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

5
Step 5 Location of solenoid slot
A. If the key frame has connecting pieces of wood between the balance rail
and the key rest felt, use a dovetail saw to cut the pieces without removing
the key frame. (See Fig. 6) Now remove the key rest rail from the keybed
being careful to keep track of the shim located under the rest rail.
End of rail section
62
58
60
56
Figure 5

6
B. Looking at the bottom side of the keybed, figure how close the back edge of
the solenoid slot can be to the plate including cutting off the plate supports to
the keybed. This will be the back of the solenoid slot. In most pianos the
back of the keybed will be cut off. (See fig. 7) (The object is to have the sole-
noid plunger tip as far back as possible.)
C. Now measure forward 1 3/4” (45mm) to establish the front of the slot. (See
Fig. 7) The back of the slot is generally close to the plate as seen in fig. 7.
D. Now place the “end of section” keys on the key frame to establish the end
cut of each of the three sections. This is assuming the piano has action
brackets at the breaks. If the piano does not have action brackets at the
breaks, a continuous slot can be cut.
E. Measure 3/8” (10mm) from the edge of keys 1 and 88 for solenoid
clearance. This will allow room for the body of the key solenoid in the end
of the slot.
F. At the tenor/treble break we want to preserve as much wood as possible as
discussed in Step 4. (See Fig. 9) So, if a long stemmed (white wire)
solenoid was planned for at the tenor/treble break, you will want to modify
the support tab to conserve the amount of wood removed at the break.
(See fig. 10c) Do the same for the other end keys that have long stem
solenoids.
Figure 7

7
Step 6 Cutting the solenoid slot
NOTE: On some pianos, the keybed is removable, which makes cutting the slot
and the plate/keybed supports easier. I prefer not removing the keybed but just
using the jigsaw to cut the keybed slot. Also I use a piano tilter to put the piano
on it’s back to cut the plate supports with a powered jigsaw.
A. With a 3/8” (10mm) drill bit, drill all the corners of each section, as marked in
step 5. Now, cut out the sections between the holes just drilled with a heavy
duty jig saw (Bosch, model #1581VS is recommended). A keyhole saw may
be useful at the ends of the slot for the close clearance. Use a double cut
file or 100 grit sand paper (with sanding block) to clean up cut.
B. Vacuum or blow out the piano with compressed air and replace the keybed
if removed for cutting. Also, replace the key frame to its’ original position if
removed.
NOTE: A portable powered bandsaw cuts the plate horns quickly and easily.
Step 7 Assembly of the solenoid rails
________________________________________________________________
A. Mounting key solenoids to rails. Starting with the bass key solenoid section,
clamp the bass rail to a workbench with the recessed side down. A 2”x2”
(50mm x 50mm) block of wood can be used to elevate the rail. (See fig. 10)
Action breaks

8
B. Place a 6x32x3/8” screw on each line marked for the top row (short stem
solenoid). Place the screw half way into the rail at each location marked
on the rail.
C. Next, place a short stem solenoid (back wire) on the flat side of the
solenoid rail at the first screw. (See fig. 10a)
D. While holding the solenoid firmly against the rail, secure the solenoid by
tightening the screw. Continue with the next solenoid until all top
solenoids are installed on this rail.
E. Remove clamps from rail plate and rotate rail 180 degrees. Clamp rail
back to the bench.
F. Now place a long stem solenoid on the solenoid rail spacing the stem
between the top row solenoids. Hold the solenoid firmly and place a
(10mm) screw in solenoid mounting slot. Install the appropriate number of
long stem solenoids on the solenoid rail. (See figure 10b)
Figure 10B
Figure 10A
Figure 10
Rubber
Spacer
End Support
Plate
Figure 10D
Figure 10C

9
H. Locate the end support plates in the kit and place them on the end of the
rail sections where there is a long stem (white wire) solenoid for support.
NOTE: It may be necessary to grind a notch into the end support plate to
preserve as much wood as possible at the breaks. (See figure 10c)
I. Twist one black and one white wire together using a wire hook with a
powered drill. This not only makes it easier to work with the wires, but
also makes a cleaner installation. (See Fig. 11)
NOTE: Be careful not to over twist the key solenoid wires causing damage to
the wire or connector.
J. Cut the rails to the proper lengths. To keep any aluminum shavings from
falling into the solenoid cylinders, pull the plungers up until the plungers in
the solenoid protrude from the tops of the cylinders by about 1/16”. Use
masking tape to hold the plungers in these positions. Carefully trim off the
excess length of aluminum rail, making sure the solenoids are not damaged
or shifted in the trimming process.
K. Thoroughly clean the solenoid rail assembly with compressed air after
smoothing the edges with a file.
L. Repeat the above mentioned steps for the tenor and treble sections.
M. Locate the baggie of rubber spacers in the kit. Notice there are two sizes
of rubber spacers. The larger diameter spacers are for the top row
solenoids and the smaller diameter spacers are for the bottom row
solenoids. Place the rubber spacers between the felt washer and the
rubber tip. (See figure 10c & 10d)
NOTE: There is a cut in the washer for ease of installation.
Figure 11

