drawing samples 1063, 1670, 1673, 1674 solidworks acad

TURRET (RoHS)

TERMINAL CONTACT: MACHINED C36000 BRASS 1/2 HARDTERMINAL PLATING: SOFT NICKEL THEN SILVERDIMENSIONS APPLY AFTER PLATINGPRODUCTION BODY: BLACK NYLON 6/6 PER ASTM D4066PRODUCTION BODY MOLDED OVER CONTACT

PROTOTYPE BODY: SOMOS NEXT STEREOLITHOGRAPHY RESIN

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

ROTHENBUHLER ENGINEERING. ANY

REPRODUCTION IN PART OR AS A WHOLE

WITHOUT THE WRITTEN PERMISSION OF

ROTHENBUHLER ENGINEERING IS

PROHIBITED.

NEXT ASSY USED ON

APPLICATION

DIMENSIONS ARE IN INCHES

TOLERANCES:

LINEAR- X.X =

X.XX =

X.XXX =

ANGULAR- =

MATERIAL

FINISH

--

--

DRAWN

CHECKED

MECH.

ELEC.

APPROVED

DATE

SIZE DWG. NO. REV

SHEET 1 OF 1SCALE: 4:1

REVISIONS

DESCRIPTION DATE APPROVEDLTR

UNLESS OTHERWISE SPECIFIED:

524 RHODES ROAD, SEDRO WOOLLEY, WA 98284

BREAK ALL SHARP EDGESALL DIMENSIONS TO USAS Y14.5'66125 FINISH ALL MACHINED SURFACES

JACK, CUSTOM BANANA, BLACK

1674-22-20-2-B5B

10/7/2013Tom Jacobson

±0.010

A REMOVED DRAIN SLOTS - NO ECO

J300-167-40

CHANGED CONTACT LOCK-IN FEATURE - NO ECOB

5/16-32 UNEF-2A

A

A 00.031

0.1320.215

0.2340.2600.313

0.857

100.000°

ø 0.203ø 0.161

0.010

ø 0.142ø 0.122

0.031

0.031 0.181

0.313

0.857

0.969

ø 0.435

ø 0.098

ø 0.125

ø 0.161

ø 0.203

ø 0.225

R0.025 R0.025

0.719

SECTION A-A

9/23/14 RTREFER ECO 3706C9/23/14 RT9/23/14 RT

Gary McCoy 9/23/14

9/23/14Rich Taft

Technical Service Number: TSB-0016

Bulletin (TSB) Page: 1 of 5

TITLE: 1064-2-1 & 1072-3-2-1 RECEIVER “L7” INDUCTOR REPLACEMENT

Rothenbuhler

Engineering

Rothenbuhler Engineering Proprietary Notice This document contains information which is the exclusive property of Rothenbuhler Engineering. Distribution, reproduction, or use by others is not permitted without the express written consent of Rothenbuhler Engineering.

Signature Date

Author Gary McCoy 4/23/15

Approved Rich Taft 4/23/15

Document #: TSB0016

File Name: TSB0016 1064-2-1, 1072-3-2-1 Receiver PCBA’s.doc




Table of Contents

Table of Contents .............................................................................................................................. 2

Table of Figures ................................................................................................................................ 2

Replacement of Toko Inductor L7 ..................................................................................................... 3

Objective of Change .......................................................................................................................... 3

Background ....................................................................................................................................... 3

Required Parts .................................................................................................................................. 4

Required Items .................................................................................................................................. 4

1064-2-3 Installation .......................................................................................................................... 4

Table of Figures

Figure 1 1064-2-3 PCB, Inductor, Adapter, Assembly View ............................................................ 4

Figure 2 1064-2-3 PCB, Inductor, Adapter, Assembly Installed ............................................................ 5




Replacement of Toko Inductor L7

Objective of Change

The objective of this change is to replace obsolete through hole Toko Inductor p/n 5PNR-T1021Z placed as designator L7 with an adapter PCB designed to accommodate a replacement surface mount Toko Inductor p/n 614AN-9561Z.

Background

When a suitable replacement for original L7 Toko Inductor was found the mounting style changed from through hole to surface mount with a value change from 680uH to 560uH. This change resulted in necessary modifications to place L7 on current and existing 1064-2-1 and 1072-3-2-1 PCBA’s. New Toko Inductor concurrently. To correct this issue the 1064-2-3 PCB, Inductor, Adapter, Assembly was created as a drop-in replacement to fit existing Inductor L7 mounting location while necessitating the change in value for capacitor C21 from 180pH to 220pH on all 1064-2-1 and 1072-3-2-1 Receiver PCBA’s. The 1064-2-3 PCB, Inductor, Adapter will ultimately extend the maintenance life of existing units.




