Packing the MagAO-X Table at SO for Shipment

This procedure describes how to pack MagAO-X optical table for shipment at Steward Observatory.

Estimated Time to Complete: 3 hrs

Safety

  • All participanets must wear safety shoes

  • Hard hats must be worn when using an overhead crane at the loading dock

Advanced Preparations and Scheduling

  • Ensure the boxes, cart, and dollies are obtained from storage ahead of time

  • Schedule delivery of a telehandler forklift.

  • Obtain the gantry crane from URIC. It may need to be washed (i.e. take to a car wash).

  • Order dessicant, thermal blankets, shrink wrap, and tape as needed

  • Verify all cart hardware is in-hand

  • Verify two wire harnesses are in hand

Initial Conditions

  • The optical table is in the cleanroom, fully disconnected from the control electronics.

Preparations

  • While still powered up, secure all optics for transport

  • Check that all components on table are securely fastened.

  • Power down all of MagAO-X

    • Ensure that stagepickoff in the out position.

    • Place the k-mirror at 180 degrees.

    • Select the CH4-Cont and CH4-875 filters on fwsci1/2

    • turn off power for all devices on MagAO-X following the regular shutdown procedure.

    • use the shutdown -h now command to halt both RTC and ICC

    • once the computers are off, turn off all things in the rack.

  • Remove blower hose and cover the hole.

  • Remove all cables

    • See detailed procedure for removing 2K DM cables

  • Tape over any cable holes, and secure any protruding cables.

  • Install dessicant.

  • Shrink-wrap the instrument.

  • Install the reflective blanket for solar shielding.

  • Remove cleanroom walls and roll the cleanroom over the testbed.

  • Lower table legs onto the casters by turning the 16 leveling bolts, and remove the metal pads

  • Ensure the area around the table is clear.

Rig Onto Cart

  • Setup the gantry crane in the hallway, at lowest setting, being sure to follow the marks

  • Move the gantry into the lab

  • Raise the gantry to the highest setting that the ducts will allow

  • Strap the two chain hoists onto the gantry

  • Move the gantry over MagAO-X, being sure to control the chains

  • Assemble the cart around MagAO-X, matching the corner labels

  • All bolts should be slightly loose at this point

  • Raise the cart with chain hoists attached to the wire lifting triangles, ensuring it does not hit the table legs

  • Install 4 bolts on the outboard side of the pads. Tighten.

  • Now tighten all bolts on the cart. Tighten until the washer stops moving, then back off 1/4 turn. This is avoid unnecessary stress on the table.

  • Now lift the table+cart off the legs. Do not go too high until all 4 pads have disconnected from the legs.

Prepare the Box.

  • Move the empty box and shipping frame into the unpacking room with the forklift, placing it on 4 furniture dollies.

    ../_images/box_forking.jpg

    The instrument box is brought to the unpacking area with the forklift.

    ../_images/box_dollies.jpg

    The instrument box being set down on dollies with the fork lift. Note the placement and orientation of the dollies.

  • Move the box towards the inside garage door, and stage 4 more dollies to accept the lid.

    ../_images/box_for_lid_removal.jpg

    Box in position to have the lid removed.

  • Remove the front panel from the box, place out of the way (e.g. outside).

  • Remove all bolts holding the lid to the pallet

  • Place the straight extension on the lifting fixture, and place it in the box-lid position.

  • Attach the lifting fixture to the lid.

  • Lift the lid with the crane, and set it down on the dollies.

    ../_images/lid_off.jpg

    Box lid off, on dollies.

  • Move the pallet into the cleanroom to make room to maneuver the lid.

  • Then move the lid out of the way, e.g. outside on the lift.

Installing The Instrument On The Frame

  • Move the pallet and frame towards the front of the unpacking room.

  • Bring the instrument and cart out of the cleanroom.

    NOTE: position the cart so that the taller heavier side of the instrument will set down on the side of the frame with the most wire-rope isolators.

  • Install the scale between the load spreader and the crane, and place the lifting fixture in the instrument+cart position.

  • Install the triangle stabilizing rope ratchets, leaving them loose.

    ../_images/lifting_fixture_install.png

    Preparation of the lifting fixture.

  • With the crane, carefully position the load spreader over the table.

    NOTE: be sure to guide both ends of the load spreader so it does not contact the instrument

  • Attach the load spreader to the cart. Two shackles are used to extend the length. The hooks should be placed opening up.

    ../_images/cart_lift_extensions.jpg

    Use two shackles for correct length.

    ../_images/cart_hooks_up.png

    Hooks must open up on the cart to get the correct length.

  • Lift the instrument+cart, which weigh 1920 lbs, until all 4 wheels are off the ground. If it is out of balance, it will be necessary to manually correct.

    ../_images/inst_cart_lift.jpg

    Lifting the instrument on its cart.

  • Adjust the load spread to find the best balance.

  • Tighten the triangle stabilizing rope ratchets.

  • With a person on each end stabilizing using the cart handles, lift the instrument to sufficient height to clear the shipping frame.

  • Carefully roll the pallet and frame under the instrument

  • Lower the instrument slowly to just touch the frame, but do not unload the crane.

    ../_images/inst_on_frame.jpg

    The instrument on the frame.

  • While the instrument is still supported by the crane, start bolts at each corner to guide the instrument down.

  • Lower the instrument until half the weight is off the crane.

  • Start all bolts, including installation of the Emerson Clamp base plates.

  • Fully lower the instrument, such that the crane is still supporting the cart weight of 320 lbs

  • Tighten all bolts holding the instrument to the shipping frame.

    ../_images/bolt_tightening.jpg

    Tightening the bolts.

  • Remove the 8 bolts holding the cart to the table.

  • Lower the cart so that it rests on the pallet.

    ../_images/cart_on_pallet.jpg

    The cart lowered onto the pallet.

  • Disassemble the cart, moving the pieces to storage area.

  • Install the Emerson Clamps.

  • Arm all drop-n-tells, and install the data loggers.

Install the Lid and Door

  • Move the pallet and instrument on the dollies back into the cleanroom to make space for the lid

  • Bring the lid back into the unpacking area and position it to be lifted on. The open side goes towards the MagAO-X label on the instrument.

  • Put the load spreader back in the position to balance the lid, and attach it with the crane to the lid.

  • Lift the lid, and roll the instrument under the box.

  • Set the lid down on the pallet

    ../_images/inst_inside_box.jpg

    MagAO-X on the shipping frame inside the box.

  • Install the bolts along the bottom of the lid, securing it to the pallet.

  • Bring the front door panel back inside, and lift it into position.

  • Bolt the lid on.

  • Remove the lifting eyes from the box lid and stow them on the lower left insspection panel.