Schatten Design Model B User manual

Assembly Instructions - Schatten Design Coil Winding Machine Model B - Kit
Tools you’ll need: rubber band, small phillips head screw driver, small flat head screw driver, ruler, needle nose pliers, small adjustable
wrench, X-Acto or other sharp knife, 8" of electrical tape, wire cutter/ wire stripper, rosin core (radio/tv) solder, small soldering iron 15 to 35
watts or soldering station set to approx. 750F. Optional tools - 10 mm socket (toggle switches), 15 mm socket or wrench (power jack),
13mm or ½" wrench (speed control).
QTY PARTS PART NUMBER QTY PARTS PART NUMBER
ASSEMBLED KITTED PARTS
ENCLOSURE ELECTRICS-1 BAGGED TOGETHER
1 ENCLOSURE, PRE-DRILLED 1594DSBK 1 100K WIRE WOUND SW POT w/lock washer, nut CT3020-ND
1 IR REFLECTIVE SENSOR w/ 6" 3 conductor
wire -PRE MOUNTED TO ENCLOSURE 958 1 MOTOR w/ PULLEY TS840
PINK BAG
CIRCUIT BOARD ASSEMBLY ELECTRICS-2 BAGGED TOGETHER
1 SWITCH CIRCUIT BOARD SW BD MODEL B - REV 4A 1 IR REFLECTOR Rotary Part IR REFLECTOR
1 DIR SWITCH DPDT ON/OFF/ON EG2414-ND 2 O-RING DRIVE BELTS 2 1/8 x 2 1/4 x 1/16 OR-034N
1 CT RESET SWITCH SP MOMENT. 432-1170-ND 1 WIRE CLIP GREY WIRE CLIP
1 3.3 VOLT REGULATOR 296-21633-5-ND 1 2.1 mm POWER JACK 27931-134-0
1 22uf CAPACITOR -C1 P5162-ND 1 POINTER KNOB POINTER KNOB
1 1uf CAPACITOR -C2 P5174-ND 1 COUNTER MINI CAL 1
1 HEAT SINK HS198-ND
MECHANICALS BAGGED TOGETHER
MOUNTING BASE 1 WINDER ARM w/ 10-24x3/8 soc set screw ARM
1 BOARD WHITE 6" x 6" x 5/8" PRE-DRILLED BASE 2 BEARINGS FR4ZZ
1 MAIN SHAFT PULLEY w/8-32x3/16 soc set screw MAIN SHAFT PULLEY
KITTED PARTS 2 1/4" COLLARS 1/4" COLLAR
CROSS FEED ASSEMBLY BAGGED
TOGETHER MAIN SHAFT 1/4" x 4 1/4" ALLEN KEY 5/64"
1 LIMIT SHAFT 4" STAINLESS 1 ALLEN KEY 5/64" ALLEN KEY 3/32"
1 ALUM FLAT, STAND OFF 1/4 X3/4 X 6" 1 ALLEN KEY 3/32"
2 1/4" FLAT WASHER 1/4" FLAT WASHER
1 1/4" LOCK WASHER 1/4" LOCK WASHER
2 1/4" NUTS 1/4" NUT WIRE BAGGED TOGETHER
2 1/4" COLLARS 1/4" COLLAR 1 WIRE BLACK 22 GA - 12" BLACK
1 WIRE WHITE 22 GA - 12" WHITE
SCREWS BAGGED TOGETHER 1 WIRE RED 22 GA - 12" RED
2 1/4 x 20 x 1" FLAT HD PAN PHIL MACHINE TO BASE MTG
SCREWS 1 WIRE GREEN 22 GA - 12" GREEN
2 M3 x 5 MACHINE SCREWS MOTOR MOUNTING
SCREWS 1 RIBBON WIRE, 4 CONDUCTOR - 4" MULTI
4 NUTS FOR TOGGLE SWITCHES ---
2 LOCK WASHERS FOR TOGGLE SWITCHES ---
2 TABBED WASHERS FOR TOGGLE
SWITCHES ---
2 #4 x 1/2" PAN PHIL STAINLESS CROSS FEED LIMIT MTG
SCREWS
4 SELF TAPPING SCREWS - BAGGED COVER MTG SCREWS
Rev 03-12-2013

Counter Installation:
1) Unpack the counter, remove the black plastic mounting
halves and set them aside. Remove the protective film
covering
the counter face.
2) Re-install the two black plastic mounting halves onto the
counter.
3) Install the counter into the machine cover with the four
solder pins to the left side as shown (fig’s 1 & 3). Note that
there is a small plastic tab on each half of the mounting that
has to gently be pried outward to secure the counter.
4) Insert the tip of a small flat head screw driver behind each
edge of a tab and pry (fig 1).
Circuit Board Installation:
1) (fig 2) Install a nut onto
each toggle switch. Rotate
the nut all the way to the
bottom of the switch.
2) Install a lock washer on top
of each nut.
3) Mount the circuit board to
the cover by inserting the
toggle switches through the holes in the cover. Note the alignment of the circuit
board as shown (fig 3).
4) Note that the toggle switches have a slot or keyway down their
threaded surface (Fig 4). Install a small tabbed flat washer (tabs should
face away from the surface of the cover) and a nut on the toggle
switches and using a 10mm socket or wrench tighten the nuts to
mount the circuit board.
Fig 1
Fig 3
Fig 2
Fig 4

