TECHNICAL INNOVATIONS TEC-PD10 Manual

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PARTS LIST PD-10 .......................................................................................................5

1. Introduction to Instructions ..........................................................................................9

Foundation ...................................................................................................................................9

Foundation bolts ...........................................................................................................................10

Installation Practices ....................................................................................................................10

2. Safety Precautions ........................................................................................................11

Fiberglass .....................................................................................................................................11

Construction and Operation Cautions ..........................................................................................12

3. Special Assembly Instructions .....................................................................................13

Nomenclature ...............................................................................................................................13

Locating Holes .............................................................................................................................13

Drilling and Bolting .....................................................................................................................14

Leveling the Foundation, Wall, and Base Rings ..........................................................................15

Leveling with Carpenter Level .....................................................................................................15

Leveling with Water Level...........................................................................................................16

Making the Observatory Circular, and maybe Centered ..............................................................16

Stainless Steel Cable ....................................................................................................................17

4. Wall Construction. .......................................................................................................18

Wall/Base Ring & Semi-Door Assembly Preparation .................................................................19

First Ring Assembly .....................................................................................................................20

Installing First Ring on Foundation .............................................................................................21

Alternative Ways to Stack Wall Rings/Base ring ........................................................................22

Base Ring Installation ..................................................................................................................23

Door and Hinge Completion ........................................................................................................24

Latch Installation ..........................................................................................................................24

Roller Mounting ...........................................................................................................................25

Support Rollers ............................................................................................................................25

Side Rollers ..................................................................................................................................25

Wall Bracing ................................................................................................................................26

5. Shutter, Rear Cover, DSR Preparation ........................................................................27

Front Shutter Preparation .............................................................................................................27

Security and Locks .......................................................................................................................28

Top Shutter Preparation and Latches ...........................................................................................29

Top Shutter Restraint System J-Guides .......................................................................................29

Rear Cover Preparation ................................................................................................................30

Electric Shutter .............................................................................................................................30

Shutter Catchers ...........................................................................................................................30

Dome Support Ring (DSR) ..........................................................................................................30

6. Dome Construction ......................................................................................................32

Overview of the Action ................................................................................................................32

Dome Quad Assembly .................................................................................................................32

Rear Cover ...................................................................................................................................33

Shutter Installation and Initial Operation .....................................................................................36

7. Finish Work .................................................................................................................38

Shutter Restraint System ..............................................................................................................38

DSR Swingout Safety Brackets. ..................................................................................................39

Soffit. ...........................................................................................................................................40

Anti Rotation Bolts. .....................................................................................................................40

Caulking .......................................................................................................................................40

Instruction Sheet ..........................................................................................................................41

8. Problem Solving...........................................................................................................42

