MESA-HPX. Assembly and Installation Manual. w/appendix A for Prodelin Antenna. 901-Manual-MESA-HPX

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1 MESA-HPX Assembly and Installation Manual w/appendix A for Prodelin Antenna 901-Manual-MESA-HPX Rev 30 March 2011

2 2

3 INDEX Installation Cautions 4 Installation Pole Height Orientation of the Mount on the Ground Pole Attaching the Mount to the Mounting Pole 5 Attachment of the Antenna to the Mount 6 Mounting of the Feed Assembly 7 Prodelin Skew Assembly 8 Routing of the TX Coax, RX Coax and Skew Cable 9 Securing of Cables from the Feed Assembly 10 Critical Wiring Instructions 11 Mount Connector Box 12 Mount Wiring Configuration 13 Skew Wiring Configuration 14 Motor Specifications 15 Appendix A: 18 Attaching the Prodelin 1.2meter Dish to the MESA 123A 3

4 CAUTIONS: INSTALLATION POLE HEIGHT The pole must be tall enough that the dish face will clear any structure or obstacle that it may encounter. Restriction of the movement in such a manner could cause damage to the dish face, mount or both. It is up to the installing personnel to assure that proper clearances are maintained. MOUNT ALIGNMENT IMPORTANT!! Before tightening the mount bolts to the installation pole, go to your HTML screen and select Calibrate Dish (See Calibrate Dish in your H3 Operating Manual under Advanced Functions.) Following a completed Calibrate Dish rotate the whole mount on the installation pole until it conforms to the instructions below. Once this operation is complete, tighten the Mount Retaining Screws. This will secure the MESA HPX mount to the pole. Face the reflector EAST for NORTHERN Hemisphere WEST for SOUTHERN Hemisphere Mount Retaining Screws at 6 locations around the mounting pipe. 4

5 Attaching the Mount to the Mounting Pole Step 2 When placed on the fixed Mounting Pole, the MESA-HPX Motorized Mount should be in this approximate position. From this position it will be easier to attached the Antenna, Feed Assembly, and run the cables as required. To secure the MESA Mount to the Fixed Pole remove all six Cap Screws from the 3.5 MESA Pole Base. (Red Arrow) Orient the mount in accordance with the instructions given in Caution section of this manual and then insert 2 of the Securing Screws (Blue Dot) and tighten securly. This step squares the outer pole to the inner pole (levels). Now replace the remaining 4 Securing Screws into the MESA Mounting Pole and tighten. 5

6 ATTACHMENT OF THE ANTENNA TO THE MOUNT Step 3 (For Prodelin Dish suggestions see Appendix A) Attach the Antenna to the MESA mount using the hardware supplied by the Antenna manufacturer in the locations shown by the (Red Arrows). (4 locations) Attach the Antenna short arm brackets (if supplied) to the MESA Mount using the hardware supplied with the MESA Mount in the locations marked by (Yellow arrows.) Assemble the Dish RF Arm Assemblies as per the Antenna manufacturers instructions using their supplied hardware. 6

7 Mounting of the Feed Assembly Step 4 Pre-grease with low temperature synthetic grease the Feed Assembly where the two Feed Clamps join together (Green Arrow). Secure MESA Skew Assembly using the Feed Assembly Clamp Screws supplied with the SkyWare Antenna (Red Arrows). Secure MESA Skew Assembly Connector Bracket to the SkyWare Side Arm Tube using the screws supplied with the Connector Bracket (Purple Arrow). Skew Cable Connector It connects the Skew Assembly to the Mount For wiring see Skew Wiring Diagram in this manual. Prodelin Skew Assembly 7

8 PRODELIN SKEW ASSEMBLY Prodelin Skew assembly Mounting Bolt Prodelin Skew Assembly (See wiring diagram in Wiring Configuration in this manual. Wave Guide Spacer Place between the Wave Guide and the Transmitter with O ring towards the wave guide. The Wave Guide Spacer rests in the cradle supplied by Prodelin. The retaining ring which is shipped the antenna must not be used. If used it will cause binding and prevent the rotation of the wave guide. 8