Warning: The circuit board assemblies of the Receiver are susceptible to damage from Electro Static Discharge (ESD). Observe proper ESD procedures while performing this update.

Warning: Ensure power is disconnected form the Receiver while performing the upgrade.

Required Parts

(1) 1064-2-3 PCB, Inductor, Adapter, Assembly (1) (C110-220-00) Capacitor, 220pf NPO, SMD

(1.5”) #24AWG, Buss-wire

Required Items

• Soldering equipment w/ Rosin Core Solder • Clear 732 RTV Sealant.

1064-2-3 Installation

1. After the 1064-2-1 or 1072-3-2-1 Receiver PCBA has been removed from the unit following cautions and warning outlined above perform the following procedure to install the 1064-2-3 PCB, Inductor, Adapter, Assembly.

2. De-solder “L7” 680µH Inductor on the 1064-2-1-1 any Revision PCB and discard.

3. De-solder “C21” Capacitor, 180pf and discard.

4. Ensure solder is removed from all through holes of “L7” and then hand clean PCB using MEK where work has been done

5. Solder new “C21” Capacitor, 220pf in place.

6. Apply small dab of clear RTV 732 sealant to bottom side of 1064-2-3 under “L1” installed inductor prior to soldering buss wire keeping “J1” and “L7” mounting holes free of RTV.

7. Align “J1” of 1064-2-3 assembly over L7 as shown pressing firmly to set the RTV.

8. Feed #24AWG buss-wire through mounting holes “J1” and “L7” and solder buss-wire in place, then cut buss-wire and repeat for each of (7) mounting holes. Ensure buss-wire is soldered (7places) on top of 1064-2-3 PCBA and bottom side of 1064-2-1-1 PCB.

Figure 1 1064-2-3 PCB, Inductor, Adapter, Assembly View

SOLDER #24 Buss-wires BOTH SIDES

1064-2-3 PCB, Inductor, Adapter, Assembly

Clear 732 RTV SEALANT

L1 J1

L7

1064-1-1-1 PCB All Revisions




9. Hand clean all solder joints and mask inductor L7 before using a brush to apply Humiseal 1B73 Conformal Coating to all rework areas.

Figure 2 1064-2-3 PCB, Inductor, Adapter, Assembly Installed

L7

Technical Service Number: TSB-0012 Bulletin (TSB) Page: 1 of 5

TITLE: 1072 RECIEVER

Rothenbuhler

Engineering

Rothenbuhler Engineering Proprietary Notice This document contains information which is the exclusive property of Rothenbuhler Engineering. Distribution, reproduction, or use by others is not permitted without the express written consent of Rothenbuhler Engineering.

Signature Date

Author Gary McCoy – Signature on File 2/13/14

Approved Rich Taft – Signature on File 2/13/14

Document #: TSB0012 Rev A File Name: TSB0012 REV A – 1072 Interconnect Board.PDF



REVISION HISTORY SHEET

ISSUE

DATE

REASON FOR CHANGE REVISED BY PAST ISSUE

STATUS

A 2/13/14 Remove the Venting “NIB” from K1 (R050-083-00) and K2 (R050-085-00) after all spraying and/or washing is complete for all new and existing 1072 Receivers.

GM C

PAST ISSUE STATUS: C = CURRENT; O = OBSOLETE



Table of Contents Revision History Sheet .......................................................................................................................... 2 Table of Contents .................................................................................................................................. 3

Table of Drawings ................................................................................................................................. 3

Objective of Change ............................................................................................................................. 4

Background ........................................................................................................................................... 4

Replacement Instruction ECO 3659 ...................................................................................................... 4

Rework Instructions from ECO 3659 ..................................................................................................... 4

Table of Drawings 1072-3-4-B0 Rev K Assembly .............................................................................................................. 5



Rothenbuhler Engineering Service Center Information Packet 1072 Receiver

Objective of Change The objective of this change is to improve the performance and longevity of the 1072 Whistle Receiver relays on all new and existing 1072 Receivers.

Background Relay K1 has had ongoing issues with sticking contacts in the field. The relay manufacturer recommends that the venting “NIB” be removed to allow pressure relief and maximize electrical longevity. Relay K2 should also be vented.

