The Zimbelstern for Creative Church Music

Der Zimbelstern

The Zimbelstern for Creative Church Music

W240 N6532 Ash Street Sussex, WI 53089-3016 1-877-240-8233

Zimbelsterns – Installation Instructions

Please read all instructions thoroughly before proceeding with the installation of the Zimbelstern!!!

Remember that not all instructions apply to all models.

Items necessary for installation:

Electric drill (It may also help to have a flexible extension shaft, depending on the access where some items are to be installed.), 3/32” bit, 1/8” bit, 5/16” bit (brad point or multi-spur is preferable), awl, small mallet or hammer, soldering iron, solder, wire stripper, an assortment of flat and Phillips screwdrivers, small round file, masking tape, and a small amount of quick-setting epoxy or similar adhesive. If the thumb piston is ordered, you will also need an 11/16” multi-spur or spade bit. If the toe stud is ordered, you will need a 3/8” bit, too. The proper drill sizes for piloting will be dependent on the quality and type of wood you’re drilling into.

1.Carefully remove Zimbelstern items from the shipping container and place them on a clean surface for easy viewing. Do not touch the bells. It should not be necessary. If the bells are ever touched, to maintain their clean appearance, use a clean cloth and wipe the bells completely, but carefully, only where needed, with minimum pressure so as not to disturb the precise way they are mounted. The chemicals from your fingers can damage the bells over the years. It is also important for the bells to be held in their position by the felt above and stay at the designated height on their respective posts.

2.Determine the best location for the bell unit. An ideal location would be as high in the church as convenient and feasible, preferably with an inexpressive division or in the general area of the pipework or organ speakers. Some units have been placed on walkboards, case roofs, and even on exposed beams in the ceiling. If the bell unit must be located in a chamber, it should be as near to the chamber’s opening and as high as possible to minimize any ‘tone shadow’ effect in the room. The bells should be able to easily project their sound into the church. Access to the bell unit should be as convenient as possible, since six wires will need to be connected to it and for any necessary adjustments to be made. The bell unit must be mounted on a level surface for it to function properly. A small level is already mounted on the bell frame’s main horizontal wood piece at the ‘wide’ end near where the wires are connected. Being level in the direction the swingers move is very important. The unit’s final adjustments are done with the bubble in the center of the level, but it is OK if the magnet side of the frame is a smidgen higher than the other side, according to the level, but the magnet side cannot be slightly lower than the other side. If desired, blocks or angle braces may be fastened to the surface the bell unit rests on so it would not get pushed over an edge. These bracing items should be felted where they rest near the bell unit so no vibrations are transmitted when the bells being struck. It is preferable that these braces not be clamped tight to the bell frame, but just to stop it from being accidentally knocked over the edge of something. The bell frame is not prone to move by itself while in operation.

3.The unit is shipped with the bells set on their respective posts. The strikers are usually packed separately in a small box (so as not to startle the shipping company people) and need to be carefully placed in their respective brackets according to the directions provided on the small box.

4.Determine the best location for the circuit board assembly. It should be located within reach of the ten foot cable provided with the controls. Be sure that the location of the circuit board assembly does not interfere with the movement of the roll top, keyboard access, the ability to lift and tilt the keyboards for servicing, or access to any other console component. Remove the four mounting screws (taped in reverse position for shipping) and set the plywood piece in its intended location. If necessary, you can get by using just two of the screws. Mark the centers of the screw positions you’ll use. Drill with a 1/8” bit and fasten the circuit board in position. Most installations are done with the three controls mounted somewhere on the console, which are connected to the circuit board assembly mounted inside the console, from which six wires run to the bell frame. Please see the related wiring diagram for the unit you ordered. Wiring the Zimbelstern should be done with wire no smaller than #26. For approximately every fifty feet of cable length (one-way) for #24 wire, there can theoretically be up to a ½ volt drop in the voltage that reaches the bell frame. There have been installations done with 80’ cable lengths and no detectable voltage drop has been measured, but in order to have the maximum possible voltage to operate the Zimbelstern, it is advisable to use large enough cable or use two wires for each connection necessary and also keep whatever cable runs to a minimum. Six-pair #24 cable has been a proven success with no voltage drop, even at 100’ lengths.