Counter Wiring:
1) A four inch piece of 4 conductor ribbon wire is provided to wire the counter to the circuit board. The color of the wires
shown does not necessarily correspond to the
ribbon wire in your kit.
2) The four different wires that make up the
ribbon have to be separated from each other for
one inch at each end.
3) (fig 5) By inserting the tip of the X-Acto into
the space between the colored wires and gently
pulling the ribbon wire away from the knife you
can separate the wires as shown.
4) Strip 1/4" and tin both ends of all four wires.
5) (fig 6) As delivered, pins A, B, C, D on the counter are straight up and
down and are very close together, which can make soldering to them
difficult. With your finger, very gently bend the pins to separate them
to provide more working room.
6) IMPORTANT ! - Cover the back side of the of the counter (where its’
circuit board is exposed) with 3 or 4 layers of electrical tape) to guard
against any solder dripping or spatter that may occur in the next 2
steps.
7) Carefully tin each of the four pins on the left side of the counter.
8) Solder the four wires from the ribbon, one each, to a counter pin.
Remove the protective electrical tape.
9) The ribbon wire is now soldered to the circuit
board as follows:
Wire Assignments:
Wire from pin A to pad 13 on circuit board
Wire from pin B to pad 12 on circuit board
Wire from pin C to pad 11 on circuit board
Wire from pin D to pad 10 on circuit board
10) Tuck the excess ribbon wire between the
circuit board and the cover. Place a piece of tape
over the ribbon as shown (fig8) to secure it.
11) Important ! - Make sure that the pins on the
counter do not come into contact with each
other.
Speed Control Pot Wiring
1) Tin Lugs 1 through 4 on the control pot. (Lug 5 is not being used)
2) Cut a 1 ½ inch piece of black wire, strip 1/4" from each end and tin. Solder the wire from
Lug 1 to Lug 3.
3) Cut an 8 inch piece of green wire, strip 1/4" from each end and tin. Solder one end to Lug 2.
4) Cut an 8 inch piece of red wire, strip 1/4" from each end and tin. Solder one end to Lug 4
5) Twist the green and red wires together along their length to keep them paired.
6) Set the unit aside.
7) Make sure that after soldering and upon assembling the machine, that none of the lugs
bend and come into contact with the pot body.
Fig 5
Fig 6
Fig 7 Fig 8
Fig 9

Motor Wiring
1) Tin the two lugs on the back of the motor.
2) Cut a 4 inch piece of white wire, strip 1/4" from each end and tin. Solder one end to the motor
lug with the red dot next to it.
3) Cut a 4 inch piece of black wire, strip 1/4" from each end and tin. Solder one end to the other
motor lug
4) Twist the white and black wires together along their length to keep them paired.
5) Set the motor aside.
Power Jack Wiring
1) Tin Lugs 1 and 2.
2) Cut a 4 inch piece of white wire, strip 1/4" from each end and tin. Solder one end to Lug 1
3) Cut a 4 inch piece of black wire, strip 1/4" from each end and tin. Solder one end to Lug 2
4) Twist the white and black wires together along their length to keep them paired.
5) Insert the power jack through the hole in the back wall of the box and tighten the nut on
the outside of the box using a 15mm wrench (fig 12).
Mount The Motor
1) (fig 13) Insert the pulley end of the motor through the
larger hole in the lower right wall of the box.
2) Slide the motor toward the rear of the box into the
smaller opening.
3) There are two threaded holes in the face of the motor.
Line up a threaded hole with the upper mounting hole
of the box. Insert an M3 x 5 philips head machine screw
and tighten about 3 turns. There is limited clearance
between the motor pulley and the motor mounting
screws; do not tighten this first screw down all the way
yet.
4) Line up the lower threaded hole in the motor with the
lower mounting hole of the box, insert the second M3 x
5 machine screw and tighten completely.
4) Now finish tightening the upper mounting screw.
Mounting The Speed Control Pot
1) Place a lock washer onto the pot shaft.
2) Note the alignment of the pot (fig 12).
3) There is a small vertical tab on the upper surface of
the pot. This tab will protrude very slightly through
small hole next to the pot shaft hole in the upper
surface of the box.
4) Install the nut and tighten using a 13mm wrench or socket.
Fig 10
Fig 11
Fig 12 Fig 13