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Page 1: Table Of Contents
TABLE OF CONTENTS PARTS LIST PD-10 .......................5 1. Introduction to Instructions ..................9 Foundation ...........................9 Foundation bolts ...........................10 Installation Practices ........................10 2. Safety Precautions ......................11 Fiberglass .............................11 Construction and Operation Cautions ..................12 3. Special Assembly Instructions ..................13 Nomenclature ..........................13 Locating Holes ..........................13 Drilling and Bolting ........................14 Leveling the Foundation, Wall, and Base Rings ................15 Leveling with Carpenter Level .....................15...
Page 2 Dome Rotation Problems ......................42 Shutter Engagement Problems .....................43 Shutter Dis-engagement Problems ....................43 Shutter Blow-off ..........................44 Base Ring Service ........................45 9. Use and Care of your PRO-DOME ................46 APPENDICES INSTRUCTIONS FOR OPTIONAL ITEMS Figures 1-24 Electric Shutter Bolt Hole Drilling Guide Electric Dome Drive Shutter Pole Design Power Supply...
Page 3: Parts List Pd-10
PARTS LIST PD-10 FIBERGLASS PIECES Right Quadrant (2) Left Quadrant (2) Dome Support Ring Sections (4 w/door swingout) Rear Cover (1) Top Shutter (1) Front Shutter (1) Base Ring Sections (6, includes molded door and two stub sections) Wall Ring Sections (6, includes molded door and two stob sections), for each ring FITTINGS AND HARDWARE Stainless Steel Carriage Bolts Stainless Steel Flat Head Bolts...
Page 4 TOOLS AND HARDWARE TO BE PROVIDED BY INSTALLER, NOT INCLUDED WITH PD-10 3/8 in electric drill with set of bits (2 drills are even more efficient) Countersink (82 deg. preferred) File or rasp Metal rule (25 ft. or longer) Carpenter level or water level Hand tools: clamps, screw drivers, socket wrench set, etc.
Page 5 TYPICAL HD/PD ASSEMBLY PROCESS 03/11/97 Read Instruction Book Check parts against parts list Dome Assembly (Non-Windy Day!) Wall Assembly Prepare Foundation Check level/draw base ring circles Mark and drill foundation bolt holes Prepare Quadrants Equatorial Flange- drill in dimples Prepare Base Ring/Wall Ring(s) Greenwich Flange-drill in dimples Drill and Assemble Assemble Right/Left Pairs...
Page 6 STAINLESS STEEL BOLT COUNT FOR PD-10 BOLT 2.25” 1.5" 1"CB 3/4"FH 3/4"CB NUTS WASHERS LOCATION BASE RING D.S.R. DOME- EQ. FLANGE GREENWICH FLANGE REAR COVER FRONT/REAR LATCH SHUTTER CATCHERS HANDLES WHEELS SHUTTER STOP BOLTS TOTALS *3/8” bolts PD-10 WALL RING BOLTS (for each ring) SCREW LESSON The outer diameter of...
Page 7: Introduction To Instructions
1. Introduction to Instructions The assembly of the PRO-DOME involves several steps. These include: • obtaining necessary permits • building the foundation • assembling the wall (if any) • installing the base ring and rollers • assuring that the top of the wall is level •...
Page 8: Foundation Bolts
Foundation bolts Selecting the appropriate foundation bolts to hold the bottom ring to your surface is your responsibility. The most common bolts are lag bolts into anchors in a concrete pad, or carriage bolts through a wood deck. In all cases, it is absolutely necessary to use washers at least 1 1/2-inch diameter under the bolt heads.
Page 9: Safety Precautions
2. Safety Precautions Constructing a PRO-DOME requires you to follow several safety precautions and use common sense, since the activity does include mechanical and manual operations. Care is needed in the use of tools and you should follow the precautions provided by the manufacturers of any tools you may use.
Page 10: Construction And Operation Cautions
gloves to be on the safe side. Of course, the surfaces of the FRP are smooth, because they have been coated with a layer of resin (called Gel-coat) that covers the glass. Fiberglass dust can irritate the eyes and skin. When cutting or trimming or filing or drilling -- in short, whenever doing something to the FRP that makes dust -- always use gloves and eye protection.
Page 11: Special Assembly Instructions
3. Special Assembly Instructions This section contains special instructions that apply to several parts of the assembly and to special hardware issues. We have written these for the relatively unskilled assembler. However, even those who are skilled in carpentry or other mechanical assembly SHOULD read and follow these instructions, especially concerning leveling the structure.