9 ROUTING OF THE TX COAX, RX COAX AND SKEW CABLE Step 5 The RF Skew Assembly rotates 102 degrees Clockwise and Counter Clockwise from the position shown in the picture below. It is extremely important to allow the Coax Cables enough slack to complete this full travel without applying any stress to the LNB and BUC connections. The example shown below is a typical wiring configuration which accomplishes this by Zip Tying the two coax cables together (Red Arrow) and then attaching the cables to the Waveguide RX Filter (Green Arrow) allowing a cable loop large enough to let the Skew Assembly travel +/- 102 degrees (204 degrees) as shown. Skew Assembly with LNB shown in Horizontal Field. Skew Cable Connector It connects the Skew Assembly to the Mount Near the top of the RF Arm secure the Coax Cables and the Skew Cable together (Purple Arrow) using another Zip Tie. NOTE: Use dielectric grease or coax sealent to prevent water intrusion into the Coax Cables. 9

10 SECURING OF CABLES FROM THE FEED ASSEMBLY Step 6 Near the bottom of the RF Arm secure the Coax Cables and the Skew Cable together (Red Arrow) using another Zip Tie as shown. Step 7 Completing the wiring from this point is critical. See Pictorial Illustration on next page. You should start your cable runs from the LNB/BUC/Skew Assembly and work down to the bottom of the mounting pole. This way the cable lengths and all cable loops will be uniform. Remember that Elevation moves approximately 90 degrees in total travel. From the lower RF Arm run the cables under to the back of the Antenna and Zip Tie to the bottom of the Angle Bracket that attaches to the Dish (Red Arrow). Make sure you are tying the Cables to the same side of the MESA Mount that the Connector Box (Yellow Arrow) is located. Once you have tied the cables to the Angle Bracket you MUST make a Cable Loop approximately 8 in diameter to allow for full MESA Elevation travel (Green Arrow). The Cable Connector Box also doubles as a Cable Clamp for the 2 Coax Cables which will pass through the connector box and the Skew Cable which will terminate inside the Box. On the right side of the Connector Box both coax cables and the Antenna Controller Cable will exit together. Make another Cable Loop approximately 12 in diameter and tie the cable about half of the remaining pole height from the ground (Purple Arrows) to allow 270 degree Azimuth Travel. 10

11 CRITICAL WIRING INSTRUCTIONS Critical wiring instructions The MESA Mount Connector Box (Yellow Arrow) serves several functions. 1> Allows easy access to all wiring of Azimuth, Elevation, and Skew motor connections. 2> Simple Controller Cable connections. (Terminal Block) 3> Cable path management to simplify and guide cables. 4> Built in Strain Relief of all external cables. 11

12 The MESA Mount Connector Box Antenna Bracing 12

13 MOUNT Wiring Configuration SKEW Cable Control Cable Wiring (Recommended wire size up to 100 is 18 AWG.) J1-1 Azimuth Motor (-) BLACK J1-2 Azimuth Motor (+) *BROWN 9 Conductor J1-3 Elevation (+)/ Skew (-) *RED J1-4 Elevation (-)/ Skew (+) ORANGE CONTROL CABLE J1-5 Azimuth Count (pulses 2-50 msecs) YELLOW J1-6 Common (Ground) GREEN J1-7 Elevation Count (pulses 2-50 msecs) BLUE J1-8 Skew Count (pulses 5-50 msecs) WHITE J1-9 DC Power (12 to 24 VDC) optional sensor volts PURPLE * The Skew Motor Shares the Azimuth and Elevation connections. To run the Skew Motor, the controller needs to switch both Azimuth Outputs at the same time to either Pos or Neg Volts and do the same with Elevation Outputs to the opposite voltage. This will prevent the AZ and EL Motors from moving when Skew Motor is moving. Skew Cable Wiring J2-11 Skew Black (-) J2-12 Skew Red (+) J2-13 Skew Green J2-14 Skew White J2-15 Skew Orange (optional hall/opto sensor) 13

14 SKEW WIRING DIAGRAM Part Number 455-A0185 Opto (Quad) Sensor RED ORANGE BLACK WHITE GREEN 14

15 . MESA 120 HS Motor Specs 08/30/2010 Azimuth Motor 1> The Azimuth Motor uses a quick rise in Motor Current to determine Stall Limits. (Max and Min Azimuth) Do not allow motor current to Exceed Azimuth Stall Current listed below. 2> Motor counts are based on total pulse transitions rise/fall or fall to rise. Total Motor Counts will vary depending on the Voltage-Current level when hitting a Max or Min Limit. 3> Total AZ Travel = 270 degrees Total AZ counts = 4610 to 4710 Counts per degree = > Count Transitions are greater than 2 milliseconds Specs> Azimuth Motor 24 5 Amps Azimuth Motor Torque 3 in/lbs Azimuth Stall Current 6 Amps (set to) Azimuth Stall Volts < 6 VDC MOTOR Volts Amps Secs/Deg Deg/Sec Azimuth Azimuth Azimuth Azimuth Azimuth Azimuth Azimuth Azimuth Azimuth Azimuth

