RIDGE MAST MOUNT (RMM)

May 5, 009 Revision E ASSEMBLY MANUAL (RMM) General Dynamics Satcom Technologies 1500 PRODELIN DRIVE NEWTON NC 8658 88-464-4141 www.gdsatcom.com

1.0 INTRODUCTION: 1.1 Features: The Ridge Mast Mount (RMM) is designed for use as a non penetrating mast mount for the.75m, 1.0M and 1.M General Dynamics Antenna. It has several unique features as given below: 1. It can be used on flat roofs (with up to 5 degree slopes) as well as peaked roofs up to a 30 degree pitch as shown in Figure 1.. The ballast is fixed and held captive by the tension rods and is integral to the mount structure. 3. The design incorporates Belville washers stamped into the end plates that allow for the expansion and contraction of the blocks during thermal changes while still maintaining a rigid structure. 4. As shown in Tables 1,, and 3, with smaller antennas, higher wind speeds, exposure factor, height above ground can be tolerated. The smaller antenna presents less area and hence has less wind force than a larger antenna. 5. Note that this mount can also be used on flat roofs and therefore substitute for the 5 1/ x 5 1/ NPMM. 6. The mount will require the use of a tether (especially when used on a peaked roof or where a sliding mount could leave the roof). Those installations where a natural barrier exist, like a parapet, will not require the tether. Initially this tether will have to be locally purchased and fabricated from 3/16 steel cable and attached to the mast and tether point with three (3) cable clamps on each end. 7. Note that the diagonal braces can be temporarily used in the peaked roof application to help hold the concrete blocks in place until they can be skewered by the rods. 8. The mount is light and compact and can be easily and economically shipped. 9. Because the mount requires 16 concrete blocks the installer cannot put too few ballast blocks on the mount.

10. Because the ballast is held captive, it is more difficult to later remove the blocks for some other purpose and hence risk the mount moving. 11. The rubber pads are provided to protect the roof as well as to provide a uniform coefficient of friction to prevent sliding. The pad is made of Butyl rubber and is designed to be compatible with most roof surfaces (asphalt, tile, membrane, tar and etc.) and to be resistant to deterioration due to weather (e.g. rain, snow and ice),most chemicals and ultra-violet light from the sun. It is not known to react with or be harmful to any roof material. 1. TOOLS REQUIRED: TOOL REQUIRED 7/16" SOCKET or WRENCH 9/16" SOCKET and WRENCH 3/4" WRENCH ( REQUIRED) HARDWARE SIZE USED ON 1/4-0 3/8-16 1/-13 MAXIMUM RECOMMENDED TORQUE (ft/lbs) 6 19 ADDITIONAL TOOLS REQUIRED: 1 Rake or Shovel (to remove rocks) 1 Broom (to sweep away dirt and small rocks) 1.3 SHIPPING / INSTALLED SIZE AND WEIGHT Shipping Size and Weight Installed Size and Weight Total Weight of Various Antennas 8 x 3 x 7 Box Mount (less pads) 70 lbs 0.75M 1.0M 1.M 97 pounds Concrete blocks (16 x 30 lbs) 480 lbs Total Mount 550 lbs Antenna Outdoor Unit(ODU) Ridge Mast Mount 5 1 550 65 1 550 67 1 550 Total Installed Wt 614 67 69 3

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.0 APPLICATION INSTRUCTIONS (1) Locate your installation site on the Wind Speed Map (10-1008) from Figure. () Determine the design wind speed from the map for your location. (3) Select the proper exposure factor (B or C) as described below. Exposure B: Urban and suburban areas, wooded areas, or other terrain with numerous closely spaced obstructions having the size of single family dwellings or larger. Obstructions must extend 1500 feet in all directions from the building. Exposure C: Open terrain with widely scattered obstructions having heights generally less than 30 feet. Includes flat, open country and grass lands. (4) Using the design wind speed and the exposure factor, determine the maximum building height from the tables 1 for 0.75M, for 1.0M and 3 for 1.M. If the actual building is taller than the height given in the table, the RIDGED ROOF MOUNT cannot be installed at this site. (5) Maximum pitch of roof for use on peaked roof is 30 degrees. (6) If used on corrugated roof, fill in between corrugations with weather treated lumber. (7) The 8" x 8" x 16" concrete blocks must be manufactured in accordance e with ASTM C90, Grade N-1. The concrete blocks shall average at least 8 pound each. If not, add weight by breaking blocks into small pieces and inserting the pieces in the cavity of the blocks, (one block per side). The pieces will be captured at final assembly. 5

