PianoDisc and Burgett Prodigy User manual

Vertical
Installation Guide
Version 3.2
Sept. 2018
© 1996 by PianoDisc™ and Burgett, Inc. All Rights Reserved.
PianoDisc and Burgett, Inc. reserve the right to change product design and specifications at any time without prior notice.

Introduction
This installation manual will guide you through the process of fitting the
PianoDisc reproducing piano system to virtually any vertical piano. Along with the
knowledge and experience gained from a PianoDisc Installation Seminar, this
guide should be an invaluable resource.
This document is considered confidential by PianoDisc, and is for the sole use of
PianoDisc Certified Technicians. It may not be reproduced, distributed or quoted
in whole or in part without the express written permission of PianoDisc.
This guide is only to be used in the installation of the PianoDisc Reproducing
Piano with the SilentDrive system.
PianoDisc systems may ONLY be installed by technicians who have been
certified by PianoDisc to perform such installations. If you have come into
possession of this manual and/or Retrofit Kit and you are NOT a PianoDisc
Certified Technician, DO NOT ATTEMPT TO PERFORM THE INSTALLATION.
Installations not performed by a certified PianoDisc technician WILL NOT meet
the requirements for warranty protection, and such an installation will likely void
the piano manufacturer’s warranty for the instrument and the player system, and
may also be a violation of FCC rules.
Technicians may only be certified by attending the PianoDisc Installation
Seminar at PianoDisc’s Factory and World Headquarters in Sacramento, CA or
by on site training evaluation and certification by one of the PianoDisc Factory
Installation Technicians duly authorized to certify technicians. A candidate for
PianoDisc certification should be a Registered Piano Technician and a member
of the Piano Technicians Guild. A candidate who does not qualify under this rule
will be evaluated on an individual basis, with an emphasis on total experience as
a piano technician and possible previous experience in retrofitting pianos with
other player piano mechanisms.
PianoDisc encourages PianoDisc technicians to comment on this installation
manual by writing to: PianoDisc, 4111 North Freeway Boulevard, Sacramento,
CA 95834, or by fax at [phone]. Please restrict telephone calls to
technical questions and installation inquiries. Thank you.
Technical assistance for PianoDisc Certified Technicians is available Monday
through Friday, 8AM–Noon and 1PM–5PM Pacific Time. The telephone number
is: [phone]
i

FCC INFORMATION
ii
NOTE: This system, when in operation, can develop radio frequency energy
which can cause harmful interference to radio communication unless the
equipment is installed and used in strict accordance with manual instructions.
This equipment has been tested and found to comply with the limits for a Class
B digital device, pursuant to Part 15 of the FCC
If the equipment does cause harmful interference to radio or television reception, which can
be determined by turning the equipment on and off, the user is encouraged to try to correct
the interference by one or more of the following measures:
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and the receiver.
Connect the equipment into an outlet on a separate circuit from that of the receiver.
Consult PianoDisc, or an experienced radio/TV technician for help.
The user may find the following booklet prepared by the Federal Communications
Commission helpful:
How to Identify and Resolve Radio-TV Interference Problems.
CAUTION: CHANGES OR MODIFICATIONS NOT EXPRESSLY
APPROVED BY THE PARTY RESPONSIBLE FOR COMPLIANCE

Table of Contents
Page
Introduction i
FCC information ii
Illustration List iv
Step 1 Measure the piano 1
Step 2 Disassemble the piano 1
Step 3 Determine the solenoid rail direction 2
Step 4 Measure the key group 3
Step 5 Location of solenoid slot 5
Step 6 Cutting solenoid slot 7
Step 7 Assembly of the solenoid rails 7
Step 8 Positioning solenoid rails 12
Step 9 Keybed support 12
Step 10 Installing keybed support 13
Step 11 Installing key rest rail 14
Step 12 Installing solenoid rails 14
Step 13 Key solenoid height adjustment 15
Step 14 Installing pedal solenoid 15
Step 15 Preparing for mounting driver boards 18
Step 16 Mounting and connecting key driver boards 18
Step 17 Mounting the boards 19
Step 18 Connect the power and data cables 20
Step 19 Installing the power supply 22
Step 20 Key control bar 23
Step 21 System start up 25
Step 22 Adjusting Pedal Solenoid 25
Step 23 Final check list 26
Step 24 PianoDisc Parts ID 27
iii

Figures Page
Figure 1: Solenoid rail gauge 2
Figure 2: Upright piano bottom view 2
Figure 3: Solenoid position 3
Figure 4: Centering solenoid rail 4
Figure 5: Marking solenoid rail 5
Figure 6: Key frame cutout 5
Figure 7: Slot location 6
Figure 9: Slot breaks (action supports) 7
Figure 10: Solenoid mounting 8
Figure 10A: Mounting top key solenoids 8
Figure 10B: Mounting the bottom key solenoid 8
Figure 10C: Key solenoid support plate 8
Figure 10D: Key solenoid rubber washer 8
Figure 11: Twisting solenoid wires 9
Figure 12: Solenoid bracket mounting 10
Figure 13: Solenoid rail adjustment 11
Figure 14: Mounting keybed support angle iron 13
Figure 15: Keybed support bar location 13
Figure 16: Pedal solenoid location 15
Figure 16A: Pedal solenoid extension 16
Figure 17: Pedal solenoid 16
Figure 18: Pedal solenoid system side view 17
Figure 19: Key driver mounting board 18
Figure 20: PC board locations 19
Figure 21: Ground cable location 20
Figure 22: CPU, Prodigy – Front view 21
Figure 22A: CPU, Prodigy – Left end view 21
Figure 22B: CPU, Prodigy – right end view 21
Figure 23: Bass driver board plug location 21
Figure 24: key and pedal sole. Power cables 21
Figure 25: Power supply 22
Figure 25A: Power supply in piano 22
Figure 26: Piano with installed system 23
Figure 27: Key hold down bar – top view 24
Figure 28: Key hold down bar – Side view 24
Figure 29: Pedal solenoid in piano 25
Figure 30: Pedal solenoid – close up adjustment 26