Replacement Instruction ECO 3659 1) 1072-3-4 Interconnect Board Assembly

a. If replacing components K1 Relay, 5v, SPDT, 20A (T90S5D12-5) (R050-083-00) and/or K2 Relay, 12 VDC, mini (RoHS) (R050-085-00) remove and install new components.

b. After installation it is necessary to clean and spray work area with humiseal, making sure components are masked properly as described in notes on the 1072-3-4-B0 Rev K Assembly Figure 1 drawing.

c. After cleaning and spraying has been performed remove venting “NIB” with a sharp knife. Refer to 1072-3-4-B0 Rev K Assembly Figure 1 for “NIB” location.

Rework Instruction from ECO 3659 1) 1072-3-4 Interconnect Board Assembly

a. Remove venting “NIB” with a sharp knife on K1 Relay, 5v, SPDT, 20A (T90S5D12-5) (R050-083-00) and/or K2 Relay, 12 VDC, mini (RoHS) (R050-085-00) as units come in for repair or for routine service. Venting “NIB” is shown on 1072-3-4-B0 Rev K Assembly Figure 1 as a reference when removing.



1072-3-4-B0 Rev K Assembly Figure 1

Number: AMP-126

Manufacturing Process Revision: C

Specification (AMP) Page: 1 of 6

TITLE: 1063-1-3 SWITCH ASSEMBLY

NAME FUNCTION SIGNATURE DATE

PREPARED BY: Gary McCoy Document Control Signature on File 6-18-15

AUTHORIZED BY: Rich Taft Engineering Manager Signature on File 6-24-15

Deborah Gregory Production Coordinator Signature on File 6-18-15

Steve Winters Operations Manager

Quality Manager Signature on File 6-24-15

Glenda Ransberger Production Supervisor Signature on File 6-18-15

Rothenbuhler Engineering Proprietary Notice

This document contains information which is the exclusive property of Rothenbuhler Engineering. Distribution, reproduction, or use by others is not permitted without the express written consent of Rothenbuhler Engineering.

Number: AMP-126




REVISION HISTORY SHEET

ISSUE

DATE

REASON FOR CHANGE

REVISED BY

PAST ISSUE

STATUS

A 07/12/07 Initial Release NA O

B 6/8/09 Update instructions to clarify that the cork washer is used. Included lock washer is not used.

LLN O

C 6/26/15 Changed # of ties in assembly from 4 to 2. Specified orientation of wire routing for use in the 1100 assemblies. Updated Switch Illustration 1-1.

GMM C

PAST ISSUE STATUS: C = CURRENT; O = OBSOLETE

Number: AMP-126




1. PURPOSE

1.1. This work procedure is for the preparation and assembly of the switch.

2. SCOPE

2.1. This work instruction procedure covers the tools required, drawings to be referenced, and instructions to be followed in the factory’s preparation and assembly of the switch.

3. RESPONSIBILITY

3.1. The Assembly Supervisor will update this work instruction as required.

3.2. The Production Supervisor, Quality Manager, Engineering Manager, and Operations Manager will approve any changes to this instruction by signing the cover sheet.

3.3. Document Control will maintain this instruction on the Quality drive such that only the most current version is available to all relevant workers.

3.4. The Production workers will reference this work instruction when preparing and assembling the sub-components of the switch.

4. DEFINITION

4.1. None

5. REFERENCES

5.1. Part Number: 1063-1-3

5.2. Description: Switch Assembly

5.3. Drawing Number: 1063-1-3-AO Revision: current revision

Number: AMP-126




6. PROCEDURE

6.1. Special Tools and Supplies Required: (All tools should be calibrated as required per the calibration schedule)

6.1.1. needle nose pliers

6.1.2. dikes (diagonal cutters)

6.1.3. ruler

6.1.4. crimping tool # 90289-1

6.1.5. rosin core wire solder

6.1.6. solder iron

6.1.7. switch wiring jig

6.1.8. Paladin wire strippers (or equivalent)

6.2 Work Instructions (Per approved drawings, assemble sub-components as follows):

6.2.1 Cut 24 AWG wires to 7 ¼” lengths. WIRE LENGTH IS CRITICAL.

6.2.2 Strip wire insulation 1/8” on one end.

6.2.3 Use the 90289-1 crimping tool to attach a connector pin to each of the stripped ends. Have crimped pins inspected.

6.2.4 Insert the connector pins into housing as shown on drawing.

6.2.5 Strip the insulation on opposite end of wires ¼” and tin.

6.2.6 Cut 20 AWG buss wire to 2” lengths.

6.2.7 Place (2) switches into the switch wiring jig as oriented on drawing (terminal 2 is away from you, terminal 1 is towards you, terminal 3 is to the left, and terminal 4 is to the right).