TABLES #1 -.75 METER RECTANGULAR ANTENNA PEAKED OR FLAT ROOFS DESIGN WIND SPEED (MPH) EXPOSURE B MAXIMUM BUILDING HEIGHT (Feet) EXPOSURE C MAXIMUM BUILDING HEIGHT (Feet) 70 75 80 85 90 95 100 105 110 115 10 15 800 540 375 64 189 137 101 75 57 43 33 5 486 67 151 88 53 3 0 TABLE # - 1.0 METER RECTANGULAR ANTENNA PEAKED OR FLAT ROOFS DESIGN WIND SPEED (MPH) EXPOSURE B MAXIMUM BUILDING HEIGHT (Feet) EXPOSURE C MAXIMUM BUILDING HEIGHT (Feet) 70 75 80 85 90 95 100 154 10 69 48 33 4 18 38 0 DESIGN WIND SPEED (MPH) TABLE #3-1. METER OFFSET ANTENNA PEAKED OR FLAT ROOFS EXPOSURE B MAXIMUM BUILDING HEIGHT (Feet) EXPOSURE C MAXIMUM BUILDING HEIGHT (Feet) 70 0 6

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RIDGE AND FLAT ROOF MOUNT INSTALLATION INSTRUCTIONS Note: The Ridge and Flat Roof Mount can be installed on peak roofs or flat roofs. The following instructions have been generalized for either type of installation. (1) See Figure 7 and 8 and Table 4 for identification of the parts. () Select the installation area. Locate South and plan to direct the mount generally South. For peak roofs select the direction closest to direction of the satellite of interest. (see Figure 1 and 7 for the definition of mount direction). (3) Assemble an end plate with full flanges to an end plate with cut-off flanges using three (3) 3/8-16 x 1.0" long bolts, six (6) flat washers, 3 lock washers and nuts. Hand tighten only. NOTE: On peak roofs position end plates so the same amount of slot shows above the tops of the end plates. FIGURE 3 8

(4) Assemble the remaining two end plates using one (1) 3/8-16 x 1.0" bolt (in the bottom slot), the large U-Bolt, U-Bolt Saddle and notched angle (in the top slot and hole), (4) 3/8" flat washers, (3) lock washers and (3) hex nuts. Bend the notched angle as required. Hand tighten the bolt but leave the U-Bolt loose. NOTE: On peak roofs position end plates so the same amount of slot shows above the tops of the end plates. (Same as Figure 3) FIGURE 4 9

(5) Place rubber pads on roof using end plates to locate position. Flanges on end plates point out, away from mount. FIGURE 5 10

(6) Place 16 concrete blocks on rubber (8 each side). Note: If concrete blocks slide on roof, they can be temporarily held in place using angle braces as shown. FIGURE 6 11

(7) Skewer threaded rods through concrete blocks and plates. Fasten using flat washers and nuts (4 places). Fully tighten nuts. Then add a second nut and fully tighten. (see Figure 7). (8) Fully tighten the straight bolts that join the end plates. Do not tighten U-Bolt at this time. (4, 3/8-16 x 1.0" bolts). NOTE: Check to be sure the same amount of slot shows above the end plates as set in steps and 3. (9) Attach angle braces using 3/8-16 x 1.0" long bolts, nuts and flat washers. Finger tight only. (see Figure 7). Note the hardware captures the notched angle (from step 4). (10) Slide mast pipe down through U-Bolt until the bottom touches the lower bolt thru the end plates. (see Figure 7). (11) Attach tube supports to the angle braces using 3/8-16 x 1.0" bolts, nuts and flat washers. Finger tight only. (1) Attach channels to mast pipe using 3/8-16 x 4.0" bolt, nut, lock washer and flat washers. Finger tight only. NOTE: The head of the bolt must be on the opposite side of the pipe from the channel it is holding. (13) Fasten tube supports to the channels using two small U-Bolts and U-Bolt plate. Position first U-Bolt to within 1" of end of tube support. Finger tight only. (14) Fully tighten angle braces to the end plates. (4 places). (15) Fully tighten tube supports to the angle braces. ( places). (16) Fully tighten channels to the mast pipe. ( places). (17) Level mast pipe and fully tighten small U-Bolts. (18) Fully tighten large U-Bolt. 1

FIGURE 7 13

FIGURE 8 14

TABLE #4 - PARTS LIST AND WEIGHT ITEM # PART # DESCRIPTION QTY 1 3 4 5 6 7 8 9 10 11 1 13 14 15 16 17 18 19 0 1 3 4 0156-905 0156-906 0156-907 0180-8 047-11 840-009 05-40 05-403 047-1 050-41 050-413 5003-015 5003-016 803-03 803-006 8100-007 810-007 8104-007 801-040 801-04 801-043 8400-001 80-040 80-04 L.H. END PLATE R.H. END PLATE MOUNTING PLATE BRACKET COMPRESSION ROD U-BOLT CHANNEL 3/8-16 x 3" U-BOLT END PLATE ANGLE DIAGONAL ANGLE BRACE CHANNEL BRACE CLAMP MAST PIPE DIAGONAL TUBE BRACE 1/16 x 18 x 70" RUBBER PAD 1/16 x 18 x 6" RUBBER PAD 3/8-16 x 4.00" BOLT 3/8-16 x.75" BOLT 1/4-0 HEX NUT 3/8-16 HEX NUT 1/-13 HEX NUT 1/4" FLAT WASHER 3/8" FLAT WASHER 1/" FLAT WASHER 1/4-0 x 1" U-BOLT 1/4" LOCK WASHER 3/8" LOCK WASHER 1 1 1 1 10 8 14 8 8 4 4 4 8 14 15