iv

1
Step 1 Measure the piano
Before attempting to install the PianoDisc system onto a vertical piano, it is
necessary to determine if the PianoDisc system will physically fit that particular
piano.
A. To determine if the solenoid rail will have the necessary room on the
keybed, make a measuring device to check the piano. Any small piece of
wood or Plexiglas will work. (See Fig. 1) The overall width of the
solenoid rail is 3“(76mm), including the brackets.
B. Measure the bottom side of the keybed, from the inside edge of the
lower panel (kick board) towards the plate. (See Fig. 2) If you measure
3” (76mm) of keybed, the system will fit.
Step 2 Disassemble the piano
A. Remove the upper panels, fallboard, and lower panel or kickboard. Put
the piano parts in a safe place.
B. Check the piano regulation, especially the key leveling and lost motion in
the keys.
NOTE: Record the key height of keys 1 and 88. Because of the slot location,
the key rest rail must be moved forward which makes it necessary to
know the key height before proceeding. Also it will be necessary to level
keys and some minor regulation after the PianoDisc installation.
C. Remove the piano action and put it in a safe place.
Tip: It is good to think about purchasing a lifting device to elevate the vertical
piano during the installation process. A hydraulic motorcycle lift works well.

2
Step 3 Determine solenoid rail direction
A. Depending on the amount of room between the piano plate and the inside of
the kickboard, it may be necessary to turn the solenoid rails around 180°,
placing the mounting brackets towards the rear of the piano. Additional
support of wood or angle iron may be necessary. (See Fig.3) The preferred
method is to place the mounting brackets forward to place the solenoid tips
at the end of the keys for the best playability.
NOTE: On some pianos, the middle area of the keybed is hollow. I this case just
fill the hollow keybed with 2” of wood in the area of the solenoid hanger
bolts. Also in most pianos the key rest felt will be in the slot location and
will need to be moved forward.
B. Once you have determined the direction of the solenoid rails, measure the
keybed and check to see how close to the end of the key you can place the
slot. The ideal location for the plunger tip is as far back as possible to the
end of the keys.
Figure 1
NOTE:
By placing the mounting bracket on the
recessed side of the solenoid rail the overall width
of the rail assembly is ¼” less.
Figure 2

3
NOTE: Most of the time it is necessary to trim the keybed supports
(hornplate extensions) to get the solenoid slot back as far as
possible. (See Fig. 3) If the keybed support is in the break
area, it is advisable not to cut them.
Step 4 Measure the key groups
A. Establish the key groups. The fronts of the keys are evenly spaced in one
continuous line: left to right, numbered 1 through 88.The stack is typically
divided into four groups. The group at the left, the bass, always has the largest
hammers. This is Group 1.The mid-range group in the center of the keyboard is
Group 2. Moving to the right is the low treble area, Group3. Group 4 is the high
treble area at the right end of the keyboard with the smallest hammers. The
small open spaces between these groups are called “breaks”.
B. Place and mark rail blanks. If there are action brackets at the breaks, it will be
necessary to preserve as much wood as possible for support, especially at the
tenor/treble break. So it is best to use a long stem (white wire) solenoid on both
Figure 3

4
sides of the tenor/treble break.
NOTE: This method of placing two long stem solenoids at the tenor/treble break will
require an extra long stem key solenoid. Only use this method if there is
an issue with the action bracket clearance. The normal method is to start
with a short stem solenoid at key one.
A. Place a rail blank across the treble section at the capstan location, centering
two bracket locations for the best support. (See Fig.4)
B. Now, put a mark on the rail indicating the beginning and end of that section. For
instance, if key #55 is the first key, place a mark on the rail at the outside edge
of key #55 and also the outside edge of key #88. (See Fig.5 Next page)
C. With rail blank still centered across the keys, skip key #55 and place a mark on
rail centered about key #56 indicating the short stem (Black wire) solenoid
locations. Skip key #57, place mark on the rail at key #58, etc. (See fig. 5)
D. Place a rail blank across the tenor section at the capstan location, centering
bracket locations for the best support and start with a long stem (white wire)
solenoid for the key #54.
E. Place a mark on the rail at the center of key #54, skip key #53, mark key# 52,
etc. If the tenor section is an even number of keys, then you will end up with a
short stem (black wire) solenoid at the bass/tenor break. This is not a problem
usually since there is more room at this break.
F. Place the last rail at the bass section and repeat the same procedure as the
tenor section.
Figure 4
Mounting bracket locations