16 Elevation Motor 1> The Elevation Motor uses a quick rise in Motor Current to determine Stall Limits. (Max and Min Elevation) Do not allow motor current to Exceed Elevation Stall Current listed below. 2> Motor counts are based on total pulse transitions rise/fall or fall/rise. Total Motor Counts will vary depending on the Voltage-Current level when hitting a Max or Min Limit. 3> Total El Travel = 93 degrees Total El counts = 3125 to 3175 Counts per degree = (non linear) 4> Count Transitions are greater than 2 milliseconds Specs> Elevation Motor Amps Elevation Motor Torque 3 in/lbs Elevation Stall Current 6 Amps (set to) Elevation Stall Volts <8 VDC Start Current at 0 degrees = 3.5 to 4.0 Amps Current at 47 degrees = 2.0 Amps MOTOR Volts Amps Secs/Deg Deg/Sec Elevation Elevation Elevation Elevation Elevation Elevation Elevation Elevation Elevation * Elevation Speed and Current vary greatly depending on direction. Above values are averaged. 16

17 Polarity (Skew) Motor 1> The Polarity Motor uses a quick rise in Motor Current to determine Stall Limits. (Max and Min Polarity) Do not allow motor current to Exceed Polarity Stall Current listed below. 2> Motor counts are based on total pulse transitions rise/fall or fall to rise. Total Motor Counts will vary depending on the Voltage-Current level when hitting a Max or Min Limit. 3> Total Polarity Travel = 204 degrees Total Pol counts = 1150 to 1170 Counts per degree = > Count Transitions are greater than 2 milliseconds Polarity Motor 12 Amps Polarity Motor Torque 43 in/lbs Polarity Stall Current 1.0 Amps (set to) Polarity Stall Volts < 8 VDC MOTOR Volts Amps Secs/Deg Deg/Sec Polarity Polarity This information It is intended for general concept of use. Document: 901-MESA-HPX Revision: 09/09/

18 PRODELIN 1.2 Meter DISH When mounting the Prodelin 1.2 meter dish it is acceptable to use the provided High/Low screws to attach the dish to the mount. If the dish is expected to be removed several times during the usage of the system it is highly recommended that the carriage bolts be used instead. To do that, follow the instructions below. Appendix A: Attaching the Prodelin 1.2meter Dish to the MESA 123A Tools : drill, 5/16 drill bit, socket wrench, ½ inch socket, 9/16 inch socket, 3/16 allen wrench. Included parts: 5/16 washers (12), 5/16-18 X 2-1/2 button head bolts (4), Hi/Lo 5/16 X 1 1/4 screws, MotoSAT 120HS Prodelin dish brackets (2). Hi/Lo Screws These screws are designed to be installed only once because of the cutting action of the threads. If the Antenna is going to be removed several times this attachment method is not recommended. They are used in conjunction with the dish brackets pictured below. Button Head Bolts These bolts are to be used when the Antenna will be removed often.. They are used in conjunction with the dish brackets pictured below. Prodelin Antenna Mounting Brackets Hi/Lo Screws 4 Places, (note recessed holes). Attach to back of antenna by inserting screw through these holes from this side. Button Head Bolts 4 Places, note that this bracket will be attached to the mount first and then using the button head bolts fasten the antenna from the front side to the bracket with bolts provided. 18

19 This is a picture of the MESA mount (Prodelin only) that has the antenna brackets installed waiting for the antenna to be mounted using the Button Head Bolts. They must be removed and attached to the back of the antenna if the Hi/Lo option is used. 19

20 Preparing the Prodelin Antenna for the option Using a 5/16 drill bit, drill the holes through to the front of the dish as indicated. Insert from the front side of the dish the (4) 5/16-18 X 2-1/2 carriage head bolts with (4) 5/16 washers. The Prodelin dish is ready for installation onto the MESA mount. Attach the dish to the mounting brackets on elevation mount plate with the (4) 5/16-18 X 1-1/4 Hex head bolts using (4) 5/16 washers 20

21 21

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