5.Using the Allen wrench provided, remove the knobs usually attached to the three controls. Remove the Zimbelstern control(s) from the clear Lexan piece(s) and use the Lexan piece as a template for you to determine an appropriate place on the console for locating the control(s). Be sure that the location of any control does not interfere with the movements of the roll top, the access to the keyboard, the ability to lift and tilt the keyboards for servicing, or access to any other console component. (Use these same directions whether you have a single plate with all three controls together or three individual plates for delay, speed, and volume.) Assuming a ¾” thick panel, each control would extend about 1 1/4” behind the panel and about 7/8” (including knob) in front of the panel. Remember to allow for fitting the 2 ½” (total length) control into the panel from behind. Mark the center for each control, punch each center with an awl, pilot with a 3/32” bit, and drill a hole with a 5/16” spur bit as straight as possible and halfway through from both sides of the console panel if practical with your drill and bit. On the back of the panel where you just drilled, place the flat Lexan mounting piece in its relative position (with the words reading backwards, facing the back of the panel). Holding it in place with tape can be helpful. Mark the centers for each of the eight mounting screws, punch them with an awl, then carefully pilot with the 1/8” bit but only halfway through the panel. Mount the control(s) properly back on the clear Lexan piece(s). Use the #8 x 1” screws and ½” long spacers to mount the Lexan plate now holding the control(s) as straight as possible through the 5/16” holes. The screw mounting holes are oversized to allow more accurate placement of the Lexan piece(s) for proper visual alignment as the control(s) come through the panel. Each control should turn freely and not be binding against the wood. Shimming a spacer or two and/or filing a hole as needed can also help.

6.Place the engraved plaque(s) on the console in position with the control(s) coming through the center of each hole. If it has a peel and stick backing be sure to align it carefully because you probably won’t get a second chance to stick it in place. If there is no peel and stick backing then remove the plaque and place a thin coat (so it won’t squish out beyond the plaque) of quickset epoxy on the back of the plaque. Hold it in place until the epoxy has set up well.

7.Turn each control counterclockwise as far as it will go. Set each knob on the shaft with indicator line pointing approximately to a “7:00” position. Using the small Allen wrench provided, tighten the knob in position. Turn the knob fully clockwise to about a “5:00” position to see if the knob movement correct and reposition it as needed. Tighten the other screw of the knob onto the shaft. Do this procedure for each control. For storing the Allen wrench, fasten the holder provided on the inside of the console near the control(s) or near the circuit board assembly and stick the provided hex wrench label nearby.

8.If you have ordered a reverser, it is the smaller circuit board mounted next to the Zimbelstern circuit board on the circuit board assembly. The toe stud and piston, either provided or existing, are to be hooked up to the two terminals listed for them. It is possible to hook two connectors to one screw terminal by placing one ‘normally,’ with the larger end ‘down,’ and place the second one in a reverse position, to minimize the height needed for the screw to tighten down upon. Be sure to follow the polarity, if necessary, with an existing toe stud or piston. If you wish to cancel the Zimbelstern with the organ’s general cancel piston, hook it up to the two terminals listed for such on the circuit board assembly terminal strip (also shown on the wiring diagram), following the polarity if necessary. For mounting the supplied Syndyne toe stud, pilot for the four mounting screws with a 3/32” bit. Drill a 3/8” hole in the center of those four corner holes for the wire with the attached terminal lugs to be fed through. For mounting the thumb piston, determine the appropriate location and pilot with a 3/32” bit. To help prevent breakouts, tightly place a piece or two of masking tape to cover where the edges of the hole would be. Punch through the masking tape for the center hole. Use an 11/16” multi-spur or spade bit to drill carefully for the thumb piston without disturbing any existing wires behind or nearby. File the hole slightly to allow for a reasonable press fit for the thumb piston. Otherwise use quickset epoxy if needed.

9.Hook up all the wires to the circuit board assembly as appropriate, observing colors, numbers and polarity. Once the unit is operational, the volume can be adjusted from the console. The unit was adjusted initially at approximately 13.5 volts (about 16 volts if an AC transformer was provided) so, depending on the voltage the unit is receiving where it is installed, the softest setting where all five bells first begin to sound together will be at approximately “8:00.” The magnets should be adjusted if needed (see item C under “Troubleshooting” below) so all the bells are silent at the lowest volume setting to allow the organist to fade the Zimbelstern up quietly or fade it out at the end of a piece of music. Enjoy your new Zimbelstern. The more you use it, the more creative ways you will find to use it. For a frequently updated list of creative ideas on how to use the Zimbelstern go to .

TROUBLESHOOTING

A.If the bell unit fails to function, first check to be sure that all wiring has been done properly and that the circuit board(s) are receiving the appropriate power.

