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Step 1
Pouring the Concrete Slab
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Installing a good foundation is the first step
before assembling your Observatory. It is essential that the cement
pad be slightly larger than the Observatory and completely level.
A level cement slab will insure that the Observatory wall units will align
together properly, and will allow the dome to rotate smoothly.
My slab is six inches thick and 90 inches in diameter. For my
Observatory I hired a local contractor who used six-bag cement and wire
mesh. You can also pour the slab yourself, following your city or township
building guidelines for pouring cement slabs.
Once the cement slab is complete you are ready to start the assembly.
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Step 2
Unpacking Your Observatory
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When you unpack your Observatory, look under
the dome for a box containing the fastening and finishing hardware.
Verify that you have 9 bolts and 18 washers per flange attachment. |
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Step 3
Assembling the Panels
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After uncrating the four base sections, you
will notice that each attaching flange is marked with a letter. Place
each section standing upright on the cement slab. Then match each
wall panel next to its corresponding letter. For example, panel A
flange on wall unit 1 will bolt to panel A flange on wall 2, and B flange
on wall 2 will bolt to B flange on wall 3, and so on.
Before your Observatory was delivered we lined up the walls and pre-drilled
the holes. Then we placed corresponding letters on the wall units.
This will help you match the walls back together in the same order we drilled
them.
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Step 4
Bolting the Panels Together
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Begin by placing two wall units upright and
bolt them together. DO NOT tighten the bolts at this point.
Leave a 3/8in to 1/2in gap. Complete this process until all four
walls are standing and loosely bolted together.
Once the walls are loosely bolted together, we are ready to make sure
that the Observatory is placed centered on your cement pad. All adjustments
should be made at this point. Once you are happy with the placement
you are ready to permanently bolt the walls together. Using the silicone
supplied in your kit, apply a ¼ bead from top to bottom between
the wall units. Repeat this for all four flanges.
Then, using one box wrench, and ratchet wrench, begin tightening the
bolts, but DO NOT completely tighten. Make sure the outside
lines, or each section aligns, especially the top where the dome wheels
rotate. The walls must be properly alignment, otherwise the wheels
will "thump" when they hit this joint. DO NOT over tighten
the bolts. If you will notice some gaps, fill in these areas from the outside
with silicone. |
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Step 5
Checking for roundness
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Now, use a tape measure and a marking pen to
make sure your Observatory is round. Then, mark the cement or deck,
of where the Observatory should fall. At the bottom it should measure
84.0 inches round. Now, place the flange at the marked position,
pull or push the Observatory, into proper roundness. |
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Step 6
Drilling The Anchor Holes For Tapcon Bolts
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You may use any anchor that is appropriate for
your application. Whatever fastener you choose, please read the instructions
and follow all safety guidelines for that fastener. Tapcons are a
commonly used, and therefore will be documented. Recommend Tapcon
size is (¼ x 1 ¾) and fender washers (1/4 x
1 ½). Each wall panel should have (3) Anchors: (1) anchor
in the middle, (2) anchors about 1-3 inches from the ends. Each wall
panel requires three bolts to anchor it to the surface. This means
a total of 12 holes drilled and 12 Tapcon bolts and washers.
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Step 7
Fastening Observatory to Slab or Deck
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Once the holes are drilled for the Tapcon bolts,
place the bolts into the hole with washer and use a socket wrench to tighten
to bolts (Do not over tighten).
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Step 8
Equipment Needed for Silicon Application
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Example of caulking gun, acetone and rag for
next step. Please read the manufacturer instructions for silicon.
When using Acetone or any chemicals follow all instructions and safety
precautions.
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Step 9
Applying Silicone
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Place a nice silicone bead on the inside flange,
and outside cylinder. Run your wet finger, along the bead.
This will make a nice bond.
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Step 10
Removing Excess Silicone
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For a clean finish, use Acetone to clean any
remaining
silicone on the Observatory exterior surface. This is best done before
the silicone dries. Once the silicone dries, it is very difficult
to remove from the surface.
Make sure the inside of the Observatory is clean from any excess silicone.
Remember, the more time you spend now, the better looking your Observatory
will be later.
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WARNING: If you have a factory Drive System
DO
NOT install the dome at this time. Please STOP
and refer to DRIVE INSTALLATION section at the end of this manual!
When you have completed the installation of Drive proceed with Step 11
below. |
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Step 11
Installing Dome
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After the silicon has dried, carefully lift
the dome into place. Verify that the dome rotates freely. |
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Step 12
Dome
Wheel Alignment
(If necessary)
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If you have any problems with wheel alignment,
remove the dome and problem wheel. Elongate the hole downwards, using
a 5/16 drill just 1/4 inch. Place one star washer, on the outside,
and one on the inside, so the star washers are against the fiberglass.
When complete, reassemble the wheel assembly. DO NOT TIGHTEN.
Place the dome back on the cylinder and adjust the problem wheel so
it now functions better. Tighten the wheel. The Observatory
dome should now work correctly. |
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Step 13
Installing Trim
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Cut white edge trim to length and apply to all
exposed fiberglass edges inside the observatory.
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Step 14
Installing the Dome Tie Down
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Select a preferred park position for your dome.
We suggest placing the shutter in the path of the prevailing wind.
