Hexapod Control Unit Hardware Interface Control Document Interface Istituto Nazionale di Astrofisica Local Area Network LCU Common Software Local Control Unit Lateral Fixed Point Lateral Safety Device VST primary mirror M1 Actuator Control Board VST secondary mirror Maximum Likely Earthquake Mean Time Between Failure Osservatorio Astronomico di Capodimonte Operational Base Earthquake Software Telescope Control Software Very Large Telescope VLT Survey Telescope VST Center at Naples Workstation VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 PPORT SYSTEM Pag 19 of 109 Qs Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 2 MIRROR CELL 2 1 Transportation A copy of the present manual will be made available together with the wooden box containi
57. able to insert it 1n the counterweight bar that was previously inserted in the seat hole of the support Pay attention that the bar has a lateral plane that has to be oriented along the direction of the two headless screws Let the support move down along the bar and when the encumbrance of the centrepiece allows it straighten up the support to centre it in its own seat b while the counterweight is being leaned inside the mirror cell screw in the regulation shaft to the bar until it gets in contact with the pivot shaft of the support of the astatic lever From this moment on the bar and relative counterweight will start to move up Continue to screw in the regulation shaft until the top of the bar will come up to the measure that has been noted before the removal c screw in the two headless screws to radially lock the bar that supports the counterweight d screw in the special nut so to lock the regulation shaft e screw in the nut of the locking bar f screw in the six M8 screws to fix the support to the mirror cell VST PROJECT iud Date 2009 03 04 VST 1 PPORT SYSTEM Pag 59 of 109 Qr ere Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 g position the arm fork on the pivot shaft and fix it on with the five M5 screws h now it is possible to reposition the safety devices that have been removed to allow the removal of the supports of the astatic lever 4 4 2 2 How to Mount the suppots of astatic lever
58. ated and they can be directly connected to the load cell electrical box Figure 46 Lateral Supports Load Cell Amplifier Box Issue 2 0 4 Date 2009 03 04 M z h VS IceA VST M1 SUPPORT SYSTEM Pag 80 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Figure 49 Lateral Supports Load Cell Amplifiers Figure 50 Lateral Supports Load Cell Amplifier connections VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 81 of 109 ceN sane Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Every load cell must be connected to its own amplifier because these have been calibrated on a test bench both in offset and in zero load So the eight amplifiers numbered 01 02 11 12 13 14 23 and 24 are those that must be connected to the load cells integrated in the arms with equal number conversely the other four amplifiers must be connected with the removable load cells Figure 51 Lateral Supports removable load cells The steps foreseen to calibrate all astatic levers are four I sector from astatic lever nr 1 through astatic lever nr 6 II sector from astatic lever nr 7 through astatic lever nr 12 III sector from astatic lever nr 13 through astatic lever nr 18 IV sector from astatic lever nr 19 through astatic lever nr 24 To calibrate one of the four sectors the delrin pads of the arms without integrated load cell must be removed from and replace
59. bol is described and commented MEANING COMMENT It warns against any danger for the user health including death DANGER It highlights any warning or remark about key functions or useful information Pay attention to the text blocks that follow this symbol PAY ATTENTION The user 1s required to read a measurement to check a warning signal etc The user is required to verify the correct INTERROGATION position of a machine element before proceeding with a specific command LOOK UP IN THE It is necessary to look up in the Manual MANUAL before carrying out a specific operation For specific working modes or in case of fault TUNING OR it may be necessary to carry out either a ADJUSTING mechanical adjusting operation or an electric tuning operation OBSERVE Table 2 Symbols likely to be used in the manual Issue 2 0 VST PROJECT Date 2009 03 04 e Pag 14 of STN VST M1 SUPPORT SYSTEM ag 14 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 For ease of reference a second set of symbols is also reported in the table below These symbols may appear on the machine elements or in the environment where the Support system will be placed SYMBOL DESCRIPTION GENERIC DANGER LOOK UP IN THE MANUAL FALL FROM HEIGHT FALLING OF MATERIAL DANGER OF CRUSHING UPPER OR LOWER LIMBS DANGER MACHINE ELEMENTS AT POSSIBLY HIGH VOLTAGE PROTECTION H
60. can still be moved down and reach the lower end of run This can be achieved thanks to the Manual Control System that is a power source outside the mirror cell Proceed as follows refer to the document VST TRE TOM 22300 2105 M1 Harness Description and see which PDB supplies the failed axial force actuator or axial fixed point cut the power supply open such PDB and identify the male connector of the failed axial force actuator or axial fixed point plug the connector of the Manual Control System in the related male connector lower down the failed axial force actuator or axial fixed point as described in the Manual Control System User Manual remove the Manual Control System t Figure 67 Motor Control Handset plugged in the PDB Figure 68 Motor Control Handset plugged in the PDB detail Issue 2 0 Date 2009 03 04 Qr VST M1 SUPPORT SYSTEM Pag 104 of 109 USE AND MAINTENANCE MANUAL Code VST TRE TOM 22300 2128 8 2 to replace an Axial Force Actuator or an Axial Fixed Point Spares Axial Actuator Axial Force Actuator or Axial Fixed Point as required Personnel nr 2 mechanical technicians In case of absence of signal from the load cell of an axial force actuator or an axial fixed point proceed to remove the axial force actuator or axial fixed point according to the instructions of respectively sections 4 1 2 or 4 2 2 replace it with a spare according to the instru
61. cedures have been read and well understood in the part concerning the required intervention e The tools necessary to carry out the required use operation or maintenance intervention are available end ready to use VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 PPORT SYSTEM Pag 12 of 109 Qr Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 1 4 Reference Documents Together with the present manual a set of documents must be available to the operator where he can find useful information and all details he may need These documents have been declared as reference documents at the beginning of this manual Besides the official documents just above mentioned the operator may need additional data sheets provided by the suppliers of some critical components asin the list that follows Calibration certificate Operation and maintenance manual Certificate of conformance Calibration test report Test data sheet Hydra Set model C Auxiliary Hoist Del Mar Avionics Cannel Supplier Device Document DS Europe Load Cell model TS 50 k Use and installation instructions 5 Calibration certificate Use and installation instructions D S Europe Load Cell model 546 QDT 220kg eee Additional notes D S Europe Load Cell model LTO05 A5 500kg Cobb Burster LVDT Transducer model 8739 2 Suet Calibration certificate Installation instructions Honeywell Load Cell model
62. cessary to remove the mirror because it is possible to have adequate accessibility from the outside of the mirror cell a verify any possible interference between the safety devices and the support to remove If there are any it is first necessary to remove all safety devices that cause interference b unscrew the five M5 screws that fix the arm fork to the pivot shaft in order to remove the arm from the support c unscrew the M8 screws that fix the support to the mirror cell d lift the support to see the counterweight hold it concentric with the hole axis and keep on lifting it until the counterweight has come out enough so to allow the rotation of the support towards the center of the mirror cell Keep on taking the support out until the counterweight has completely come out of the holes e now it is possible to remove the support of the astatic lever from the mirror cell Astatic lever support M8 screws Arm Figure 32 Astatic Lever Support type removable with mirror installed VST PROJECT iud Date 2009 03 04 VST M1 PPORT SYSTEM Pag 58 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 4 2 How to Mount an Astatic Lever To proceed with mounting the support of an astatic lever it is necessary to verify the code because depending on this one two different procedures are foreseen to bre followed 4 4 2 1 How to Mount the suppots of astatic levers 1 2 3 4 9