B.The console controls are intended to increase the delay, increase the speed, and increase the volume as each of the respective knobs are turned clockwise. If the opposite is happening, switch the outside connection at the control in question to the other outside connection.

C.If a bell is sounding too loud or too soft in relation to the other bells, first be sure that the adhesive felt is across the top of each bell to hold them in position and that each magnet’s horizontal spring is in position between the back of the brass adjustment screw and where the magnet mounts to the wood frame. Also be sure that each swinger is properly mounted in the center of each bracket and swings freely. Turn the speed all the way down so that it is easier to hear the bells individually. To equalize the softest beginning volume of the bells turn the volume knob to about “8:00” or where they first start to sound. To increase the sound of a bell, use the screwdriver provided and turn the spring-loaded brass screw on the magnet arm counterclockwise, moving it “out” ever so slightly. It may take only a fraction of a turn to make a big difference. To decrease the sound of a bell, turn the screw clockwise, moving it “in.” If you ever adjust any of these brass screws, be sure to adjust one magnet at a time between listening for the resulting sound balance.

D.If a magnet seems to make a noise when striking the bells or when returning to its resting position, first check to be sure that the mounting screws, plus the bolts and nuts for the magnet’s vertical arm are tight. Also be sure that the magnet has its small, horizontal return spring in position (mentioned in C above) and that there is a cylindrical piece of gray felt (probably with another color of felt at the end) coming out from the horizontal wood the magnet is screwed onto. This acts as a ‘stop.’ If a “thunk” is heard only when the striker hits its bell, be sure the swinger bracket has just a slight bit of movement when lightly ‘twisted’ side to side and is not screwed tight against the horizontal wood piece from which it hangs. Another rare possibility is to tighten (or loosen and retighten) the washers on the swinger so that they hit the bell evenly. If the noise comes only when the magnet is moving to the “off” position, check to be sure that the lower, curved part of the magnet lever arm is hitting the damping cylinder properly. Also re-read “C” above.

E.If the console has a large solenoid for operating the combination action, there is the possibility of a large voltage spike occurring. Even though it is only for a fraction of a second, the spike could ‘zap’ the Zimbelstern circuit board’s output transistors. If this happens, one or more of the bells may be frozen ‘on’ as soon as the unit is turned on by the switch or piston. I can send replacement transistors (or you can find some locally; it’s a rather standard transistor, 2N4403, or 2N4402) or a new circuit board if absolutely needed (the ‘old’ one to be returned), but then I will also send a small AC transformer that can plug into a (preferably) switched AC outlet to resolve the situation. If provides about 16 volts DC, so the ‘soft’ end of the volume of the bells may need to be adjusted.

F.On some consoles a voltage drop occurs as more stops are added or more notes are played which can affect the softest volume or the volume level in general or create a volume inconsistency when playing notes and using the Zimbelstern at the softest level. The same AC transformer mentioned in “E” above should help to resolve this kind of problem.

G.Of course, if a problem still does not seem able to be resolved, please write or call and give the specifics of the problem encountered. If permission is given to return a part of a Zimbelstern, any warranty repairs necessary will be completed as quickly as possible.

WARRANTY

Zimbelsterns are warranted to the original purchaser (church and/or organ builder) against defective workmanship or materials for a period of five (5) years after the unit is installed. This warranty shall not apply to any unit that has been improperly repaired, rebuilt, altered, or in any way tampered with, improperly installed, or abused. If any part of a Zimbelstern is found to be defective, return authorization must first be acquired before it is returned to Der Zimbelstern, Gary W. Foxe, W240 N6532 Ash Street, Sussex, WI, 53089-3016, all transportation charges prepaid. Careful packing and appropriate insurance are the customer’s responsibility. If, upon examination, a part is found to be defective under the terms of this warranty, it will, at the option of Der Zimbelstern, be repaired or replaced, free of charge. Should repairs or replacement of parts be necessary due to improper installation or improper usage, or other causes for which the manufacturer is not responsible, a charge for such parts and repairs will be made at the then prevailing labor and material rates. Der Zimbelstern shall not be liable for direct or consequential loss or damage resulting from the Zimbelstern and/or the use thereof and/or installation. This warranty is expressly made in place of any and all other warranties.

Prices – While every effort is made to maintain prices as currently stated, prices are subject to change without notice.

Terms – One-third downpayment with order, balance C.O.D. or prior to shipment. Other payment terms can be made through special arrangements made prior to shipment. Orders, once received, can only be canceled upon receipt of written notice by Der Zimbelstern, provided Der Zimbelstern is fully compensated for any losses due to said cancellation.