After selecting the position swing up the rubber "T" handle clamp, placing
a piece of masking tape behind it on the dome. Mark through the hole
of rubber "T" handle clamp, onto the masking tape, a point that is slightly
higher than the center of "T" handle clamp. Note.. The "T" handle
must stretch over the knob. Now drill a 3/16 hole to accept the small
black receiver knob to be secured to your dome. Using the supplied
hardware, secure the black receiver knob with acorn nut and washer to the
outside. This will be required at two locations. Each location
should be at opposite ends of the Observatory. Repeat the procedure
above for installation of second "T" handle clamp. After observing
for the night secure the "T" handles to the knob at both locations, your
Observatory dome will now be secure from high winds.
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Step 15
Operating the Dome
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You have now completed the base unit.
You may wish to add some indoor/outdoor carpet with padding. This
will enhance your observing comfort, especially during the winter.
Never, push open the front hatch, but rather gently lower it.
Use the hook to SLOWLY open the top hatch. Slowly, push the top hatch
shut. Now secure the cam lock. To lock the door, push at top
and bottom, and lock like a Bank Vault.
I suggest applying, a good quality Boat Wax twice a year. This
will give your Observatory added protection and shine.
Your observatory is now ready for use. ENJOY!!
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DRIVE INSTALLATION
If you have ordered your 5.5 model, with an installed drive, we will
now take you through the steps for proper installation, maintenance and
usage. The drive consist of a DC gear motor, mounted up on the Cylinder
wall, and electronic relay package control box, also Hand Pendant for East
& West Rotation. Note the Spur Gear Drive Track ( patent pending)
mounted up on the dome perimeter, additionally the SEC professional DC
Power Supply, which should be placed on the floor or desk. The motor
runs at 36RPM, thus it requires two minutes for one complete rotation. |
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Step 1
Unpacking the Drive
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First locate the drive and make sure all the
shipping ties and materials have been removed. Also make sure all
the exposed bolts are tight and uncoil all wires. (The hand control will
be in the large box under the Dome). Next plug in the hand pendant
control. DO NOT install the dome at this time.
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Step 2
Removing Capture Plate
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At the top of the drive motor, remove the three
screws which hold the Teflon
Capture Plate to the Motor Bracket assembly.
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Step 3
Installing Dome, Reinstalling Capture Plate
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CAREFULLY install the dome on top of the cylinder.
Do not be concerned if the Motor Gear is not in contact with Dome Spur
Track at this time. Swing motor up until gear is in contact with
Spur Gear making sure Motor Gear and Spur Gear Track is in proper engagement.
Now reinstall Teflon Capture Plate, placing it over the top of the Gear
Track and reinstalling the three screws.
During this step it may be required to pull the dome over so the gear
and track stay engaged while reinstalling the Teflon Capture Plate. Make
sure all three screws are reinstalled and tight. Spray Gear Track,
Motor Gear, Dome Wheel Track, and Capture Plate with Teflon lubricant.
Note: The purpose of the Teflon Capture Plate is to insure that both the
Motor Gear and the Gear Track never becomes disengaged resulting in high
reliability. |
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Step 4
Attaching to Power Supply
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Warning
Make sure the power supply is
unplugged.
The DC Voltage wire assembly can now be attached to your power Supply.
Remove the red and black screw terminals on the S.E.C. power supply and
install the two wires, also marked red and black. Place the red terminal
on the positive (red) side, and the black terminal on the negative (black)
side. Reinstall and hand tighten the plastic red and black nuts.
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Step 5
Final Check & First Rotation
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Warning
Make sure there is no water
or dampness in the observatory, this could result in accidental electrocution!!!
Check over your complete assembly, making sure the following is completed.
1) The gear and track are engaged.
2) The Capture block is installed.
3) All electrical connections are proper.
4) No human hands are on the track, loose rags or debris.
5) Insure no bolts and tools have been left in the wheel track area,
up on the cylinder walls.
WARNING: If the dome wheels encounter an object in wheel
area, dome will stop, likely resulting in the motor shaft to "Shear Off".
After you have checked all the above, plug in the power supply and turn
switch to ON. The red light should come on as an indicator the unit
has AC power.
Now holding the hand pendant switch to either position, dome should
now move East or West, as you hold the toggle switch in that direction.
Do not be alarmed, if motor floats or moves up and down, it is designed
to work in this fashion! |
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Step 6
Congratulations!
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You have successfully installed your dome and
drive system. Lubricate Gear Track, Motor Gear, Dome Wheel Track,
and Capture Plate monthly. In addition we recommend putting Petroleum
Jelly on the Gear Track (top & bottom) Motor Gear and Capture Block.
Fuses protect your system and are located on the power supply and control
box. If the system fails, these fuses should be checked for contiguity.
If the dome is forced to stop, a special safety circuit will detect a rise
in Amperage and shut down the complete system. To restart, turn power
supply off, check the fuses and then turn back on. Remember, the
fuses are provided to protect the system from damage, therefore, if the
fuse(s) keep blowing then something is wrong. Please consider your
SAFTY first. Always contact our factory (810) 749-9525 before you
second-guess, it will perhaps save you money in costly repairs. Boyd
Observatories staff are always here to help you. |
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Step 7
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Return to Step 11 in " Installation Guide for
Boyd Observatories – Model 5.5 Observatory. |