63. crew the special nut to unlock the adjustment shaft screw or unscrew the adjustment shaft to decrease or increase the voltage read on the voltmeter to arrive to the theoretical value 2mV given in the table above screw the special nut to lock the regulation shaft screw the nut that lock the bar screw the two headless screws to radially lock the bar move back the mirror cell to 90 rotate the mirror cell to 0 repeat the procedure to adjust the force on the 244 astatic levers until the error is within 1 N rotate the mirror cell to 0 remove the four removable load cells from the arms and mount their own delrin pads Repeat the same procedure reported in sections 6 3 4 and 6 3 5 adjustment of the arm length and of the counterweight for the other three sectors 11 12 13 14 15 At the end rotate the mirror cell at 0 verify that the total load on the lateral fixed points is less than 50 N evaluate the possible overload and spread it proportionally to each astatic lever there 1s a linear correspondence between load and voltage mV so every overload share must be transformed into mV and added or subtracted to the values reported in the column labeled as 0 repeat the procedure to adjust the force on all astatic levers by adjusting the distance of the counterweights and fixing the counterweight position if necessary repeat the whole procedure Issue 2 0 VST PROJECT Date 2009 03 04 6 7 N VST M1 SUPPO
64. ctions of respectively sections 4 1 1 or 4 2 1 Figure 69 Mounting an Axial Force Actuator with the Support Rod Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 PPORT SYSTEM Pag 105 of 10 Qr SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 9 3 How to Replace a Lateral Fixed Point Spare Part nr 1 Lateral Fixed Point Personnel nr 1 mechanical technician nr 1 electronics technician In case of absence of signal from the Load Cell of the lateral fixed point proceed as follows take the spare lateral fixed point and connect the cable to the load cell hold the lateral fixed point in horizontal position with the help of a string supporting the spacer 15 as defined in the assembly procedure VST TRE TOM 22300 2124 setthe offset of the related amplifier at 2 5 V remove from the lateral fixed point to be replaced remove the counter weight shaft from the lateral fixed point just removed fix the counter weight shaft part 13 in the assembly procedure VST TRE TOM 22300 2124 to the spare lateral fixed point mount the spare lateral fixed point onto the mirror cell according to the procedure detailed in section 4 3 1 How to Mount the Lateral Fixed Points VW wy E 4 Figure 70 Lateral Fixed Point adjusting the length and checking the gaps VST PROJECT uc Date 2009 03 04 Qe VST M1 SUPPORT SYSTEM Pag 106 of 109 USE AND MAINTEN
65. d turning the arm outwards has to pose it on its own support C once posed it is necessary to insert their own locking spring in the provided seat to constrain the arm to remain sufficiently far from the dummy v 5 Lateral special devices 2 11 14 and 23 have to be disconnected from the dummy a starting from astatic lever number 02 and proceeding counter clockwise the first person has to unscrew the two MS screws that locked the special device on the non removable lateral invar pad b until the second person brings the upper part of the counterweight bar and pulls it outwards the first one verifies that the special device has come out of the two alignment pins and turning the arm outwards inserts their own locking spring in the provided seat to constrain the arm to remain sufficiently far from the dummy v 6 All the top arms of safety devices have to be open except safety and 15 a unscrew the two M10 upper screws b slide externally the top locking plate along the pivot pin c rotate the locking plate around the pivot pin d open the top arm Issue 2 0 VST PROJECT Date 2009 03 04 Qr VST M1 SUPPORT SYSTEM Pag 72 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Figure 44 Safety Devices steps to open the Top Arm No bottom arm of safety devices has to be moved 8 Demount completely from the mirror cell axial safety devices 0505 0511 0519 and 0525 and
66. d with removable load cells equally numbered Afterwards the two integrated load cells must be connected respectively to the electrical cables of the amplifiers equally numbered and the removable load cells respectively to the electrical cable of the amplifiers where is the same number Now it is possible to feed the electrical box and to measure the voltage that every load cell is measuring connecting the channels 5 and 7 to the voltmeter The correspondence between the read voltage mV and the measured force N that charges the load cell is either 1 V 400N 1mV 0 43 If one or more load cells are measuring a load it 1s necessary to recalibrate the respective arm lengths because it 1s necessary to reposition the counterweights axis along the vertical direction The procedure is the following 1 unscrew the two M6 screws on the load cell support and on the support of the spherical joint to release but maintaining a certain friction torque the rotation of the arm length adjustment Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 PPORT SYSTEM Pag 82 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 2 screw left or right the arm length adjustment and adjust the length until the read force is 0 N IN and fix the length screw the two M6 screws 3 repeat the above two points for all remaining astatic levers of the sector Screw on load cell support Screw M6 on spherical
67. e Because electronics 1s part of the design also basic electrical instrumentation must be made available Besides this specific electronics 1s foreseen for specific purposes 3 4 1 General Purpose Tools and Instruments General purpose tools and electric instruments are not included in the shipping but are equally necessary to carry out the use operations and maintenance interventions later described in this manual It is recommended to provide the following digital multimeter power supplies for Load Cells feeler gauges gauges endowed with magnetic base nr sets of keys for hexagonal seats 2 sets of fork keys 3 4 2 Special Tools and Instruments In the course of the integration of the axial force actuators in the mirror cell a special tool was developed to make the operation easier It 1s the matter of Support Rods with a shaped end that fits in the bottom seat of the axial force actuators Two extension rods were produced and are available with different lengths so to accommodate different mounting situations The extension rods are contained in a coffer referred to as coffer nr 2 Figure 16 Support Rod for the axial force actuators and axial fixed points The operation of mounting and demounting the Safety Devices needs for a set of tools some of which are obtained by simple adaptation of commercial tools In coffer nr 2are also nr 3 sets of the following keys Issue 2 0 VST PROJECT Date 20
68. e actuators of ring nr 1 from OACNO1 0102 054 0 through OACNO1 0102 071 0 for the axial force actuators of ring nr 2 from OACNO1 0103 031 0 through OACNO1 0103 037 0 from OACNO1 0103 039 0 through OACNO1 0103 045 0 and from OACNO1 0103 047 0through OACNO1 0102 053 0 for the axial force actuators of ring nr 3 numbers OACNO1 0103 030 0 OACNO1 0103 038 0 and OACNO1 0103 046 0 refer to the three axial fixed points and also belong to ring nr 3 from OACNO1 0104 000 0 through OACNO1 0104 029 0 for the axial force actuators of ring nr 4 WARNING It is not possible to mount an Axial Force Actuator of ring nr 1 in either ring 2 3 or 4 Accordingly it is not possible to mount an Axial Force Actuator of ring nr 2 or nr 3 in either rings nr 1 or nr 4 Again it is not possible to mount an Axial Force Actuator of ring nr 4 in any of rings nr 1 2 or 3 In order to quickly identify the ring an axial force actuator belongs to the bottom cover of each axial force actuator has been painted with different colours namely BLUE PAINT COVER axial force actuators to be mounted on ring nr 1 RED PAINT COVER axial force actuators to be mounted on ring nr 2 and nr 3 BLACK PAINT COVER axial force actuators to be mounted on ring nr 4 Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 37 of 109 Qr Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 v ks E a d Hn i q YA e KU MES
69. e safety pads in the position Top Bottom and Lateral then for each one the elastomer pad surface foreseen mm 0602 L 200x40 0516 T L 160x30 200x40 0503 T B 160x30 160x30 0517 T B 160x30 160x30 0604 L 120x115 0618 L 120x115 0610 L 160x115 0624 L 160x115 0511 T B 160x30 160x30 0525 T B 160x30 160x30 0612 L 120x115 0626 L 120x115 0513 T B 160x30 160x30 0527 T B 160x30 160x30 0614 L 200x40 0528 T L 160x30 200x40 Table 7 Safety Devices pads size According to this disposition safety devices 0505 0606 0511 0612 0519 0620 0624 0525 are located at the four arms of the handling supports and therefore they must be removed during mirror integration Conversely safety devices 0501 and 0515 that are located in correspondence of the other two arms and that for accessibility problems cannot be demounted can be drawn back using their own slide Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM 64 of 109 ISTce Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 5 2 Integration of the safety devices To mount all safety devices on the mirror cell it is necessary to fix the different bases that every type of the safety device has on their own threaded holes It must be taken into account that safety devices only T B have the main structure directly fixed to the mirror cell fig 24 while the other types
