Assembly Instructions for the CNCTRK AZ/EL Positioning Unit

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1 Assembly Instructions for the CNCTRK AZ/EL Positioning Unit Introduction/Overiview The AZ/EL Unit consists of two stages of identical gearboxes joined together with a configuration adapter. Note that this unit is "hackable" and can be assembled in several configurations; the assembly instructions provided in this document will result in a unit that will either sit on a tabletop, or be mounted on a (sturdy) camera tripod. Other assembly options may be discussed at the conclusion of this document. One may choose to use only a single stage of the assembly to make a separate AZ or an EL positioning unit as an alternative to the full-up AZ/EL assembly. All of these configurations can be controlled by the real-time open source software, LinuxCNC, at This manual will guide the user through the process of assembling the AZ/EL Unit in preparation for full tracking capability using the CNCTRK system. Details of setting up software for satellite tracking is covered in the CNCTRK Configuration Guide. The mechanical components needed for satellite tracking consist of only a computer with parallel port and cable, a power supply, and the AZ/EL Unit. A complete tracking system running GPredict and LinuxCNC is shown in the photograph below. [[[Tracking System Components (less RF Gear)]]]

2 Parts Identification Before proceeding with assembly, identify and verify that all the necessary parts that are required in the assembly are contained in the package received from FRFMW. The quantity and identifying features and descriptions of the necessary parts are listed in Table 1, below. [[[AZ/EL Unit Parts]]]

3 TABLE 1 Item No List of Parts With Reference Identification Description 10104_AZ_Plate_disc_RevC.ems 10110_Bearing_Cap.ems 10113_AZ_Housing4rad_tmp.ems 10114_Motor_Driver_Mount.dxf 10116_EL_Shaft_Bracket 10117_AZ_Adapter.ems Qty _AZ_Shaft.dxf (6343-like, all) _AZ_Shaft_Worm.dxf 5 inches 10107_EL_Shaft_Upper.dxf 8 inches _Worm_Gear_Kit.dxf (41A817) Stepper Motor ebay Motor Driver Bearings DB5 Female Connector Standoffs, DB5 Connector, 4-40 x TBD Long Wire and JST XH 6pin Motor Conn., 6 AWG, Stranded Screws 8-3 x 1/ SHCS Screws 8-3 x 5/8 SHCS + 1 SHCS Spacer, Nylon 3/8 OD x.194 ID x 1/ LONG Spring Pin, 5/64in diameter Flat Washer 1/ Jackscrew. Long A/R CAUTION: The motor and shafting are provided as a matched pair of components. This is due to the fact the motor shaft is match drilled for the roll pin to shafting interface. These parts should remain together as a pair for smooth operation. Once all parts are verified to be complete, proceed to the AZ stage Assembly

4 AZ Stage Assembly AZ01. Install four (4) Spacers onto the bottom of the AZ Housing using four(4) Socket Head Cap Screws. This step enables the AZ Housing to sit flat on a worksurface. AZ0. Pick the four inch (4") long Shaft from the package and using large pliars (preferred) or hammer install the Roll Pin into the AZ shaft. AZ03. Select one of the Gear Kits and pick the following components for use in the next assembly step: Large Diameter Plastic Gear Collar Large Roll Pin 1/" Washer 0.06" thick (this item not from the gear kit) AZ04. Assemble a total of three (3) Bearings and three (3) Bearing Caps onto the AZ Housing in the locations indicated in the figure below. [[[AZ Housing with Three Bearing Locations]]] Fasten the Bearing Caps using #8-3 Socket Head Cap Screws (SHCS) and leave screws loosely fitted (i.e. un-torqued) for the present time. Now, temporarily remove the TOP bearing and bearing cap.

5 AZ05. With the AZ Housing standing on one of the open ends, feed the clear end (no dimple) of the AZ Shaft through the TOP bearing; the fit is close but should not offer significant resistance if aligned properly. Continue to feed the Shaft pregressively as the parts are installed, taking care to align the Roll Pin with the notch in the gear as needed to engage these components. Install the following items on the shaft in order: 1/" Flat Washer Large Plastic Gear Collar IMPORTANT NOTE: The plastic gear may have a "U-shaped" notch and a "V-shaped" notch to accept the roll pin; use the "U-shaped" notch, else excessive bearing pre-load may result. Use of a file may be required to enable the pin to seat fully into the gear. AZ06. Feed the Shaft through the bottom Bearing and, using a 1/8" Hex Driver, tighten the two Collar set screws hand tight to secure the AZ shaft in place. Verify the shaft does not protrude beyone the plane of the spacers on the bottom of the unit. The AZ Shaft assembly into the Housing should look like the photograph below. [[[AZ Shaft Inserted In Housing]]]

6 AZ07. Collect the following items in preparation for the AZ Motor and Worm Gear assembly: Stepper Motor Five Inch (5") Shaft (matched to motor) Motor Mount Plate Roll Pin, 0.080" Roll Pin, 0.171" Two 1/" long spacers (bronze color) Worm Gear from the Gear Kit bag AZ08. Install the Motor Mount Plate onto the AZ Housing. Visually center the plate in the middle of the slotted mounting feature and assemble with four (4) screws. Torque the four (4) screws to recommended value. AZ09. Position the five inch (5") Shaft over the Stepper Motor shaft and press the 0.080" Roll Pin into the shaft until flush. Waterpump or wire pliars are suitable for pressing the small Roll Pin (see photograph below). [[[Photograph of Roll Pin Installation]]] Similarly, press the Roll Pin into the five inch (5") Shaft until approximately equal lengths are observed on each side of the Shaft. The fit is tight; a light tap with a hammer may be required. A Knurled Pin may be supplied with the kit instead of the Roll Pin; either of these may be used. AZ10. Feed the Five Inch (5") Shaft (with Stepper Motor attached) through the available hole in the Motor Mount and partially into the AZ Housing. AZ11. Install the following items onto the Shaft, in order: Worm Gear with notches facing Motor Mount Spacer, 1/ inch long Spacer, 1/ inch long

