Doc #: 2100 AD 015 0020 Revision: MOSAIC Removal Procedure Author(s): Hillary Mathis, Bill McCollam
Contents Contents... 2 Revision History... 3 1. Purpose... 4 2. Applicable To... 4 3. Scope... 4 4. Definitions... 4 5. Training... 4 6. Safety... 4 7. Personnel, Equipment and Materials Required... 4 8. Procedure... 5 9. Procedure Review... 11 10. Records... 11 11. References... 11 2100 AD 015 0020.docx Page 2 of 11
Revision History Rev Date Approved Sections Affected Remarks and/or Change Details 0 Initiated 5, 7 and 8 Complete rewrite, also added labels and arrows to photos, Bill McCollam Authorized by: SigEng Name, ME Title Bill McCollam Name, EL Maint SigSciOps Name, SciOps Tammie Lavoie 29 July 2016 Tammie Lavoie, Safety Manager Date 2100 AD 015 0020.docx Page 3 of 11
1. Purpose To remove the MOSAIC imager from Prime Focus 2. Applicable To KPNO 4 Meter telescope 3. Scope To be done any time MOSAIC is needed off the telescope for repair or maintenance 4. Definitions 5. Training No special procedural training required. On the job knowledge of Mayall dome environment required. Fall protection training required. Lock out tag out training required. 6. Safety 1. JHA Form 2. Kitt Peak Emergency Manual 7. Personnel, Equipment and Materials Required 3 people o 2 installers and 1 crane operator One installer must have previously participated in procedure Orange drivable scissor lift Extension step for orange scissor lift Gray MOSAIC tool box containing the following o Full set of standard allen wrenches o An adjustable wrench o 2 9/16 box end ratchet wrenches o Philips head screwdriver o 3 foot lifting strap o 2 7/8 shackle Blue lifting fixture (if it is not already attached to MOSAIC) MOSAIC window cover (Stored on SE Annex) Corrector cover (Stored on SE Annex) 2100 AD 015 0020.docx Page 4 of 11
Crane scale MOSAIC frame bottom (Stored on SE Annex) 8 cage weights (Stored on orange scissor lift) See JHA for PPE 8. Procedure 1. Turn off the large mixing fan. 2. Place Instrument Change in Progress sign on console. 3. Turn off MOSAIC. a. Shut down MOSAIC software. i. Double click on MOSAIC 3 icon on the Mayall 2 (observers) desktop; a menu GUI will appear. ii. In the MOSAIC3 menu GUI; click Stop MOSAIC and wait until Ready appears. iii. In the MOSAIC3 menu GUI; click Stop Cameras and wait until Ready appears. b. Turn off the Lakeshore temperature controller and CCD controllers using remote power switch i. In a terminal window type the commands: ii. telnet 4m pf power iii. username> kpno iv. password> (Staff password) v. RPC 3> on 1 vi. Turn on LakeShore3 power (y/n) > yes vii. RPC 3> on 2 viii. Turn on MOS3 CNTRL power (y/n) > yes ix. RPC 3> logout Figure 1 2100 AD 015 0020.docx Page 5 of 11
10 MOSAIC cables on secondary ring (Step 8) Cable box doors (Step 8) Figure 2 4. Move the telescope to the SE Annex (JHA Item #1) 5. If necessary, flip to PF using Secondary Major Flip from F/8 to PF with MOSAIC Installed Procedure DOC# 2100 AD 015 0021 6. Attach the pedestal focus handpaddle. (See Figure 1) Note: Handpaddle is stored on right side of SE Annex equipment box 7. Drive the focus all the way in and disconnect handpaddle. 8. Disconnect the 10 MOSAIC cables on the secondary ring; (See Figure 2) a. They are stored in the place holders under the ring b. J50 does not have a place holder and is attached with velcro to the other cables c. Close cable box doors and tighten screws Lockout/Tagout (Step 10) RA & DEC Breaker (Step 10) Figure 3 RUPS Power Panel (Step 10) 2100 AD 015 0020.docx Page 6 of 11
9. From the control room, move the telescope to meridian and 45 in dec. (JHA Item #2) Stay Bar (Steps 11 and 58) Figure 4 10. On the P floor, behind the screen room, turn off the breakers for the Dec and RA drives on the Brake Circuit Cabinet and the RUPS Power Panel 5 breaker. Lockout/Tagout (LO TO) the RUPS breaker. (See Figure 3) (JHA Item #3) 11. Install the stay bar. (See Figure 4) (JHA Item #4) 12. Unstow the 1 ton crane; a. Turn on the low dome lights from the console panel in the control room. b. Rotate the dome to the East to be able to reach the crane to unstow it. c. Turn on the two breakers at the crane control station. d. Use the handpaddle cable to manually pull the crane boom to the middle of the track. e. Unstow the arm; 2100 AD 015 0020.docx Page 7 of 11
i. One person pushes the button on top of the solenoid box and holds it to disengage the crane arm locking pin. ii. The other person needs to rotate the arm out. iii. Released solenoid button once the arm is all the way out and the pin is aligned with the engagement hole. (JHA Item # 5) 13. Rotate the dome until the MOSAIC marks on the dome line up with the marks on the floor behind the SE Annex platform; ensure crane and telescope don t come in contact. (JHA item #6) The crane should be centered over the Prime Focus cage opening; adjust crane as necessary. 14. Drive the orange scissor lift under the prime focus cage. Ensure extension step, gray MO SAIC tool box, MOSAIC window cover, Corrector cover, MOSAIC frame, crane scale and 8 weights are on the scissor lift. 15. Put on your fall protection safety harnesses. (JHA Item #7) 16. Clip 9 foot SRL to your Safety Harness and the lift railing. (JHA Item #8) 17. Raise the scissor lift until floor of lift clears the secondary ring, stop and put the extension step into place. (JHA Item #9) 18. Unclip your 9 foot SRL from the lift railing and clip it to the safety attachment points inside the PF cage. (JHA Item #10) 19. Raise scissor lift until railing is 2 inches from prime focus cage. 20. Turn off the blue sync box. 21. Unplug the CCD controller power supply. 