Page 12: Drilling And Bolting
Failing this may cause interference, or may cause you to run out of the proper bolts later in the assembly process. FIG 1 Drilling and Bolting Many PRO-DOME parts are held together with carriage bolts or flat head bolts, 3/4 or 1 inch long.
Page 13: Leveling The Foundation, Wall, And Base Rings
However, be careful not to go too deep. Also, note that the angle of the cone may not match very well the bolt that will go in it (usually 82 deg). • Sometimes the gelcoat will chip when drilling or sawing. If this is a problem, there are tricks to use.
Page 14: Leveling With Water Level
from this center to the outer ring, and place the level on the bar. Now as you swing the bar around, you can track which parts of the ring are high or low relative to the center. It is easy then to adjust the wall ring to a level condition. FIG 3 Leveling with Water Level This is the best! A water level is made of two see-through...
Page 15: Stainless Steel Cable
You will use several dimensions later in the assembly: You will use several Average Outer Diameter Circumference dimensions later in the (inches) (inches) assembly: Item Base Ring 119.00 373.85 *378.5 Dome 120.00 nom 377.00 nom * Measured just below the top of the skirt Stainless Steel Cable Stainless steel cable is used in several parts of the observatory.
Page 16: Wall Construction
If you are constructing a wall of your own design, we urge that you send a copy of your proposed wall design to Technical Innovations. We can review it, and may have suggestions or cautions that will make the wall easier to build, or otherwise help assure a successful installation.
Page 17: Wall/Base Ring & Semi-Door Assembly Preparation
FIG 9,9B Wall/Base Ring & Semi-Door Assembly Preparation Constructing all or part of a wall with PRO-DOME wall rings is very easy because every ring is the same size, material and design. The base ring differs from the wall rings by having a reverse upper flange, an access hole for aid in assembly, and holes cut into the upper flange for the rollers and electric drive plates.
Page 18: First Ring Assembly
FIG 9B First Ring Assembly To assemble your foundation (lowest) ring, select three full-length sections, a left stub, right stub, and molded door. Remember, this is the ring without holes drilled in the lower flange (and with the foundation hole locations simply marked). Assemble the three 90 degree arcs and the right stub (not the door or left stub) on your foundation or on a reasonably level surface, with male ends pointing left.
Page 19: Installing First Ring On Foundation
Installing First Ring on Foundation Now the job is to put the first completed wall ring on the foundation with the door section at the desired front (i.e., the entrance) of the observatory. If you are installing a rectangular or circular skirt, plan where the joints of the skirt will be placed (in most installations, a skirt is placed below the lowest ring).
Page 20: Alternative Ways To Stack Wall Rings/Base Ring
• Set the ring lightly on top of the foundation bolts. Make the ring circular, then mark the bolt locations on the underside of the wall ring flange. • Drill your foundation bolt holes in the lower flange of the wall ring •...
Page 21: Base Ring Installation
Prepare a flat and level working surface, such as a FLAT plywood sheet screwed to straight 2x4s. Clamp a straight piece of wood (a guide) onto the surface. Lay all the door sections together, blue side up, so that their edges butt against this guide. The goal is to end up with door edges that are as vertical as possible.
Page 22: Door And Hinge Completion
FIG 22 Door and Hinge Completion With all the wall and base rings assembled, remove the 2x4s that are supporting the stubs. Set the door (hinge attached) into position. Using clamps to hold the free flap of the hinge in place, mark two hinge screw locations onto the door jamb. Drill and install two screws and check that the door opens and closes without binding.
Page 23: Roller Mounting
Roller Mounting You have two kinds of rollers: • three inch "support" rollers on which the dome rotates • small, thin "side" rollers that keep the dome centered. FIG 11 Support Rollers The three inch support rollers are mounted in the base ring upper flange.
Page 24: Wall Bracing