70. e to be screwed until the gap measured with a plastic feeler gauge between the top dummy surface and the pad and at both sides of he pad is within 0 4mm and 0 6mm lock the two top arm mechanical references with their own M10 nuts from this moment on these mechanical references must not be touched because they have become the references for next top axial repositioning of the safety devices screw the top arm mechanical locking until it gets in contact with the arm and lock its rotation with its own M12 nut 6 3 7 Verifying Safety Devices 0501 and 0515 a Acting on the angular gearbox see figure 40 section integration of the safety devices 0501 0515 move the sliding structure against the lateral surface of the dummy at this point the angular gearbox has to be acted in the opposite direction to have a gap between the dummy lateral surface and the radial pad within 0 8mm and 1mm this must be verified with a plastic feeler gauge at all four corners of the radial pad b c d e g Issue 2 0 VST PROJECT Date 2009 03 04 USE AND MAINTENANCE MANUAL Qr VST M1 SUPPORT SYSTEM Pag 88 of 109 Code VST TRE TOM 22300 2128 Top arm mechanical references Top arm mechanical locking Bottom arm mechanical reference Bottom arm mechanical locking Figure 56 Safety Devices 0501 and 0515 position adjusting elements screw the two sliding structure mechanical references against the bl
71. econd one fits a spacer between lateral fixed point invar tube side and the mirror pad e fix the lateral fixed point together with the spacer to the mirror pad with M6 screws BEWARE NOT TO TOUCH THE HEADLESS SCREWS IN THE MIRROR PAD f fit and screw the connector of the load cell WARNING The flange of the invar tube won t be in contact with the flat surface of the lateral special pad but will couple with the theoretical plane given by the four headless screws fixed in the pad itself THESE FOUR HEADLESS SCREWS MUST BE UNSCREWED FOR NO REASON ONLY QUALIFIED PERSONNEL CAN DO IT IN ORDER TO ADJUST THE MIRROR OPTICAL AXIS Proceed with the following steps if the mirror has been removed from the cell VST PROJECT iud 6 Date 2009 03 04 Pag 52 of 1 STce VST M1 SUPPORT SYSTEM ag 52 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 a verify that the counterweight is oriented as shown in the picture below b while the one operator holds the lateral fixed point in contact with the column support that is fixed onto the mirror cell the second one can fix the flange of the flexible joint to the column support with M6 screws c let the fork support already mounted onto the mirror cell bear the lateral fixed point d fit and screw the electrical connector of the load cell This same procedure must be followed when integrating the mirror in the cell so to gave the three lateral fixed point ready to be con
72. ed just below the sphere block In case a thicker spacer replaces the previous one the force on the mirror can be higher Conversely in case a thinner spacer replaces the previous one the force on the mirror can be lower Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 96 of 109 Qr Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 7 3 Lateral Fixed Points Load Cell Offset every Lateral Fixed Points zero 1 mirror adjusting with mirror electronics multi meter 1 2 hour removal removed technician When the mirror is removed from the cell the lateral fixed points are still connected to the mirror cell through the column support The offset of the load cell will be checked Open the box containing the three amplifiers of the lateral fixed points so to access the amplifiers of the lateral fixed points Connect a multi meter to the output nodes of the one axial fixed point at a time at a time Take a string and pass it around the spacer 15 as defined in the assembly procedure VST TRE TOM 22300 2124 and support the lateral fixed point with the string making sure to avoid any axial load along the load cell of the lateral fixed point Turn the offset regulation screw of the related amplifier so to read a voltage equal to 2 5V 5 mV 391 OOC OC ASAN ZU y C rr Figure 60 Lateral Fixed Point multi meter connected to the load cell amplif
73. ed onto the mirror cell from the bottom side preferably with an altitude rotation of 90 cell pointing to zenith The procedure how to mount them onto the mirror cell is very similar to that of the axial force actuators as hereafter detailed a verify that the axial fixed point 1s completely assembled don t forget to check the two brackets at the top and that the height is within tolerance b place and center the body of the axial fixed point inside the hole of the flange c turn the body of the axial fixed point taking the electrical connectors as reference d plug and fix with the appropriate screws the two electrical connectors of the cell harness to the base of the axial fixed point e choose either support rod and push the axial fixed point up to make the interface surface of the axial fixed point touch the bottom surface of the interface flange f while the one technician holds the axial fixed point in contact with the interface flange the other one fits the M5 screws and locks the actuator on the interface flange four screws are necessary 4 2 2 How to Verify the Height of an Axial Fixed Point The axial fixed points have a given height by design and have been realised within the required tolerance In this section height is referred to as the height difference of the top of the sphere from the reference plane that couples with the interface flange This is 241 00 0 20 mm In case any part of an axial force actuator or
74. ed points 1s about 300 N taking into account the measured weight with the Hydra Set switch on the Axial Force Actuators set the above mentioned theoretical mean force and read the remaining loads on the three Axial Fixed Points if necessary change the force setting according to the value of the force on the three axial fixed points spreading the correction among the 81 actuators verify that the dummy is at the reference height for all three absolute transducers fix the arms of all astatic levers on the related lateral dummy mirror pads starting at the same time from astatic lever 01 and 13 moving counter clockwise and following the procedure described in the related section 6 3 3 Centering the Dummy Mirror in the Mirror Cell Proceed with adjusting the length of the lateral fixed points following the instructions of the related section Figure 46 Lateral Fixed Points length adjusting To check whether the three lateral fixed points have been assembled correctly it is necessary to use a spacer 0 4mm thick and verify whether this passes completely through the eight cuts obtained in the two flexible joints see pictures Issue 2 0 VST PROJECT Date 2009 03 04 ve N VST M1 SUPPORT SYSTEM Pag 78 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Ls M Flexible joint mounted on support device fixed on the mirror cell Figure 47 Lateral Fixed Points verifying the gap of the f
75. eeessseseeee enne eene nnns 43 Figure 24 Axial Force Actuator held with the Support Rod 44 Figure 25 Measuring the Height of the Axial Force Actuators with respect to the reference plane by IEEE 127 8101 TON T 45 Figure 26 Axial Fixed Point cross section 47 Figure 27 Lateral Fixed Points 50 Figure 26 Lateral Fixed Point adjusting the length eese 53 Figure 29 Lateral Fixed Points verifying the gap of the four flexible plates esses 23 Figure 30 Lateral Supports astatic levers enne eene nnne ees nn nennen eene 54 Figure 31 Astatic Lever Support type removable with mirror removed eese 56 Figure 32 Astatic Lever Support type removable with mirror installed cesses DU lieure S3 o5dley Devices 60 Figure 34 Safety Devices North East section enne eene nnne 61 Figure 35 Safety Devices North West section positions eee eene nnn eene nnne 61 Qr Issue 2 0 Date 2009 03 04 Pag 10 of 109 Code VST TRE VST PROJECT VST M1 SUPPORT SYSTEM USE AND MAINTENANCE MANUAL TOM 22300 2128 Figure 36 Safety Devices South West section positions eeeeeeeeeeeeeseseeeeeeee eene nennen nennen 62 Figure 37 Safety D
76. em are of course sent together high accuracy 50kg full scale Load Cell used to test the static behaviour of the axial force actuators below 400N 220kg full scale Load Cell used to test the static behaviour of the axial force actuators in critical conditions 3000kg full scale Load Cell used to test both the safety devices and the movement allowed to the mirror dummy inside the mirror cell Issue 2 0 VST PROJECT Date 2009 03 04 eT N VST M1 SUPPORT SYSTEM Pag 31 of 109 ce Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Figure 13 high accuracy 50kg full scale Load Cell Figure 14 220kg full scale Load Cell VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 32 of 109 Qe ag 320 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Figure 15 3000kg full scale Load Cell Issue 2 0 VST PROJECT Date 2009 03 04 Qe VST M1 SUPPORT SYSTEM Pag 33 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 3 4 Instruments and Tools In order to carry out the use operations and the maintenance interventions the necessary tools and instrumentation must be made available In the case of some specific operations or interventions special tools are required that are not available on the market It is both the case of commercial tools that have been slightly modified for the sake of accessibility or the case of a special design to help a specific purpos