22. Turn off the lakeshore. 23. Disconnect MOSAIC from the telescope; a. Disconnect the green grounding cable from the DHS box. b. Disconnect the two cables from the DHS box. c. Disconnect the shutter cable from the DHS box. d. Disconnect the guider camera cables from the telescope. e. Disconnect the fibers from MOSAIC. f. Disconnect the ethernet cable from the lakeshore. g. Turn off the N2 and disconnect the hose. h. Disconnect the compressor line. i. Disconnect the fill line. j. Disconnect the remaining cable bundles from MOSAIC. Rotator clamp ratchets (Steps 24 and 26) Figure 5 2100 AD 015 0020.docx Page 8 of 11
24. Loosen the 4 ratchets to the MOSAIC rotator clamp. (See Figure 5) 25. Rotate clockwise until the top of MOSAIC is centered on the upper Prime Focus cage opening. (See Figure 6) Rotation handle (Step 25) Figure 6 26. Lock down the rotator with the 4 ratchets. (See Figure 5) 27. Attach the bottom of the MOSAIC frame. 28. Lower the crane hook so it is reachable through the opening at the top of the Prime Focus cage. 29. Climb up into the cage using the orange step by the light switch, and the grab handle. 30. Attach the top ring of the scale to the crane hook, turn on and zero it. 31. Attach the bottom ring of the scale to the blue lifting fixture with a lifting strap and 2 shackles. Note: Make sure that the slide on the blue fixture is towards the telescope as much as possible. 32. Bump up the crane until the scale reads 480lbs, the weight of MOSAIC. 33. Unbolt the instrument from the corrector plate. 34. Slowly lift the crane while holding the instrument. (JHA Item #11) 35. Maneuver the instrument up and towards the dome with the crane until it is free of the corrector plate. 36. Place the covers over both the MOSAIC window and the corrector window. (JHA Item #12) 37. Unclip your 9 foot SRL from the safety attachment points inside the PF cage and clip it to the lift railing. (JHA Item #13) 38. Lower MOSAIC and the scissor lift in unison taking care to steady MOSAIC on the way down, when the floor of the scissor lift has cleared the secondary ring, stop and remove the extension step. (JHA Item #14) 39. Lower scissor lift to its lower limit, drive lift far enough out of the way to allow MOSAIC to be lowered onto it s cart. 2100 AD 015 0020.docx Page 9 of 11
40. Position the instrument cart under MOSAIC. 41. Lower MOSAIC the rest of the way down until it is resting lightly on the cart. 42. Start the captive bolts on the bottom of the MOSAIC cart. 43. Lower MOSAIC all the way down. 44. Tighten the captive bolts on the bottom of the MOSAIC cart. 45. Remove the lifting strap and scale from the crane hook and MOSAIC. 46. Move MOSAIC to the coude room for storage. 47. Raise crane hook and then stow the crane; a. Rotate the dome to the East. b. Stow the arm; i. One person pushes the button on top of the solenoid box and holds it to disengage the crane arm lock pin. ii. The other person pulls the crane arm in towards the dome. iii. The solenoid button can be released once the arm is all the way in and the pin is aligned with the engagement hole. (JHA Item #15) iv. Manually move the crane boom to the base of the crane arm. v. Turn off the two breakers at the crane control panel. 48. Move the scissor lift back under the prime focus cage. 49. Clip 9 foot SRL to your Safety Harness and the lift railing. (JHA Item #16) 50. Raise the scissor lift until floor of lift clears the secondary ring, stop and put the extension step into place. (JHA Item #17) 51. Unclip your 9 foot SRL from the lift railing and clip it to the safety attachment points inside the PF cage. 52. Secure all cables and the N2 line inside the cage with tie wraps or velcro straps. 53. Attach weights to back of cage, 4 on each side. 54. Unclip your 9 foot SRL from the safety attachment points inside the PF cage and clip it to the lift railing. 55. Lower the scissor lift until the floor has cleared the secondary ring, stop and remove the extension step. (JHA Item #18) 56. Stow scissor lift and plug it in. 57. Move dec axial counterweights all the way up. 58. Remove stay bar. (See figure 4) 59. On the P floor, behind the screen room, Remove Lockout/Tagout (LOTO) from the RUPS power panel 5 breaker and turn it on then turn on the breakers for the Dec and RA drives on the Brake Circuit Cabinet. (See Figure 7) (JHA Item #19) 60. In the control room, bring the telescope to zenith. 61. Flip to F/8 using the Secondary Major Flip from PF to F/8 with No Instrument Procedure DOC# 2100 AD 015 0022. 2100 AD 015 0020.docx Page 10 of 11
Lock Out/Tag Out (Step 59) RA & DEC Breaker (Step 59) RUPS Power Panel (Step 59) Figure 7 62. Balance the telescope using Balancing the 4 Meter Procedure DOC# 2100 AD 015 0016. 63. Turn on the large mixing fan. 9. Procedure Review Once a year or as safety procedures or instrumentation mentioned changes 10. Records 11. References See Balancing the 4 Meter Procedure DOC# 2100 AD 015 0016 See Secondary Major Flip from F/8 to PF with MOSAIC Installed Procedure DOC# 2100 AD 015 0021 See Secondary Major Flip from PF to F/8 with No Instrument Procedure DOC# 2100 AD 015 0022 See NOAO Lockout/Tagout (LOTO) policy 2100 AD 015 0020.docx Page 11 of 11