7 Align the Worm Gear with the Roll/Knurled Pin and slide gear toward the Mounting Plate until the pin is engaged in the Worm Gear. Use a file on the gear notch, as needed, to seat the pin, similar as above. AZ1. Assemble the Stepper Motor onto the Motor Mount; rotate the motor as needed to position the electrical connector toward the connector mounting feature of the bracket (the #4-40 threaded holes). Secure in place using four (4) screws; tighten screws only snug -- just enough to join the units together for inspection. AZ13. Tighten six (6) screws to secure all Bearing Caps in place (NOTE: tighten to snug fit only as full torque is not required in this application and will warp the components). AZ14. Adjust the Motor Mount for proper gear mesh, if needed. Turn the motor shaft by hand to assess the gear mesh for excessive binding or excessive backlash. If adjustment is needed to improve the mesh, remove the motor and shaft assembly, adjust the position of the Motor Mount to increase the mesh (i.e. gears closer together) or decrease the mesh (i.e. gears farther apart), and re-assemble as before. AZ15. Once a satisfactory mesh is achieved, torque four (4) motor mount screws. AZ16. Assess the assembly. If gaps greater than 1/3" remain on the bearing-end of the shaft, add additional washers to reduce the gaps, and thus, the potential end play of the Worm Gear. AZ17. Lubricate the two gears. Turn the motor shaft by hand and apply a small amount of grease uniformly ofer the two gears; a small brush may be useful. Rotate the worm drive shaft several times to distribute the lubricant. AZ18. Once the gear asssembly operates without binding, application of a threadlocker compound is advised to keep fasteners held in place securely. At this point we have an assembled gearbox that is suitable for use in the AZ axis application see photograph of completed AZ Stage below. The motor driver electronics could be installed at this stage but, instead, the driver installation is held for a later time as this allows the completed assembly to serve as a reference for the second gearbox. [[[Photograph of AZ Stage Assembly]]]

8 EL Stage Description The EL Axis Gearbox uses many parts that are identical to those in the AZ axis unit. For reference, the differences are itemized below: a. The EL axis gearbox omits the four spacers used as feet in the AZ axis b. The Motor Mount is rotated 90 degrees relative to the AZ axis application c. The EL axis Shaft is eight inches (8") long EL Stage Assembly EL01. Repeat the steps AZ0 through AZ07, substituting the 8" Shaft for setp AZ04. EL0. Repeat the steps AZ08 by rotating the Motor Mount 90 degrees as depicted below. [[[Photograph Showing 90 Degrees Rotated Motor Mount Bracket]]] EL03. Repeat the steps AZ09 through AZ19, using the completed unit as a reference. EL04. Pick the following parts needed to complete the EL axis gearbox assembly: Configuration Adapter Plate AZ Disk and two () #8-3 SHCS 10 ea. #8-3 x 1/" SHCS (one 5/8" and one 1 long) EL05. Using four (4) of the 1/" SHCS, screw the AZ Disk onto the Configuration Adapter Plate and torque the screws. Install the two longer SHCS into the AZ Disk (these will serve as set screws).

9 [[[Configuration Adapter]]] EL06. With the AZ Disk facing outward, screw the Configuration Adapter Plate onto the end of the newly assembled EL axis Gearbox and torque the six (6) screws. [[Completed EL Gearbox]]] This completes the assembly of the EL Axis Gearbox. will now be joined together in the following steps. The AZ Gearbox and EL Gearbox

10 AZ/EL Unit Assembly AE01. Place the AZ Stage on a level surface with the exposed Shaft positioned vertically. AE0. Place the EL Stage unit over the AZ Stage and position the AZ Shaft into the AZ Disk and Configuration Adapter. Position the AZ Shaft as needed to engage the (SHCS) set screw into the (single) conical hole in the AZ Shaft. Torque both set screws to value. Again, for permanent assembly, the use of a threadlocker compound my be desired. [[[AZ/EL Unit Assembly Side View]]]

11 [[[AZ/EL Unit Assembly]]]

12 AE03. Pick two () Motor Driver Circuits, two () Cable Assemblies, and two () #4-40 SHCS from the packaging. Assemble the Motor Driver circuits onto their respective axes locations. [[[Motor Driver Circuit Mounting Location]]] AE04. Wire the Stepper Motors as depicted in the following photograph. [[[Photograph of Stepper Motor Connector Wiring]]]

13 AE05. Wire the Power and Control Connector as depicted in the following schematic. [[[Schematic of Power and Control Wiring]]]

14 AE06. Assemble the Power and Control Connector onto the AZ/EL Unit Assembly, as follows: a. b. Pick spacers and #4-40 Jackscrew hardware Mount the connector as shown below [[[5 Pin Control Connector Mounting]]] AE07. Route cabling to accommodate rotation about the AZ axis with a service loop as shown in the photograph below.

15 AE08. The type of mount used to attach an antenna or other device to the AZ/EL Unit will vary from case to case. A bracket is supplied to accommodate standard UBolts; this is depicted in the photograph of a completed AZ/EL Unit below. [[[Completed AZ/EL Unit Assembly]]] END OF ASSEMBLY INSTRUCTIONS

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