77. evices South East section eene nennen nennen es 62 JOB mes IPE T B 64 Figure 39 Safety Devices type T B L or just 65 Figure 40 Safety Devices 0501 and 0515 position adjusting with the Shaft Extension 66 Figure 41 Safety Devices 0501 and 0515 top arm adjusting with the Key Extension 66 Figure 42 Axial Absolute Transducer integrated esses 67 Figure 45 Radial Absolute Transducer apart and integrated cesses enne 67 Figure 44 Safety Devices steps to open the Top Figure 45 Safety Devices moving back away from the mirror eee 73 Figure 46 Lateral Fixed Points length adjusting cessisse eene eene nnne nnns Ir Figure 47 Lateral Fixed Points verifying the gap of the flexible plates cardanic joints 78 Figure 48 Lateral Supports Load Cell Amplifier Box esses nennen 79 Figure 49 Lateral Supports Load Cell Amplifiers 80 Figure 50 Lateral Supports Load Cell Amplifier connections eese nnne 80 Figure 51 Lateral Supports removable load 5 81 Figure 52 Lateral Supports lever arm 4 82 Figure 53 Lateral Supports adjusting the position of the counter weight cesses 85
78. f 109 d Ce Code VST TRE USE AND MAINTENANCE MANUAL 22300 2128 In case any part of an axial force actuator or axial fixed point is removed and assembled back then the height should be checked with the help of Johnson blocks and a gauge 7 4 in Figure 25 Measuring the Height of the Axial Force Actuators with respect to the reference plane by differentiation Once the axial force actuator or axial fixed point has been placed back onto the mirror cell the height of the top of the sphere should be measured again but this time from the references available at the top of the mirror cell in case of intervention on one single actuator it is possible to quickly check whether the height 1s correct by simply measuring the height of the tops of the spheres of the actuators in the neighbourhood but belonging to the same ring in case of intervention on any actuator of the 1 3 4 ring it is possible to measure the height with reference made to the average height of any three actuators of the 2 ring in case of intervention on any actuator of the 2 ring but this holds as well for actuators of the 1 3 and 4 ring the height must be referred to the plane defined by three reference points taken on the surface of the cell at the interface with any three astatic levers spaced 120 around the z axis The theoretical height of the Axial Force Actuators are reported in the table below
79. he manufacturer of the support system Four lifting plates shown in the next picture are fixed at the four corners of the Mirror Cell by means of eight M16 threaded rods with related nuts the plates are foreseen for the insertion of four locking rings each one having a load capacity of at least 10 ton The technical documentation concerning the resistance calculations of the lifting plates is available on request Issue 2 0 VST PROJECT Date 2009 03 04 Qe VST M1 SUPPORT SYSTEM Pag 20 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Figure 1 Lifting Plate with Locking Ring The ropes or chains that will be used to lift the mirror cell must have a load capacity of at least 10 ton each The personnel involved in the handling of the Mirror Cell must be adequately prepared to this task Additional warning reminders are added on the surface of the lifting plate as shown in the next figure Figure 2 warning image for cell lifting When supplied each lifting plate will be already fixed onto the mirror cell with 8 M16 class 10 9 threaded rods that 1s with 180Nm A mark will be traced on the nut and on the plate together so to show any accidental nut release Issue 2 0 VST PROJECT Date 2009 03 04 N VST M1 SUPPORT SYSTEM Pag 21 of 109 Code VST TRE USE AND MAINTENANCE MANUAL DS The Mirror Cell can be lifted horizontally by means of four ropes or chains with the angle between the r
80. he pads of the lateral fixed points disengage the lateral absolute transducers in order to read the lateral position of the dummy monitor the force of the axial force actuators and of the axial fixed points lower the dummy with the crane step by step verifying its height by means of the absolute transducers until it is about 4 mm over its final position mount the lateral pads of the three lateral fixed points inside the appropriate pins and fix the pads with the screws verifying with a plate that they are parallel to the pads of the dummy within 0 2 mm now it 1s possible to proceed with mounting the three lateral fixed points following the instructions in the dedicated section Now the dummy mirror is mechanically assembled and it is possible to verify whether also all electronics works properly It is necessary to connect the electrical cables to the connectors of the Lateral Fixed Points to the electrical boxes and then connect the LCU It must be checked whether all electrical devices M1ACBs of the axial force actuators and of the axial fixed points load cells of the lateral fixed points axial and radial position transducers work properly 18 19 20 2 22 23 24 29 26 verify that the dummy is in its theoretical final position within Imm by measuring equal distances of the lateral pads in relation to two couples of symmetrical tapered holes M on the mirror cell radially move the four main safety devices until t
81. heir mechanical end of stroke without opening the top arms Inserting the appropriate special elongation device in the lateral hole of the angular gearbox it 1s sufficient to rotate 1t until the slide that supports all lateral and axial safety devices reach the external end of stroke v 12 Verify that all three axial and two lateral positioning transducers are read by the LCU v 13 Verify that the load cells of all axial actuators are read by the LCU 6 2 2 Lifting the Mirror Dummy Now it 1s possible to proceed with lifting the dummy mirror from the mirror cell VST PROJECT iud 6 Date 2009 03 04 Pag 74 of 1 STce VST M1 SUPPORT SYSTEM ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 a use the remote control UP of the Hydra Set to start lifting the dummy b read the load cell display of the Hydra Set to know how the weight is that the handling device is charging and compare this value with that read from the LCU pay attention that the load cells of the axial actuators have to measure similar decreasing of the load If this condition is not verified it means that the dummy is not correctly balanced by the handling device so it is necessary to lower the dummy and proceed with a more accurate adjustment when the load cells of the axial actuators are equally discharged it 1s possible to continue with the lifting operation with the remote control UP until the total load on the axial actuators 1s
82. hether a red LED is on then check that the LED on is associated to that actuator or fixed point if it is so than change the fuse that supplies that axial force actuator axial fixed point Figure 72 PDB changing the fuse Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 108 of 109 Qr iss Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 8 6 How to replace a Cable Material power cable or CAN bus of appropriate length Personnel electronics technician When it comes to changing a cable do not remove anything before you have taken a picture of it It is in fact necessary to take pictures of the whole path of the cable to be changed from the PDB to the axial force actuator or axial fixed point These pictures must then be used as reference in order to repeat the same path with the new cable It 1s suggested to take an overall picture of the cabling from the axial force actuator or axial fixed point to the PDB take a picture of each cable segment that 1s significant for the cable path for each picture taken mark a number 1 2 3 on the cell structure with an erasable pen Figure 73 overall picture of the cabling for traceability example Issue 2 0 Meroe Ee Date 2009 03 04 VST M1 PPORT SYSTEM Pag 109 of 109 Qr SS opens ee Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 9 Attachement CONFORMITY DECLARATION DE E d TOMELLERI