6.2.8 Solder the 20 AWG buss wire between terminal 4 of left switch and terminal 3 of right switch as shown on drawing. The wire shall run through the hole in the terminal and be wrapped to contact both sides of the terminal. Solder the buss wire to the switches so that the wire has an “S” in it for stress relief. Do not completely fill the pin 3 hole with solder as you will need to solder the brown wire to this same pin.

Number: AMP-126




6.2.9 Solder the 24 AWG wires to the appropriate terminals. These wires need to be attached in the same manner; the wire shall run through the hole in the terminal and be wrapped to contact both sides of the terminal.

Red = pin 3 of left switch

Brown = pin 3 of right switch

Orange = pin 4 of right switch

6.2.10 Attach (2) cable ties to switch assembly as shown in illustration below.

Illustration 1-1

Number: AMP-126




6.2.11 Install the cork washer and a nut on each switch (hardware included; if lock washer is included it can be disposed of).

6.2.12 Deliver completed switch assemblies to inspection. Inspector will inspect and test switches then return them for conformal coating process.

6.2.13 Using cardboard switch holder jig located in cabinet; insert switches into holes wire side up and keep all the switch assemblies aligned in the same direction.

6.2.14 Place switches in conformal coating booth, push-button of switch facing down. Spray only the back side of switches with Humiseal 1B73 Conformal coating. Do not spray connector housing or push-button side of switch.

7. Attachments

7.1. None

NOTE(S) (UNLESS OTHERWISE STATED):

2. SKIVE FOAM FOR LOWER LAYER TO 0.500".3. USE REMAINING 2.000" FOR UPPER LAYER, THEN DIE CUT.

MATERIAL = 2.5" 1.7 CHARCOAL POLYETHYLENE FOAM.

1. CHAMFER CORNERS BEFORE SKIVING.

REFER ECO 3691A

7

D

C

B

AA

B

C

D

1234568

8 7 6 5 4 3 2 1

E

F

E

F

1678-18-1-D5SHEET 1 OF 5

4/22/13Gary McCoyUNLESS OTHERWISE SPECIFIED:

SCALE: 4:5 F300-322-00

REVDWG. NO.

DSIZE

TITLE:

DATE

APPROVED

ELEC.

MECH.

CHECKED

DRAWN

DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL ±ANGULAR: MACH ± BEND ±TWO PLACE DECIMAL ±THREE PLACE DECIMAL ±

APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIALTHE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFROTHENBUHLER ENGINEERING. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFROTHENBUHLER ENGINEERING IS PROHIBITED.

A

ROTHENBUHLER ENGINEERINGRHODES ROAD - SEDRO WOOLLEY, WASHINGTON - 98284

BREAK ALL SHARP EDGESALL DIMENSIONS TO ASME Y14.5'94 ALL MACHINED SURFACES

ALL ANGLES AND BENDS 90 °

CONSTRUCT IN ACCORDANCE WITHIPC/IEA J-STD-001C CLASS IIIINSPECT IN ACCORDANCE WITHIPC-A-610C CLASS III

APPROVEDDATEDESCRIPTIONLTRREVISIONS

8 POSITION FOAM SET, UPPER LAYER0.010

0

0.75

01.

250

2.85

03.

450

7.87

58.

525

8.67

59.

150

9.27

59.

400

9.85

010

.039

15.5

5016

.450

16.6

6416

.789

16.8

2516

.907

16.9

8817

.113

17.2

0017

.428

18.0

8618

.725

18.7

7518

.925

19.0

1219

.137

19.2

1919

.300

19.4

7519

.675

20.5

75

26.1

0026

.275

26.7

2526

.850

26.9

7527

.450

27.6

0028

.250

32.1

7532

.775

34.8

75

35.6

25

00.6120.7191.674

2.6743.1123.4873.5693.6193.7374.2464.3754.4374.4876.9967.1257.1877.3007.7547.8268.2638.6198.9349.1269.2519.3269.826

10.50410.57610.70011.26311.45011.95012.26313.01313.625 R0.437

NOTE 14 PLACESR0.125

130 PLACES

0

2.000

Gary McCoy 6/25/14

Rich Taft 6/25/13

LOWER LAYER MATERIAL = 0.5" 1.7 CHARCOAL POLYETHYLENE FOAM.