IR Sensor:
1) The main box of the machine has the IR Sensor installed and partly
pre-wired.
Main Shaft Bearings:
1) Press the main shaft bearings into place in the holes provided in the
box side walls. They are pressed from the outside of the box.
2) Put a piece of tape over each bearing on the outside of the box. The
bearings are a very light press fit. They will be held securely in place
when the main shaft and cover are installed later.
Main Circuit Board Wiring
As shown in fig 15, align the winder cover to the right
and the winder box to the left.
1) Solder the black wire from the motor to pad 1
2) Solder the white wire from the motor to pad 2
3) Solder the red wire from the pot to pad 3
4) Solder the green wire from the pot to pad 4
5) Solder the white wire from the power jack to pad 5
6) Solder the black wire from the power jack to pad 6
7) Solder the white wire from the IR sensor to pad 9
8) Solder the red wire from the IR sensor to pad 8
9) Solder the bare wire from the IR sensor to pad 7
Installing The Main Shaft
Note: The main shaft has a flat surface on one ‘side’.
When securing collars, IR reflector, and
pulley, make sure that all of the allen
screws are tightened down onto this flat
surface.
1) Install a wire clip on the inside of the
main box as shown in the photo. Make
sure that it is placed so that it will not
interfere with the IR reflector.
2) Slide the red and green wires from the
control pot into the wire clip.
3) Install one collar at one end of the end
of the main shaft. Line up the allen with
the flat of the shaft and tighten the collar.
4) Remove the tape holding the bearings
in place. Insert the main shaft through the
bearing on the IR wall side of the box.
5) Slide the IR reflector onto the main shaft
with the collar part away from the IR
sensor as shown.
6) Holding the IR reflector so that it doesn’t jam against the control pot, slide the main shaft through the bearing on the
opposite wall of the box.
Fig 14
Fig 15
Fig 16

7) Fold the wires to the circuit board so that you can put the cover on the box. Take a rubber band and place it around the
box and cover.
8) Install the second collar onto the main shaft and slide it down flush
with the bearing. Do not exert any real pressure or squeeze the box as
this collar is installed. Tighten the allen on the collar. The main shaft
should turn freely with no side to side slop.
9) Remove the rubber band and open the cover. The IR reflector now
must be distanced properly from the IR sensor.
10) As per upper photo, the face of the IR reflector should be set so that
it is 3/16" (4.5mm) from the inner box wall. Position the IR reflector at the
proper place, make sure the allen will contact the flat of the main shaft
and tighten the allen.
11) Install the 4 self tapping screws to secure the cover to the box.
12) Slide the main shaft pulley onto the main shaft. Install the drive belt
around both pulleys. Position the main shaft pulley so that the drive belt
is in a straight line with the motor pulley. Make sure that the allen on the
main shaft pulley is aligned on the flat of the main shaft. Tighten the
allen.
13) Install the winder arm flush at the end of the main
shaft.
Cross Feed Assembly
1) Thread a 1/4" nut all the way down onto the cross
feed shaft and tighten.
2) Install a 1/4" flat washer onto the shaft.
3) Insert the shaft through the aluminum stand-off.
4) Install a 1/4" washer,
5) Install a 1/4" lock washer.
6) Install a 1/4" nut and tighten.
7) Set aside the two 1/4" collars from this kit.
Mounting The Winder
1) Line up two holes in the Cross Feed Assembly with the two pre-
drilled holes on the side of the box and cover. Install the assembly
using the two ½" self tapping screws provided.
2) Attach the machine to the white base using the two large 1/4 x 20
screws provided. Insert the screws from the counter-sunk side of the
board and tighten into the pre-tapped holes in the bottom of the
machine.
3) Install the two 1/4" collars from the cross feed assembly kit onto
the cross feed shaft. The allens on the collars should be positioned
so that they will come into contact with the upper surface of the
shaft only. Since the coil wire will pass under and against the lower
surface of the limit shaft, it is imperative that the lower surface of
the bar remain unmarked and smooth.
3) Install the speed control knob.
Fig 17
Fig 18

Attaching A Bobbin To The Winder Arm
We have found that the simplest and usually the best method
for securing a bobbin to the winding arm is by using a piece of
double sided tape. Supplied with the machine is a sample of this
type of tape. It can be a cloth or a fiber glass woven double
sided tape (usually marketed as a carpet tape) and can be found
in most hardware stores. Notice from the sample that the tape is
folded in two to provide the best conformity. The same piece of
tape can normally be used numerous times.
Before pressing the bobbin into place, visually make
sure that the bobbin is centered on the arm so that the coil
winds evenly.
Starting A Wind
1)Place your spool of coil wire about 3 or 4 feet behind you and
about on the level of the winder base so that the wire may
unspool end on. It will help if the leading edge of the spool is
tipped up about 15 degrees.
2) Take a bit of masking tape and tape the end of the coil wire to underside of the winding arm. This should provide enough
‘free’ wire after the wind is completed to solder to the bobbin’s eyelets or to the lead out wires.
3) Rotate the winder arm by hand to run the coil wire around the bobbin about 6 turns.
4) Run the wire under the limit shaft and adjust the inner limit collar so that the wire winds inside of the inner bobbin edge.
You should be rotating the winder by hand to make this adjustment.
5) Repeat the same procedure to set the outer limit collar.
6) The coil wire is grasped lightly between thumb and forefinger so that it may be controlled and moved between the set
limits. The pressure that is exerted on the wire by the thumb and forefinger provides the winding tension.
7) When you are satisfied that the limits are properly set, turn the machine on at low speed. Slowly move the wire back and
forth between the limits to again check that the wire is winding properly within the bobbin.
8) If everything is satisfactory, increase the speed as required.