83. hey have 1mm gap from the lateral cylindrical surface of the dummy lock the position of the four safety devices lower the dummy with the Hydra Set step by step continuously verifying the load on the three Axial Fixed Points until the load read 1s between 200 N e 400 N each one set to zero the height read from the three axial absolute transducers set to zero the distance read from the lateral absolute transducers verify that the load on the Axial Force Actuators 1s still the initial value close to Zero in this case it is necessary to take note of the actuator number and later verify its height in relation to the axial fixed points and correct it adjust the position of all lateral safety devices with 1mm gap lower the dummy down slowly with the Hydra Set verifying that the load on the Axial Force Actuators is less than 300 N and that the load on the Axial Fixed Points Issue 2 0 VST PROJECT Date 2009 03 04 USE AND MAINTENANCE MANUAL Code VST TRE VST M1 SUPPORT SYSTEM Pag 77 of 10 Qs S SUPPORT SYS ag of 109 27 28 29 30 3 22 33 TOM 22300 2128 is less than 900 N verify that the displacement read from the axial absolute transducers is less than Imm below the zero setting position disengage the handling from the dummy and lift it verify the force on all Axial Force Actuators and take note of possible errors evaluate the theoretical mean force on the axial force actuators when the force on the three axial fix
84. ial actuators axial fixed points astatic levers and safety devices have with respect to the dummy mirror The first dummy integration starts with the dummy already integrated into the mirror cell Indeed according with INAF the supply foresees the dummy being laid on the axial force actuators and on the axial fixed points with the astatic levers already applied to their lateral pads and with both axial and radial safety devices locking the dummy in this position After unpacking and before starting with the operations that allow to remove and mount the dummy into the mirror cell it is necessary to verify that all the subsystems have been correctly assembled any visible damage is present allastatic levers have been correctly applied to the lateral pads of the dummy all Teflon pads of safety devices axial and radial are in contact with the dummy 6 2 Removing the Mirror Dummy 6 2 1 Before Lifting the Mirror Dummy Before proceeding with the dummy mirror removal from the mirror cell it is necessary to check or to do or to verify the following items step by step v The mirror cell must be at an elevation angle equal to 90 0 05 to do this 1s possible to use a spirit level with precision 0 02 mm m leaned on the top plane of the mirror cell 2 The three lateral fixed points have to be disconnected from the dummy a one person has to sustain the lateral fixed point until the second one unscrews the eight M6 screw
85. ic Feeler Gauge Support this tool is needed to control the backlash that both axially and radially the two safety devices have from the dummy or from the mirror VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 PPORT SYSTEM Pag 90 of 109 Ee Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 MISSING PICTURE plastic feeler gauge support being produced Figure 56 Safety Devices 0501 and 0515 Plastic Feeler Gauge with Extension VST PROJECT iud USE AND MAINTENANCE MANUAL Code VST TRE 6 Date 2009 03 04 Pag 91 of 1 STce VST M1 SUPPORT SYSTEM ag 91 of 109 TOM 22300 2128 6 4 Subsequent Integrations of the Mirror Dummy 6 4 1 Set Up The mirror cell lays horizontally on the supports within 0 1 mm 1000 all Axial Force Actuators are at the lower end of stroke position the top arms of the Axial Safety Devices are open in the external position the Lateral Safety Devices have been shifted backwards 8mm away from the working position the astatic levers lay on their own supports and are locked with their own springs the three lateral fixed points disconnected from the invar lateral special pads are fixed to the related squares and lay on their own supports the lateral absolute transducers are locked in the rear position by the proper locking device the dummy is on the appropriate support e g three columns at the same height within 1 mm
86. ier Issue 2 0 VST PROJECT Date 2009 03 04 Qe VST M1 SUPPORT SYSTEM Pag 97 of 109 Code VST TRE USE AND MAINTENANCE MANUAL OND LM 5 TWO N x n n TLLA i Figure 61 Lateral Fixed Point supported by means of a string WARNING Pay attention and do not move a lateral fixed point over 8mm in neither vertical or horizontal direction Issue 2 0 VST PROJECT Date 2009 03 04 6 7 N VST M1 SUPPORT SYSTEM Pag 98 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TONS OT 7 3 Lateral Supports Rotations every Lateral Supports astatic nr mirror levers verification with mechanical 1 2 hour removal mirror removed technician The risk is that unexpected loads may damage the ball bearings and friction doesn t allow free motion of the astatic levers When the mirror is removed from the cell the astatic levers have four degrees of freedom namely refer to the assembly procedure VST TRE TOM 22300 2125 pad 42 around fork 20 fork 20 around the arm the arm around shaft 2 shaft 2 in the welded support Move by hand the astatic lever so to check that the four above mentioned motions are all allowed Figure 62 Checking the movements of the four joints of the Lateral Supports the right hand thumb is parallel to the joint axis Issue 2 0 Vo ERREGI Date 2009 03 04 VST M1 PPORT SYSTEM Pag 99 of 109 Qr Suns en ente
87. is within 0 4mm and 0 6mm h lock the two top arm mechanical references with their own M10 nuts from this moment on these mechanical references must not be touched because they have become the references for the next top axial repositioning of the safety devices i screw the top arm mechanical locking until it gets in contact with the arm and lock its rotation with its own M12 nut 6 3 7 1 Special Tools for the Calibration of Safety Devices 0501 and 0515 Because there are some problems to get adequate accessibility to this two type of safety devices it 1s necessary to use some special tools to perform all operations that are necessary for them best positioning near the dummy or mirror surfaces In the following it 1s better specified what the tools are Shaft Extension it is needed to operate the stroke of the sliding structure by means of the trapezoidal screw Inserting this tool in the lateral hole of the angular gearbox it 1s possible to position the safety device near the lateral surface of the dummy or of the mirror during telescope nominal working conditions Otherwise when removing the dummy or the mirror it is necessary to move the safety devices backwards to their external mechanical end of stroke Key Extension onto this tool it is possible to mount different fittings that are necessary to adjust the positioning of the mechanical references during the integration phases and lock them definitively and 0515 Plast
88. itioning of the safety devices screw the radial adjustment until it gets in contact with the sliding structure and lock it with its own nut screw the six MIO screws to fix the sliding structure to the base with a tightening torque of about 70 Nm acting on the bottom arm mechanical adjustment see figure above move the bottom arm against the bottom surface of the dummy at this point the radial adjustment has to be unscrewed until the gap measured with a plastic feeler gauge between bottom dummy surface and pad and at both sides of pad is within 0 4mm and 0 6mm screw the bottom arm mechanical reference until it gets 1n contact with the arm and lock it with its own MI2 nut from this moment on these this mechanical reference must not be touched because is has become the reference for next bottom axial repositioning of the safety devices lock also the bottom arm mechanical adjustment with its own M12 nut Issue 2 0 VST PROJECT Date 2009 03 04 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 VST M1 SUPPORT SYSTEM Pag 87 of 10 Qr S SUPPORT SYS ag of 109 Top arm mechanical references Top arm mechanical locking Figure 55 Safety Devices adjusting the Top Pads h close the top arm over the dummy 1 J k unscrew the two top arm mechanical references see picture above to move the top arm against the top surface of the dummy at this point the two top arm mechanical references hav
89. joint support Arm length regulation Load cell Delrin pad Figure 52 Lateral Supports lever arm adjusting Now the adjustment of the arm length is done but not the verification and the possible adjustment of the load that the counterweight explain against the dummy when the mirror cell starts rotating So before disconnecting all load cells from the electrical box to remove the removable load cells from the arms and to replace them with own delrin pads the first sector must be verified also following the instructions reported in the next section 6 3 5 Calibrating the Counter Weight of the Astatic Levers When the mirror cell starts rotating the load that the three lateral fixed points have to read must be always between ON and 300N for each angular position that the mirror cell can reach in the range between 90 and O If this does not happen it means that the counterweights of the astatic levers are not positioned correctly so the astatic lever acting against the mirror dummy causes a wrong balancing load In this case it is necessary to recalibrate the position of the counterweight in the following way 1 verify that the resulting force on the lateral fixed points is less than about 50 N each one when the mirror cell is at 90 if required the procedure to adjust the arm length can be repeated as described in the previous chapter 2 rotate the mirror cell at 0 verifying that the angle is accurate within 2