10
NOTE: The purpose of the washer is to shorten the stroke of the key solenoid to
accommodate the shorter travel distance of most vertical pianos. If you
find that the travel distance of the key (at the solenoid contact area) is
.340” (8.6mm) or more, then the rubber spacer is not necessary.
N. Attaching the bracket to the rail requires (2) #10 x 1/2” hex-headed screws
per bracket, which are provided in the kit. Each bracket location has (3)
sets of mounting holes. Always use the middle set of holes. The
mounting bracket should be positioned so that it extends down from the
slot. The bracket should be positioned so that the mounting screws are
approximately in the middle of the slot. This leaves room for a small final
adjustment. Mount (2) brackets on each rail. (See Fig. 12)
Figure 12

11
Figure 13

12
Step 8 Positioning solenoid rails
A. Place the end section keys on the keyframe.
B. Place the (2) stud locators (blue blocks, supplied by PianoDisc) onto the
bass section hanger brackets.
C. Place the bass solenoid section into the piano centering with the end keys
and tap the pins with a hammer to locate the studs. Now do this with the
other two sections.
NOTE: If the studs are forward of the slot, it is important to place the keybed sup
port (Angle Iron) at the stud location. In this case, a 3 1/2” (89mm) fully
threaded bolt (supplied in the kit) will be used to attach the keybed
support to the keybed. These bolts will also serve as the hanger studs for
the key solenoid rails.
D. Drill the (6) hanger bolt locations with an 11/32” (9mm) drill bit. Use a drill
guide to maintain a 90 degree hole. Use a ¾” Forstner bit to counter sink
the head of the bolts into the top of the keybed.
E. In the event the mounting brackets must be placed toward the plate, the
hanger studs will normally be used. (Available from PianoDisc) It is
important to have 1 1/2” (38mm) thickness of keybed for mounting the
hanger stud. For example, if there is only a 3/4” thick keybed, an additional
3/4” of wood must be glued to the keybed, at the stud location, to proper
support of the solenoid rails.
NOTE: Very few times do you need to mount the solenoid rail behind the slot.
Step 9 Keybed support
A. The support of the keybed is very important. Added support is necessary
because the keybed plate supports have been cut away for the key solenoid
slot.
The best material to reinforce with is 1/8” x 1 1/2” (3mm x 38mm) angle
iron. It provides more clearance and strength than the 1” (25mm) square
tube used in the past.
B. Cut a piece of 1 1/2” (38mm) angle iron the full length of the solenoid slot.
Temporarily clamp the angle iron under the keybed centered over the
hanger bolt holes. (Flush with the front edge of the slot) (See Fig.

13
C. Use a pencil to mark the location on the angle iron through the keybed holes
just drilled.
D. Remove the angle iron from the piano and with the drill press, drill the 6 -
11/32” (9mm) holes. Now file any sharp edges or burrs off and paint black.
Step 10 Installing keybed support
A. Place the (6) 5/16 x 3 1/2” (8mm x 89mm) bolts in the keybed and bolt the
angle iron in place with lock washers. (See Fig. 15)
Angle iron is flush
with front of slot
Figure 14
Figure 15

14
B. As in the case of the solenoid rail brackets in the rear, there must be the 1
1/2” (38mm) angle iron support on the keybed in front of the slot. Use the
appropriate length lag bolt to attach the angle iron.
Step 11 Installing key rest rail
A. Position the rest rails on the keybed close to the solenoid plunger tip while
still maintaining a 1/4” (6mm) clearance. (See figure 13 on page 12) With
the end keys of each section in place, space the rails side to side.
B. Holding keys #1 and 88 in the rest position, measure the key height and
determine if any shimming up of the rest rail is necessary. Key height
measurement was taken in Step 2.
C. Secure the rest rails to the keybed with the original screws.
NOTE: This is a good time to level the keys. Most vertical pianos need key
leveling because of the key rest rail re-location.
Step 12 Installing solenoid rails
A. Place the end keys of each section onto the keyframe.
B. Put a nut on each hanger bolt about halfway on the threads.
C. Place all (3) solenoid rails on the piano with another nut on each bolt and
tighten temporarily. Now see if they are equally spaced between the end
keys of each section.
D. If some adjustment is necessary, remove the section, mark the location of
both brackets with a pencil, loosen the bracket screws and relocate the
brackets side to side.. Place the solenoid rail back into the slot location and
recheck.
Now is the time to install the rest of the keys and observing the plunger tip
location on the key. The plunger tip should be close to the center of each key.