increase the force needed to turn the dome. The solution is to use side rollers to center the dome. In general, you should space the 16 side rollers evenly around the base ring. [Bolt Hole Drilling Guide#5] To install, set a side roller on the base ring so that it projects about 1/8-3/16 in.
Page 25: Shutter, Rear Cover, Dsr Preparation
5. Shutter, Rear Cover, DSR Preparation Overview You will now prepare the shutters and rear cover. By doing so, the actual dome assembly will proceed quickly, and you will be able to get the dome covered and safe. In this chapter, we will prepare the •...
Page 26: Security And Locks
DANGER Once the low friction strips are in place, the front shutter will move very easily on the slot edge. As noted in Chapter 2, uncontrolled motion of the shutters can result in damage to the shutters or in serious personal injury. Always have the shutters under control when moving them.
Page 27: Top Shutter Preparation And Latches
Top Shutter Preparation and Latches You will now install the latches and shutter restraint system cable guides on the top shutter. FIG 16B Latch Installation. The short latch will go on the rear of the shutter and engage the hole in the rear cover, while the longer latch is on the front of the top shutter and engages the hole in the front shutter.
Page 28: Rear Cover Preparation
FIG 16, 16B Rear Cover Preparation The rear cover is the narrowest of the three and has a downward lip at the top (front) end. The rear cover fills in the circle at the rear of the dome, and stabilizes the two quadrant pairs near the zenith. Referring to the drawing, check that the bevels are correct in the latch receiving hole in the rear cover, and on the top (front) edges of the rear cover.
Page 29 Tape a dozen or more pieces of 1/4 in. thick material (such as masonite or plywood) around the outside of the base ring, up between the base ring and the DSR. This will establish the DSR gap and assure a round DSR (because the base ring is round). Using 24 in.
Page 30: Dome Construction
6. Dome Construction The wall and base rings are done as well as all the shutter preparation: now comes the real fun. But first, here are some words of caution: • Two people make the job of holding pieces in place much easier. •...
Page 31: Rear Cover
Pick out the right and left rear quads. Refer to the drawing to identify what we call the equatorial (lower) flange. Measure and mark the guide hole locations on the equatorial flanges [Bolt Hole Drilling Guide#27-28] (also refer to the drawing for hole locations) and drill 9/32 holes.
Page 32 want to use a prop or C-clamps to hold it in position. Using the previously drilled holes in the rear cover as guides, drill 9/32 in. holes into the rear slot edge. Start at the bottom of the rear cover. Drill both left and right holes, and install 1 1/2 in. flat head bolts. Then work upwards, doing the next pair of left and right holes, and so on.
Page 33 When you are done, remove the DSR lip bolts (or leave them in if they do not interfere with rotation.) Turn the dome! If you assembled the dome correctly, it will turn easily. But don't panic if it doesn't. See Chapter 8 for how to investigate and fix any problems. Note: fix any rotation problems BEFORE continuing.
Page 34: Shutter Installation And Initial Operation
Shutter Installation and Initial Operation Install the shutter catchers onto the rear cover using the previously drilled holes using 1 in. carriage bolts. Place the front shutter on the rear of the dome so that the handle is up and toward the front, and the flanges straddle the rear cover.
Page 35 We strongly recommend that as soon as you have verified full shutter latching, you drill holes in the shutter and flange as discussed below, and use spare bolts or the lynch pins from your kit to secure the front shutter. The wind will blow tonight! Constructed according to these directions, the past zenith opening of the dome shutter will be about 16 in., and the front shutter when closed will extend about 2 in.
Page 36: Finish Work
7. Finish Work Overview of Finish Work There is only a bit of finish work left. You will need to complete or install a number of items that help protect the observatory and make it safe and enjoyable to use. These items include •...
Page 37: Dsr Swingout Safety Brackets
At the rear of the dome, where the cable is outside the top shutter J-guides, small cable posts mounted on the dome keep the cable from sliding across the dome surface. You have already installed the J-guides on the Top Shutter. You will now install the remaining items.