90. lexible plates cardanic joints 6 3 4 Adjusting the Arm Length of the Astatic Levers When the mirror cell lays in horizontal position the load that the three lateral fixed points have to read must be less than 20N If this does not happen it means that the arms of the astatic levers have not been correctly adjusted the counterweights act against the dummy mirror and cause a certain load that 1s not desired In this case it 1s necessary to recalibrate the length of the arms repositioning the counterweight axis along the vertical direction The arms of the astatic levers connected to the dummy mirror are of two types a arms with integrated load cell b arms without integrated load cell In both cases it 1s necessary to use the Calibration Box where are the load cell amplifiers see next pictures and one voltmeter able to read every load on each load cell The calibration of the length of all arms 15 divided into four steps each corresponding to the verification of six arms at a time this 1s so because it 1s necessary to replace the four Delrin pads in the arms without load cell with four external load cells see figure 51 removable load cells by which it 1s thus possible to evaluate the load along the arms Issue 2 0 VST PROJECT Date 2009 03 04 ecT N VST M1 SUPPORT SYSTEM Pag 79 of 109 ce Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 conversely in the other two arms the load cells are already integr
91. limited t the sliding structure from the base radial safety devices nr 0606 0610 0620 and 0624 because they have interference with the arms of the handling device As for the axial safety devices a unscrew the six M10 screws that lock the safety structure to the mirror cell b now it 1s possible to remove the axial safety device As for the radial safety devices a unscrew the four M8 screws that lock the bridge and remove the bridge from the base b unscrew the six MIO screws that lock the safety structure to the base c now it is possible to remove the radial safety device v O Position the crane with the Hydra Set on which the mirror handling device has been hooked over the mirror cell and proceed with all the operations needed to hook the dummy mirror All radial safety devices have to be moved back of 8mm referred to the v 10 lateral surface of the dummy mirror a unscrew the six M10 screws that lock the sliding structure to the base b unscrew the headless screw 8mm c move back the sliding structure by hand until it stops against the headless screw d screw the six M10 screws to lock the sliding structure Issue 2 0 VST PROJECT Date 2009 03 04 ecT N VST M1 SUPPORT SYSTEM Pag 73 of 109 ce Code VST TRE USE AND MAINTENANCE MANUAL TONS OS Distance of 8mm c d Figure 45 Safety Devices moving back away from the mirror v 11 Special safety devices 1 and 15 have to be moved back to t
92. mirror mechanical Lubcon 12 hours re greasing with the oe removal technician grease mirror removed This operation requires that all Auxiliary Units have been removed from the Mirror Cell Fill in the pump with Lubcon grease and verify that the pump is completely full To make sure it is so try and pump grease out until grease is getting out of the pump at each pumping action Remove the bottom cover of each axial force actuator and of each axial fixed point then grease it with just one only pumping action Figure 65 Greasing with the Pump WARNING Pay attention and do not pump grease in the same axial force actuator or axial fixed point more than once Issue 2 0 d Date 2009 03 04 Qv VST M1 SUPPORT SYSTEM Pag 101 of 109 M USE AND MAINTENANCE MANUAL Code VST TRE TOM 22300 2128 7 6 Safety Devices Pad nr mechanical test bench 1 2 hour technician every Safety Devices 5 years verification of the pad Remove all poly urethane pads from the safety devices Place the poly urethane pads on the test bench that has been designed for the axial force actuators and can be used to test the stiffness of the pads of the safety devices as well Set the gauge to zero and load 15kg on a pad surface area as by test bench design The height change is expected to be in the range 2 2mm 0 2mm Figure 66 Test Bench to be used for the Pad of the Safety Devices as well VST PROJECT iud
93. n and the position of all absolute transducers is read by the LCU All subsystems that performed the mirror support and safety are already calibrated on the dummy mirror dimensions that are very similar to those of the real mirror so it is not necessary to check all the positioning that the axial actuators axial fixed points astatic levers and safety devices have with respect to the dummy mirror FIRST DUMMY MIRROR INTEGRATION DUMMY MIRROR CHECK LIST v 15 verify that the mirror handling device has been adjusted to lift the dummy mirror verify that the dummy mirror suspended from the mirror handling device lays in a horizontal plane to do this it is possible to use an air level with precision 0 02 mm m leaned on one axial pad and verify the planarity in both perpendicular directions within 2 mm on the diameter lt lt m verify that the removable invar pads 1 2 11 12 14 14 23 and 24 are fixed on lateral pad of the dummy mirror v 18 verify that the lower Hydra Set is connected to the handling device and that the two remote control devices are unlocked and sufficiently stretched out to allow all necessary maneuvers 6 3 2 Lowering the Mirror Dummy down in the Mirror Cell 1 Move the three axial fixed points up to 0 4 mm over the lower end of stroke position 2 lift the dummy 500 mm over its final height in the mirror cell 3 horizontally move the dummy until it 1s about on top of i
94. nected to the three special lateral invar pads of the mirror 4 3 2 Howto Remove the Lateral Fixed Points The removal operation of a lateral fixed point must be carried out by two mechanical technicians In case the mirror is integrated in the cell the lateral fixed point must be removed from the mirror as first and only then from the column support which is fixed onto the mirror cell In any case the altitude rotation angle must be 90 that is the cell points to zenith Proceed with the following steps when the mirror has already been integrated in the cell a release the electrical connector of the load cell b while the one operator holds the lateral fixed point the second one can release the M6 screws that fix the flange of the flexible joint to the invar extension as the first operator keeps holding the lateral fixed point the second one releases the M6 screws that fix it to the column support and removes the lateral fixed point from the mirror cell Remark that the invar extension is still mounted on the mirror at the end of this operation 4 3 3 Disassembly of a Lateral Fixed Point In case of any intervention that requires to open and disassemble a lateral fixed point more information is necessary which can be easily found in the Design Description VST TRE TOM 22300 2013 3 1 in the Assembly Procedure VST TRE TOM 22300 2124 1 0 or derived from the Drawings OACNO1 0301 000 0 and OACNO1 0302 000 0 4 3 4
95. ng the mirror cell It will be placed inside a plastic envelope stuck on the front side wall of the box so the operator may refer to it at any time A set of standardized images are used as warning reminders for safety reasons both for the material being handled and for the operators All sub systems of the M1 Support System have been integrated in the M1 Mirror Cell before delivery to I N A F so the following items have been transported together with and mounted on the Mirror Cell nr 81 Axial Force Actuators nr 3 Axial Fixed Points nr 24 Astatic Levers 3 Lateral Fixed Points nr 28 Safety Devices nr 7 PDB Boxes nr 1 CAN Bus Box nr 1 Load Cell Box nr 1 Dummy Mirror The total weight of the Mirror Cell including all above mentioned sub systems 1s about 12 000 Kg Before starting handling the Mirror Cell verify that it has not been damaged at all neither any of the above mentioned sub systems Carefully avoid any contact with them during the time the Mirror Cell 1s being lifted and handled The Mirror Cell must lay on wooden supports pay attention that it is supported only through the structural parts 2 2 Handling The handling procedure is the exclusive responsibility of the user Nevertheless here follow some information about how to handle the mirror cell together with support system and mirror dummy because the interface to the handling device has also been designed and supplied by t
96. ocks and tighten the two M10 nuts that lock the rotation of the two mechanical references from this moment on these two mechanical references must not be touched because they have become the references for next radial repositioning of the safety devices sliding structure acting on the bottom arm mechanical locking see picture above move the bottom arm against the bottom surface of the dummy at this point the mechanical locking has to be unscrewed until the gap measured with a plastic feeler gauge between the bottom dummy surface and the pad and at both sides of pad 15 within 0 4mm and 0 6mm screw the bottom arm mechanical reference until it gets in contact with the arm and lock it with its own M12 nut from this moment on this mechanical reference must not be touched because it has become the references for the next bottom axial repositioning of the safety devices lock also the bottom arm mechanical locking with its own M12 nut close the top arm over the dummy unscrew the two top arm mechanical references see picture above to move the top arm against the top surface of the dummy at this point the two top arm mechanical references have to be screwed until the gap measured with a plastic feeler gauge Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 PPORT SYSTEM Pag 89 of 10 Qs S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 between the top dummy surface and the pad at both sides of the pad