1. DIE CUT WITH SKIVE SIDE DOWN.NOTE(S) UNLESS OTHERWISE STATED:

0.010

D

C

B

AA

B

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

1678-18-1-D5SHEET 2 OF 5

8 POSITION FOAM SET,LOWER LAYER


SCALE: 4:5 F300-322-00

REVDWG. NO.

DSIZE

TITLE:

DATE

APPROVED

ELEC.

MECH.

CHECKED

DRAWN


APPLICATION

USED ONNEXT ASSY


A






C

00.500

00.612

1.674

2.5002.6743.112

4.4874.650

7.3007.826

8.9348.9759.1269.2519.826

10.07610.57610.70011.12511.20011.26311.45011.95012.26313.01313.625

0

1.00

0

3.45

0

8.52

58.

675

9.15

09.

400

9.85

0

16.4

5016

.789

16.8

2516

.907

16.9

8817

.113

17.2

0017

.428

18.0

8618

.775

18.9

2519

.012

19.1

3719

.219

19.3

0019

.675

26.2

7526

.725

26.9

7527

.450

27.6

00

32.1

75

35.6

25

R0.12578 PLACES

Gary McCoy 6/25/14

6/25/13Rich Taft

(2.00" PEAK, 0.75" VALLEY, 2.75" OVERALL)CASE TOP FOAM MATERIAL = CONVOLUTED POLYURETHANE CHARCOAL FOAM, PU90

0.010

A

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

1678-18-1-D5SHEET 3 OF 5

8 POSITION FOAM SET,TOP FOAM


SCALE: 1:2 F300-322-00

REVDWG. NO.

DSIZE

TITLE:

DATE

APPROVED

ELEC.

MECH.

CHECKED

DRAWN


APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIAL

A






THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFROTHENBUHLER ENGINEERING. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFROTHENBUHLER ENGINEERING IS PROHIBITED.

0

35.3

75

0

13.604

Gary McCoy 6/25/14

6/25/13Rich Taft

USE MATERIAL FROM 2.0" CUT OUTS AND SKIVE FOR CORRECT SIZE1.OF INSERT. PRESERVE NON SKIVE SIDE.

NOTE(S) UNLESS OTHERWISE STATED:

0.010

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

1678-18-1-D5SHEET 4 OF 5

8 POSITION FOAM SET,INSERT


SCALE: 2:1 F300-322-00

REVDWG. NO.

DSIZE

TITLE:

DATE

APPROVED

ELEC.

MECH.

CHECKED

DRAWN


APPLICATION

USED ONNEXT ASSY


A






5.700

1.50

0

R0.1254 PLACES

5.700

0.80

0

0.800

1.50

0

Gary McCoy 6/25/14

6/25/13Rich Taft

1. CENTER UPPER LAYER SKIVE SIDE DOWN ON TO LOWER LAYER SKIVE SIDE DOWN AND HEAT WELD LAYERS TOGETHER.THEN CHAMFER AT A 45° ANGLE SO THAT EACH BOTTOM EDGE HAS 0.500" REMOVED.

2. PLACE INSERT 1 WITH SKIVE SIDE DOWN AND WELD.

NOTE(S) UNLESS OTHERWISE STATED:

3. RETAIN BLOCKS WITH SKIVE SIDE DOWN. DO NOT WELD.

0.010

4. AFTER ASSEMBLY MAKE FINAL CUT AS SHOWN IN SECTION A-A.

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

1678-18-1-D5SHEET 5 OF 5

8 POSITION FOAM SETASSEMBLY


SCALE: 1:2 F300-322-00

REVDWG. NO.

DSIZE

TITLE:

DATE

APPROVED

ELEC.

MECH.

CHECKED

DRAWN


APPLICATION

USED ONNEXT ASSY


A






4.65

0

2.15

0

4.65

0

2.15

0

AA

0.30

0

1.000

SECTION A-A

SCALE 1 : 1

NOTE 4

NOTE 3

NOTE 38 PLACES INSERT 1

NOTE 24 PLACES

12

34

56

78

0.50

0

0.500

NOTE 1

Gary McCoy 6/25/14

6/25/13Rich Taft

drawing samples 1063, 1670, 1673, 1674 solidworks acad

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