Page 38: Soffit
The DSR Swingout Safety Brackets hold the DSR swingout close to the top of the semidoor as the semidoor is opened or closed. Besides simplifying semidoor operation, the brackets also prevent the dome from turning unless the DSR swingout is closed. Bolt these brackets onto the semidoor, about 2 in.
Page 39: Instruction Sheet
else the caulk will not make a good bond. You can wait, and verify dryness by looking into the joints or inserting a paper strip. But an easier way to get the water out is to use a hair dryer or compressed air or similar means to blow out the water. Our experience is that simply injecting caulk into the (dry) exterior seams from the outside forms a completely effective seal.
Page 40: Problem Solving
You will find that fiberglass is very forgiving of errors, and that fixing problems is usually very easy, once the problem is understood. If you find that you need to, call Technical Innovations and we will try to help.
Page 41: Shutter Engagement Problems
Case 1 shows correct circumferences, with the dome centered on the base ring. As you turn the dome, you can push the dome off center (Case 2), given the DSR-base ring gap. This is normal. Now, suppose the circumferences are OK, but the base ring and/or DSR are out of round. If centered, Case 5 shows that the gap may be uniform around the dome.
Page 42: Shutter Blow-Off
When opening, if the front latch disengages while the rear latch remains engaged (the opposite of what should happen), then when the rear of the front shutter reaches the latch it will force a disengagement. The top shutter will then slide to the back OUT OF CONTROL and will usually break the shutter catchers.
Page 43: Base Ring Service
Base Ring Service If you identify a problem that requires you to work under the DSR, you can do this WITHOUT disassembling the dome from the DSR. Simply turn the dome to the position needed, and open the DSR swingout, thus allowing access to the base ring beneath. However, remember, UNDER NO CIRCUMSTANCES should you turn the dome unless the DSR is closed and locked.
Page 44: Use And Care Of Your Pro-Dome
9. Use and Care of your PRO-DOME Your PRO-DOME should give you many years of faithful service. Feel free to modify it, drill holes in it, and generally add your own personal touches to it. The walls are strong, so you can use any fastening means (including fiberglass) to add desks, benches, etc. as you desire.
Page 45 You'll find a kit for this purpose in an auto parts shop or marine supply. If you wish, you may contact Technical Innovations for advice and/or replacement parts. After 15-25 years, the surface may begin showing its age, usually by a dulling or chalking of the finish.
Page 46 Bolt Hole Drilling Guide PD10 Introduction and Terminology When the dome has not been preassembled, there are a number of holes that need to be drilled in order to attach one fiberglass section to another or install miscellaneous add-on parts. Throughout the process, it is extremely important to maintain roundness and levelness, while keeping a pleasing “cosmetic”...
Page 47 “Guide” holes for base and wall ring sections are made at the “flat” end, only the right stub section is drilled at this time. Two holes are drilled (9/32 inch bit) on the “flat” end of each of the stub sections. The locations are, 2 inches down from the top and 2 inches up from the bottom, with both 1&...
Page 48 6. Wheels, Final* Locate the wheel cutouts in each base ring section (on the underside of the reverse flange). Find the center of each cutout and measure down the outside wall of the base ring 7/8 inch (use the template provided with the dome hardware). Drill (5/16 inch bit) and then countersink the outside of the hole to a depth that results in the head of the 2 ¼...
Page 49 clamps, this ring is adjusted until it is circular and meets the circumference measurement tolerances. All of the initial “Guide” holes for these ring sections are on the outside of each joint and are used as guides to drill the Final overlap holes (9/32 inch bit). The sections are bolted at this point to form the solid bottom ring.
Page 50 The upper latch is made up of two parts, the “latch” section (which is mounted on the inside upper left hand corner of top door section), and the “receiver” section (which is mounted on the inside upper right hand corner of the top - base ring - left stub section). (Remember that even though these are mounted on the inside of the door, the left/right orientation references are ALLWAYS from the outside of the dome looking in).