97. opes or the chains being less than 60 Figure 5 lifting the cell in horizontal configuration Issue 2 0 VST PROJECT Date 2009 03 04 ecT N VST M1 SUPPORT SYSTEM Pag 22 of 109 idiom USE AND MAINTENANCE MANUAL ee aa TOM 22300 2128 The Mirror Cell can also be lifted vertically by means of two ropes or chains with the maximum angle between the ropes or the chains being less than 45 Um i LU E Qu Figure 4 lifting the cell in vertical configuration Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 PPORT SYSTEM Pag 23 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 2 3 Mirror Dummy Removal WARNING Do not touch the screws marked with either a yellow or a red dot they can be released only for respectively ordinary and extra ordinary maintenance reasons After the Mirror Cell has been mounted on the telescope structure the Mirror Dummy shall be removed following the procedure later described in this manual with the help of the Hydra Set and of the Handling Device supplied by INAF The Hydra Set must be used for all mounting and removal operations of the Mirror or of the mirror Dummy on or from the Mirror Cell Figure 5 hydra set for load monitoring when lifting the mirror In order to read the applied loads act on the switch located aside the display but keep in mind that the reading accuracy is affected by the friction of the piston P
98. ord the height of the tip of the bar see picture with respect to the top surface of the mirror cell e release the two headless screws see picture just the necessary to unlock along the radial direction the bar that supports the counterweight f Unscrew the locking bar nut release the special nut see picture to unlock the regulation shaft see picture h release the regulation shaft in this way the bar will move down until the counterweight leans in a plate inside the mirror cell When the counterweight has been leaned unscrew completely from the bar the regulation shaft i Lift the support until it comes out from its mirror cell centring and then rotate the support towards the center of the mirror cell so to allow taking the support out from the bar Keep on taking the support out until it has completely come out from the bar p Now 115 possible to remove the support of the astatic lever from the mirror cell Bar Fork Pivot shaft opecial nut Astatic lever support Arm Regulation M8 screws headless shaft Screws seat Figure 51 Astatic Lever Support type removable with mirror removed Issue 2 0 VST PROJECT Date 2009 03 04 VST M1 PPORT SYSTEM Pag 57 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 4 1 2 Demounting the support of astatic levers 5 6 7 8 17 18 19 and 20 To remove the supports of these astatic levers as said before it 1s not ne
99. ribed in the following sub sections 4 1 AXIAL FORCE ACTUATORS Abad S 20040058 OO Figure 18 Axial Force Actuators and Axial Fixed Points arrangement top view Issue 2 0 Vo ERREGI Date 2009 03 04 VST M1 PPORT SYSTEM Pag 36 of 10 Qr S SUPPORT SYS ag of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 The 81 axial force actuators are applied at the related 81 seats obtained in the central aera of the mirror cell by machining As shown in the figure the seats are divided in four rings the innermost ring 1s referred to as ring nr 1 and has 12 seats next outwards is ring nr 2 with 18 seats then comes ring nr 3 that has 24 seats and eventually the outward ring with 30 seats referred to as ring nr 4 Every seat 1s identified by a number as follows ring 1 seats from 72 through 83 numbered in clockwise direction ring nr 2 seats from 54 through 71 numbered in clockwise direction ring nr 3 seats from 30 through 53 numbered in clockwise direction ring nr 4 seats from 0 through 29 numbered in clockwise direction The axial force actuators that belong to ring nr 1 are different from those of rings nrs 2 3 and 4 further the axial force actuators that belong to rings nrs 2 and 3 are different from those of ring nr 4 Every single actuator is identified by a label with an identification code that 1s structured as follows from OACNO1 0101 072 0 through OACNO1 0101 083 0 for the axial forc
100. s 5 6 7 8 17 18 19 and 20 The supports of these astatic levers can be mounted from the outside of the mirror cell because there is adequate accessibility a rotate the support of the astatic lever outwards of the mirror cell so to be able to insert the counterweight into the hole of the seat in which the support has to be mounted Let the counterweight move down in the hole and when the encumbrance of the centrepiece allows it straighten up the support to centre it in its own seat b rotate the support around the vertical axis so to position it in the right orientation along which the arm must be repositioned C screw in the six M8 screws that fix the support to the mirror cell d position the arm fork on the pivot shaft and fix it with the five M5 screws e now it is possible to reposition the safety devices that have been removed to allow the removal of the support of the astatic lever 4 4 3 Lateral Support Assembly Procedure To have further information see document VST TRE TOM 22300 2125 VST PROJECT uc Date 2009 03 04 N VST M1 SUPPORT SYSTEM Pag 60 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 45 SAFETY DEVICES The 28 safety devices SD are applied as shown in fig 19 onto the top side of the mirror cell They are applied on the top surface of the mirror cell 0610 0509 0508 0507 0606 Le MAR Q 29 92 fos 0620 0524 0522 0523 0624 Figure 33 Safety Devices
101. s must be the first sub systems to be connected to the mirror during the integration phase in the same way they must be the last sub systems to be removed from the mirror when removing the mirror from the cell 4 3 1 How to Mount the Lateral Fixed Points Within this scope two different situations are to be considered a the mirror is integrated in the mirror cell b the mirror 1s removed from the mirror cell In both cases two mechanical technicians together must carry out the operation The Lateral Fixed Point must first be fixed onto the column support which is already fixed on the mirror cell and then it gets either fixed to the mirror when this is integrated in the telescope Or it is beard by the appropriate fork support which is already fixed on the mirror cell if the mirror 1s removed from the cell The altitude rotation angle must be 90 cell pointing to zenith Proceed with the following steps when the mirror has already been integrated in the cell a fix the support of the lateral fixed point onto the top side of the mirror cell b place the lateral fixed point and verify that the counterweight 1s oriented as shown in the figure below c while the one operator holds the lateral fixed point in contact with the column support that 1s fixed on the mirror cell the second one can fix the flange of the flexible joint with M6 screws to the column support d as the same operator bears the lateral fixed point the s
102. s that connect the mirror flexible joint to the invar extension b move outwards the unlocked end of the lateral fixed point and insert it over its own support c lock the lateral fixed point in this position v 3 Lateral removable invar pads 4 5 6 7 8 9 15 16 17 19 20 21 and 22 included special invar pads 3 10 and 18 have to be disconnected from the dummy a starting from astatic lever nr 03 and proceeding counter clockwise one person has to sustain the arm on whose end is a removable invar pad until the second one unscrews the three M8 screws that connect the removable pad to that fixed to the dummy lateral surface VST PROJECT Qr VST M1 SUPPORT SYSTEM USE AND MAINTENANCE MANUAL Issue 2 0 Date 2009 03 04 Pag 71 of 109 Code VST TRE TOM 22300 2128 b once disconnected it is necessary to insert their own locking spring in the provided seat to constrain the arm against the safety device structure and to remain sufficiently far from the dummy v 4 Lateral special devices 1 12 13 and 24 have to be disconnected from the dummy a starting from astatic lever 01 and proceeding counter clockwise a first person has to unscrew the two M8 screws that locked the special device to the non removable lateral invar pad b until a second person brings the upper part of the counterweight bar and pulls it externally the first one verifies that the special device has come out of the two alignment pins an
