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

Left to right, the small, medium and large torque drivers.

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. 

   A photograph of AKR box and barcode
   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.
   1. SCAN AKR serial numbers onto log sheet
   2. SELECT the correct power adaptor in the dropdown on the traveler
   3. PRINT the log sheet & barcodes

NPT Fitting Sub-Assembly

1. 

   A photograph of AKR box and barcode
   UNBOX the AKR, discard the bubble bag, recycle the box and set aside the ESD bag
2. 

   A photograph PolyTemp HD tape

   

   A photograph of the tape wound around the tubing
   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. 

   A pretty picture of gloved hands.
   TEAR the tube and tape away from the roll with a quick tug.
4. 

   A picture of a person winding the tape around the NPT fitting.

   

   A photograph of the tape on the NPT fitting.
   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. 

   NPT-to-PTC fittings

   

   A photograph of the NPT fittings on the AKR.
   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. 

   A PTC-to-PTC fiting

   

   A piece of tubing

   

   The assembled tubing and PTC fitting
   PUSH one PTC coupler onto the end of the tubing
   1. The tubing must seat fully into the PTC fitting
2. 

   The PTC fitting on the flow sensor
   PUSH one PTC coupler onto the end of the flow sensor:
   1. The orientation is critical
   2. The PTC fitting must be on top, with the arrow on the flow sensor facing down
   3. The flow sensor must seat fully into the PTC fitting
3. 

   The AKR with the tubing and flow sensor
   PUSH the tubing into the port closest to the metal end of the AKR:
   1. The tubing must seat fully into the port
4. PUSH the flow sensor into the port furthest from the metal end of the AKR
   1. The flow sensor must seat fully into the port

Housing and Control Board Sub-Assembly

1. 

   Control board and four #4 screws
   PLACE one #4 x 5/16” self-tapping screw through the hole in each corner of the control board
2. 

   Control board screwed into the clamshell housing

   

   Picture of the board with the screws numbered
   PLACE the control board with the black external port facing out of the rectangular opening in the housing
3. ENSURE the board sits flat before tightening screws
4. TIGHTEN the screws in the order shown in the picture, using the small torque screwdriver set to 3 in-lb

Control Body Sub-Assembly

1. 

   AKR wire attached to control board

   

   AKR wire attached to AKR and flow sensor
   ATTACH the AKR connector, making sure the tab locks.
2. CONNECT the flow sensor wire
3. 

   Wires wrapped they they will fit in the box nicely.
   BEND the wires as shown to accommodate cable length
   1. 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.
4. 

   Clamshell lid with one #6 screw.

   

   Image of the sub assembly being screwed together.
   PLACE one #6 x 1/2” Long Type A/AB Tapping Screw into backside enclosure half
5. PLACE the backside of the enclosure into a nested condition with the frontside of the enclosure
   1. TIGHTEN #6 screw using the medium torque screwdriver set to 10 in-lbs while holding the enclosure together with your other hand
   2. Be careful to avoid any cable pinches!
6. PLACE the assembled Flash unit back in the AKR bag, PTC side down
7. ISOLATE any failed components immediately. Do not discard.
   1. Any failed parts should be segregated into the non-conforming bin, and labeled with the date and non-conformance.
   2. Parts that fail may need to be investigated with the manufacturer by the area engineer.

Quality Assurance

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The content of the document, and every subsequent change, needs to be approved by the team shown below.

The content should also be reviewed annually for accuracy and applicability.

• Records of reviews are stored and recorded on this Review Sub-Page.

Training against this document should be preformed annually for relevant employees.

• Records of trainings are stored and recorded on this Training Sub-Page.

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

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