Page 51 19. Front Shutter, Handles, Final* A centerline should be drawn 5 inches in from front edge of the front shutter. The shutter handles (one will be mounted on the outside while the other is on the inside – each sharing the two holes/bolts) are each centered on the shutter with the handle holes centered on that line.
Page 52 followed by the next 5, each 11 ½ ” apart. All holes are approximately centered on the flange width. 25. Rear Left Dome Quadrant, Greenwich Flange, Guide Seven holes (9/32 inch bit) are drilled into the center, Greenwich flange of the front right dome quadrant.
Page 53 flange), the guide holes drilled previously in the shutter flanges will be use to drill the final seven (9/36 inch drill bit) holes used to attach the right rear quadrant to the rear shutter panel. 31. Rear Left Dome Quadrant, Shutter Flange, Final Once the rear shutter panel is positioned (overlapping the shutter flanges of the two rear dome quadrants –...
Page 54 (9/32 inch drill bit) down through the DSR flange. Each hole will then be countersunk from the bottom (underside of DSR) as flathead bolts will be used to attach the dome to the DSR. 35. DSR Swing-out Safety Brackets, Final The two DSR Swing-out Safety Brackets are mounted on the top door section and are used to prevent the swing-out from wildly moving in the open direction by itself and possibly damaging the swing-out hinge.
Page 55 C a r r i a g e B o l t F l a t F l a t H e a d H e a d B o l t B o l t ( 8 2 ( 8 2 d e g .
Page 56 Foundation Bolt or Lag Bolt W o o d F o r m 24-30" 2 4 - 3 0 " 5" F i g u r e 6 F i g u r e 4 W o o d P i e r F o u n d a t i o n R i n g F o u n d a t i o n C r o s s - s e c t i o n ( P o s t i n G r o u n d ) ( P o u r e d C o n c r e t e )
Page 57 m i n i m u m p a d s i z e = d o m e d i a m e t e r ( b e t t e r t o m a k e p a d l a r g e r ) 4 i n .
Page 58 F O U N D A T I O N ( u s e r p r o v i d e d ) PD-10 Wall/Base Ring Structure Figure 9 Technical Innovations 7851 Cessna Ave. P D 1 0 5 E Gaithersburg, MD 20879...
Page 59 F R O N T B A S E R I N G A R R A N G E M E N T PD10 Technical Innovations, Inc. 22500 Old Hundred Road Barnesville, MD 20838 F I G U R E 9 B...
Page 60 F R O N T S H U T T T E R - P A R T I A L L Y R E T R A C T E D R E A R C O V E R I N S I D E S U R F A C E D O M E Q U A D R A N T...
Page 61 T O P S H U T T E R ( M O VA B L E ) R E A R C O V E R ( B O LT E D ) F R O N T S H U T T E R ( M O VA B L E ) G R E E N W I C H F L A N G E ( I N N E R F L A N G E )
Page 62 1 1 / 4 9 / 3 2 h o l e 7 / 8 B A S E R I N G - R O L L E R H O L E SUPPORT ROLLER Side Roller 1/8-3/16 in. "JAM"...
Page 63 B E V E L I N S I D E E D G E S D S R - W E B / S K I R T D S R L I P D S R - B E V E L S F i g u r e 1 2 G R E E N W I C H F L A N G E ( H I D D E N I N T H I S V I E W )
Page 64 R E A R C O V E R B O L T S R E A R C O V E R R I G H T R E A R Q U A D R A N T S H U T T E R C A T C H E R : M O U N T A T L O W E R C O R N E R S O F R E A R C O V E R...
Page 65 FRONT SHUTTER LATCH CUT-AWAY (REAR COVER LATCH SIMILAR) FIG 16 PD109...
Page 66 SHUTTERS CLOSED AND LATCHED REAR FRONT FRONT/TOP SHUTTERS MOVE (FRONT PUSHES TOP SHUTTER) TOP SHUTTER UNLATCHES (FRONT KEEPS MOVING) TOP SHUTTER RESTS IN BACK FRONT SHUTTER STORED F I G 1 6 B S H U T T E R O P E R AT I O N PD109B NOT TO SCALE...
Page 67 S H U T T E R S L O T E D G E D O M E S U P P O R T R I N G U S E S H U T T E R C A T C H E R B O L T S T O A T T A C H S O F F I T ( P R O - D O M E O N L Y ) F i g u r e 1 7...
Page 68 J O I N T T w o G l i d e S t r i p S e c t i o n s I n s i d e F r o n t S h u t t e r P o l y e t h y l e n e S t r i p ( H e a t a n d b e n d a r o u n d e a c h e n d o f e a c h s t r i p )
Page 69 1 / 4 i n . 1 / 4 i n . 1 / 2 i n . 1 / 2 i n . 1 / 8 i n . 1 / 2 i n . 1 / 8 i n . 1 / 4 i n .
Page 70 U P P E R F L A N G E O F DOOR BOTTOM DOOR L E F T S T U B S E C T I O N FLANGE EDGE D R AW L AT C H A D J S C R E W S L AT C H R E C E I V E R &...
Page 71 FRONT SHUTTER TOP SHUTTER J-CABLE GUIDE CABLE Cable Loop CABLE GUIDE POST (See Note below about quantity) SPRING POST SHUTTER SHUTTER CATCHER CATCHER RAMP J-GUIDE REAR COVER MOUNTING LOCK NUT COUNTERSINK REAR CABLE BRACKET Notes: 1. Drawing is generic-different domes use different numbers of parts Generic 2.

TECHNICAL INNOVATIONS TEC-PD10 Manual

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