103. side the mirror cell wouldn t be enough Within the group of astatic levers discussed in this paragraph it 1s necessary to proceed in two different ways depending on the shape of the counterweight e astatic levers nr 1 3 10 12 13 15 22 and 24 a verify any possible interference between the support and the safety devices if it is the case it 1s first necessary to remove all safety devices that cause interference b remove the fork see picture from the shaft see picture and then remove the arm from the support c remove the M8 screws that fix the support to the mirror cell d lift the support so to see the counterweight then hold it concentric with the hole axis while lifting it and do so until the counterweight has come out of the hole enough to allow the support to rotate 1n direction internal to the mirror cell e remove the support of the astatic lever from the mirror cell Issue 2 0 VST PROJECT Date 2009 03 04 Qe VST M1 SUPPORT SYSTEM Pag 56 of 109 M Code VST TRE USE AND MAINTENANCE MANUAL OND e astatic levers nr 2 4 9 11 14 16 21 and 23 a verify any possible interference between the support and the safety devices if it is the case it 1s first necessary to remove all safety devices that cause interference b remove the fork see picture from shaft see picture and then remove the arm from the support c remove the M8 screws that fix the support to the mirror cell d measure and rec
104. t axial support system Special Spacers have been designed for the purpose of calibrating the Safety Devices These are represented in the picture below and are also contained in a coffer nr 1 VST PROJECT Issue 2 0 Date 2009 03 04 VST M1 SUPPORT SYSTEM Pag 29 of 109 Qr e Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 MISSING PICTURE spacers being produced Figure 9 Spacers for gap adjusting safety devices The Test Bench used to test the static behaviour of the axial force actuators is also included in the shipping Figure 10 Test Bench for the static tests and of the axial force actuators Together is the Test Equipment used to verify the dynamic performance of the axial force actuators hard steel plates screws and pipe segments as you can see in the figure below that also shows how to use these parts Issue 2 0 VST PROJECT Date 2009 03 04 ecT N VST M1 SUPPORT SYSTEM Pag 30 of 109 d i Ce Code VST TRE USE AND MAINTENANCE MANUAL Figure 11 Test Equipment for the dynamic test 2 of the axial force actuators The Reference Weights are also shipped together they had been mostly used to load the axial force actuators but also to verify the good reading of the reference load cells before calibrating the astatic levers Figure 12 5Kg 10 and 20Kg reference weights The load cells used in the course of the different tests of the M1 Support syst
105. t 70 Nm insert the sliding structure on the base insert the bridge in the seats foreseen on the base and fix it with the four M8 screws slide the main structure along the base until the distance in the radial direction between the radial pad and the lateral surface of the dummy is about Imm verify that the rotation around the pivot pin of the top arm locking allow the opening of the top arm verify that the rotation of the top arm is free from any encumbrance verify accessibility to adjust backlash and lock the forward position toward the mirror fix the sliding structure on the base with the six M10 screws The final tightening torque will be given during the radial adjusting operation as shown in chapter 3 3 4 VST PROJECT Issue 2 0 Date 2009 03 04 ecT VST M1 SUPPORT SYSTEM Pag 66 of 109 ceN RM Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 4 5 3 Integration of the safety devices 0501 and 0515 a Position the base with their own threaded holes obtained on the upper surface of the mirror cell and fix it with the M10 screws foreseen tighten them with a torque of about 70 Nm b slide the main structure along the base acting on the angular gearbox with a special tool shaft elongation until the distance in the radial direction between the radial pad and the lateral surface of the dummy is about 1mm c verify and take note what the best accessibility is to adjust the gaps between the three pads and the dummy
106. tors and axial fixed points functional height table esses 45 7 84 00 Devices DOGS SIE GV UP 63 Table 8 Axial Force Actuators main 66 Table 9 Axial Fixed Points main 66 Table 10 Lateral Fixed Points main parameters 69 Table 11 Lateral Supports force data sese 63 Table 12 Lateral Supports theoretical load cell reading at altitude 1 53 Table 13 Ordinary Maintenance frequency sub system and resources eese 94 FIGURE INDEX Figure l Lifting Plate with Locking Ring sisvescissevenassssnsressinsenanssevencies esI eroe M9R EE SUR A UE VER EIUS Nen ASA PESE Ve 20 Figure 2 warning image for cell lifting cessisse eese 20 Figure 3 lifting the cell in horizontal configuration 21 Figure 4 lifting the cell in vertical configuration cecinere 22 Figure 5 hydra set for load monitoring when lifting the mirror eese 23 Figure 6 User Manual of the Hydra Set Cover sees eene eene eene nnne nnne eene nnns 24 Figure 7 Calibration Box with load cells and 28 Figure 8 Motor Control Handset axial support 1
107. ts final position in the mirror cell 4 verify that the dummy orientation around the z axis 1s correct 5 lower the dummy down to 100 mm over any possible contact point with the safety devices of the support system 6 horizontally move the dummy until it is about on top of its final position in the mirror cell VST PROJECT iud USE AND MAINTENANCE MANUAL Code VST TRE Date 2009 03 04 VST M1 PPORT SYSTEM Pag 76 of 109 Qr Suns en ente p 8 9 10 11 12 13 14 15 16 17 TOM 22300 2128 lower the dummy down to 10 mm over any possible contact point with the safety devices of the support system horizontally move the dummy until it 1s about on top of its final position in the mirror cell horizontally move the dummy in the two directions until it has backlash between 5 mm and 15 mm in relation to the lateral safety devices lower the dummy until the bottom of the dummy is 5 mm over the same height as the top of the lateral safety devices of the support system horizontally move the dummy in the two directions until it has backlash between 5 mm and 11 mm in relation to the lateral safety devices slowly lower the dummy until it touches the three axial absolute transducers that are about 20 mm over the final position rotate the dummy around the z axis in order to reach its final orientation within 5mm tangential distance between the pads of the dummy and the pads of the astatic levers or t
108. ull the wire to act on the right lever this lowers the Mirror at a speed proportional to the angle made by the lever Pull the wire to act on the left lever this lifts the Mirror of about 0 1 mm for each time In rest conditions when the Hydra Set is off the two levers must be up and locked by the appropriate locking piece The User Manual of the Hydra Set is made available and 1s shown in the picture below to be easily identified by the operator Issue 2 0 VST PROJECT Date 2009 03 04 Qe VST M1 SUPPORT SYSTEM Pag 24 of 109 Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 Hydra Set Model C Auxiliary Hoist Control Del Pub 81 2 Rev C Operation and Maintenance Manual October 2004 Figure 6 User Manual of the Hydra Set Cover VST PROJECT ud Date 2009 03 04 VST M1 PPORT SYSTEM Pag 25 of 109 Qr Supr beds Code VST TRE USE AND MAINTENANCE MANUAL TOM 22300 2128 3 MATERIAL SPARES EQUIPMENT INSTRUMENTS AND TOOLS In this section all spare parts and material are considered as well as all tools for use operations and maintenance interventions Besides being a list this section helps to identify material and tools and further shows where to find them in the packing 3 1 Material Here below follows a short list of the material that has been made available for maintenance interventions as below better detailed nr 3 Lubcon grease jars 5m power cable Sabix 5x2 5mm2
109. zero If the hook crane 1s not correctly aligned with the dummy center of gravity it may happen that the dummy undergoes a lateral translation it 1s necessary therefore to center the hook so to have the dummy equally spaced between all pads of the lateral safety devices At this point the dummy is suspended from the hook of the crane and centered in the mirror cell so it 1s necessary to read the value given by the two lateral position transducers and the three axial position transducers These values are those that will have to be reached first of all during the following dummy mirror integration C 6 3 First Integration of the Dummy in the Mirror Cell 6 3 1 Starting check Before proceeding with the dummy mirror integration into the mirror cell it is necessary to check and verify the following items step by step FIRST DUMMY MIRROR INTEGRATION MIRROR CELL CHECK LIST v Verify that the mirror cell is at an altitude angle of 90 0 05 to do this it is possible to use a level with accuracy 0 02 mm m leaned on the top plane of the mirror cell v 2 Visual control of all heights of the Axial Force Actuators spheres considering the possibility that someone might have mounted an axial force actuator in the wrong position v 3 Verify that all top arms of the Safety Devices are open while the Safety Devices 1 and 15 shall be in the rear position v 4 Verify that all radial safety devices are in the rear position external with

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