User:Jrkenti/TST-WI-061

AKR Flash Assembly Work Instruction explains the proper way to assemble a Flash reactor.

= Materials = This section describes the tools and the consumables needed to execute this work.

Tools
Consult with a lead or engineer if you are unsure of the proper tool for any particular step.
 * 1) Small Torque Screwdriver – 3 in-lbs (for control board screws)
 * 2) Medium Torque Screwdriver – 10 in-lbs (for single clamshell screw)
 * 3) Large Torque Screwdriver with 11/16” hex socket - 13 in-lbs (for NPT fittings)

Inputs

 * 1) Parts per DEV-BOM-005

Outputs

 * 1) Assembled Flash Reactor, ready for testing according to TST-WI-062

= Process = Klaran WS (Flash) units can be assembled one at a time start to finish, or sub-assemblies can be made and each reactor can involve just assembling the completed sub-assemblies. If building sub-assemblies, build 20 of each sub-assembly before starting any final assembly.

Prepare

 * 1) Collect 20 AKR reactors from finished goods
 * 2) Sit down at a computer work station with a label printer (loaded with white 0.75x2.25" stickers), and with ActiveBarcode properly installed.
 * 3) Open & log into Unipoint and download a new copy of the Flash traveler (TST-F-049) from Unipoint.  A VBA macro should immediately begin, follow its instructions.
 * 4) SCAN AKR serial numbers onto log sheet
 * 5) SELECT the correct power adaptor in the dropdown on the traveler
 * 6) PRINT the log sheet & barcodes

NPT Fitting Sub-Assembly

 * 1) UNBOX the AKR, discard the bubble bag, recycle the box and set aside the ESD bag
 * 2) Using a section of ¼” tubing with some print on it, WRAP ¼” wide Poly-Temp HD PTFE Tape around the tube 5 times by spinning the tube as shown. Use the print on the tubing as a guide to count the turns of the tubing.
 * 3) TEAR the tube and tape away from the roll with a quick tug.
 * 4) APPLY the PTFE tape to the middle of the NPT threads on the AKR in a clockwise direction when viewing from the open end of the NPT fittings, as shown.
 * 5) REPEAT the above steps for both NPT fittings on the AKR.
 * 6) Hand TIGHTEN two NPT to ¼” PTC fittings to the AKR ports
 * 7) SNUG fittings using the large torque screwdriver with 11/16” socket set to 13 in-lbs. Continue turning the screwdriver slowly until it clicks several times in a row.

Tubing PTC Sub-Assembly

 * 1) PUSH one PTC coupler onto the end of the tubing
 * 2) The tubing must seat fully into the PTC fitting
 * 3) PUSH one PTC coupler onto the end of the flow sensor:
 * 4) The orientation is critical
 * 5) The PTC fitting must be on top, with the arrow on the flow sensor facing down
 * 6) The flow sensor must seat fully into the PTC fitting
 * 7) PUSH the tubing into the port closest to the metal end of the AKR:
 * 8) The tubing must seat fully into the port
 * 9) PUSH the flow sensor into the port furthest from the metal end of the AKR
 * 10) The flow sensor must seat fully into the port

Control Body Sub-Assembly

 * 1) ATTACH the AKR connector, making sure the tab locks.
 * 2) CONNECT the flow sensor wire
 * 3) BEND the wires as shown to accommodate cable length
 * 4) If the flow sensor is not in the same orientation as shown in the image to the right, it was installed backwards, and needs to be reversed.
 * 5) PLACE one #6 x 1/2” Long Type A/AB Tapping Screw into backside enclosure half
 * 6) PLACE the backside of the enclosure into a nested condition with the frontside of the enclosure
 * 7) TIGHTEN #6 screw using the medium torque screwdriver set to 10 in-lbs while holding the enclosure together with your other hand
 * 8) Be careful to avoid any cable pinches!
 * 9) PLACE the assembled Flash unit back in the AKR bag, PTC side down
 * 10) ISOLATE any failed components immediately.  Do not discard.
 * 11) Any failed parts should be segregated into the non-conforming bin, and labeled with the date and non-conformance.
 * 12) Parts that fail may need to be investigated with the manufacturer by the area engineer.

= Quality Assurance =

Required Signees for Document Approval

 * Me: Jrkenti (talk) 02:49, 25 March 2022 (UTC)
 * Joe Schmoe: Joe (talk) 23:14, 7 April 2022 (UTC)
 * Kermit the Frog: unsigned
 * Document Control: unsigned