4096-432 June 15, 2011 REVISION D ASSEMBLY MANUAL SERIES 1125 1.2M Ku-BAND Rx / Tx ANTENNA SYSTEM General Dynamics 1500 PRODELIN DRIVE NEWTON, NC 28658
PRODELIN CORPORATION 4096-432 SERIES 1125 1.2M Ku-BAND Rx/Tx ANTENNA SYSTEM D Revised Company Name, Logo, and Part Tables 6/15/10 RAH C Rev. Assembly DWG Page 9 11/9/2001 CLT B Item 7 qty was 3. Added item 18 to tbl & dwg 02/20/98 PWG A REV. PG. 8 ITEMS 8, 14, 16. 07/13/95 R Frye - ORIGINAL RELEASE 5/5/95 R FRYE REV. DESCRIPTION DATE APPROVED
TABLE OF CONTENTS SECTION I TITLE INTRODUCTION 1.0 GENERAL INFORMATION 1.1 UNPACKING & INSPECTION 1.2 FREIGHT DAMAGE 1.3 MATERIAL MISSING OR DAMAGED 1.4 MECHANICAL INSTALLATION TOOLS II ANTENNA SYSTEM ASSEMBLY 2.0 ANTENNA ASSEMBLY 2.1 FEED ASSEMBLY III SATELLITE ALIGNMENT 3.0 SATELLITE ALIGNMENT IV MAINTENANCE 4.0 MAINTENANCE OVERVIEW 4.1 PERIODIC INSPECTION 4.2 REFLECTOR 4.3 MOUNT & REFLECTOR SUPPORT 4.4 FEED & FEED SUPPORT 2
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SECTION I INTRODUCTION 1.0 GENERAL INFORMATION This manual describes the assembly and installation of General Dynamics' 1.2 meter antenna system. The General Dynamics 1.2 meter is a rugged, reliable antenna system, which will operate in the Ku-Band frequency with high efficiency and at the same time successfully withstand the effects of the environment. These instructions are listed by sections that cover all areas of assembly and installation. Additional sections are included in the manual to provide information on antenna alignment to the satellite and maintenance. 1.1 UNPACKING AND INSPECTION The system containers should be unpacked and inspected at the earliest date to insure that all material has been received and is in good condition. A complete packing list for each major component is supplied. 1.2 FREIGHT DAMAGE Any damage to materials while in transit should be immediately directed to the freight carrier. He will instruct you on matters regarding any freight damage claims. 1.3 MATERIAL - MISSING OR DAMAGED Any questions regarding missing or damaged materials that is not due to the freight carrier should be directed to General Dynamics' Customer Service Department at: General Dynamics 1500 PRODELIN DRIVE NEWTON, NC 28658 (828) 464-4141 4
1.4 MECHANICAL INSTALLATION TOOLS The following tools are suggested for the antenna installation. 1 RATCHET 1 SOCKET, - 7/16" 1 SOCKET - 1/2" 1 SOCKET, - 9/16" 1 SOCKET, - 3/4" 1 WRENCH, COMBINATION - 7/16" 1 WRENCH, COMBINATION - 1/2" 1 WRENCH, COMBINATION - 9/16" 1 WRENCH, COMBINATION - 3/4" 1 WRENCH, ADJUSTABLE - 8" 1 COMPASS - FOR ALIGNMENT TO SATELLITE 1 INCLINOMETER - FOR ALIGNMENT TO SATELLITE 5
SECTION II ANTENNA SYSTEM ASSEMBLY 2.0 ANTENNA ASSEMBLY Refer to figures 2.0-1 and 2.0-2, the parts list, and follow the instructions in the listed sequence. Do not tighten any hardware until instructed. The interface from the ground to the antenna mount is a 2-1/2" schedule 40 pipe (2.88" O.D.). A Suggested In-Ground Foundation is shown on page #7. It is assumed the mast pipe has been properly installed. STEP 1: STEP 2: STEP 3: STEP 4: STEP 5: STEP 6: Place the canister (item# 1) onto the mast pipe. Using a compass, aim the canister's high end tabs (see figure 2.0-1) toward the selected satellite. Insert the [6 ] 3/8-16 x 1.00" set screw assemblies (item# 6) and hand tighten. A ground strap may be attached as shown. See figure 2.0-1. Attach the reflector support tube (item# 2) to the canister with [1] 1/2-13 x 3.25" bolt, [2] flatwashers, [1] lockwasher, and [1] hex nut (items# 13,14,15,16). See figure 2.0-2. Attach the elevation channel (item# 3) between the [2] lower end tabs of the canister (oriented as shown) with [2] 3/8-16 x 1.00" bolts, [2] flatwashers, [2] lockwashers, and [2] hex nuts (items# 7,9,10,11). Place [1] 1/2-13 nut, then a narrow flatwasher (items# 8,16) well up onto the elevation rod (item# 4), insert the elevation rod through the elevation channel (plate end toward reflector support tube), and secure with another flatwasher and [1] 1/2-13 coupling nut (items# 14,17). See figure 2.0-2. Attach the elevation rod to the reflector support tube with [1] 5/16-18 x 1.00" bolt, [2] flatwashers, [1] lockwasher, and [1] nut (item# 18,19,20,21). Find the three holes in the rim of the reflector (item# 5). Make sure the middle one of the three holes (bottom of reflector) is pointing down, lift, position and attach the reflector to the reflector support tube angles with the [4] 27/64-13 x 1-3/8" hi-lo screws (item# 12). DO NOT OVER TIGHTEN AS THIS WILL PERMANENTLY DAMAGE THE REFLECTOR. 6
2.1 FEED ASSEMBLY Refer to the manual shipped with your feed system. 7
SUGGESTED IN-GROUND FOUNDATION 12.0 30.0 (MIN) 2 1/2 SCH 40 PIPE (2.88 O.D.) SECTION A - A 30.0 SEE NOTE #7 A A 45 NOTES: 1. 2 1/2 schedule 40 pipe should conform with ASTM A53 2. All concrete should conform to building code standards and have a minimum compressive strength of 3000 PSI at 28 days. (Per ACI-318-77) 3. Soil bearing capacity should be no less than 2000 PSF. 4-. Concrete should be poured against undisturbed soil. 5. Allow concrete 24 hours set time before installation of antenna. 6. The antenna should be properly grounded to meet applicable local codes. 7. Minimum depth as shown or extend to local frost line. 8. Foundation meets the design requirements as set forth by the uniform building code. (1982 edition) (GENERAL DYNAMICS DOES NOT REPRESENT OR WARRANT THAT ANY PARTICULAR DESIGN OR SIZE OF FOUNDATION IS APPROPRIATE FOR ANY LOCALITY OR EARTH STATION INSTALLATION.) 8
ANTENNA ASSEMBLY PARTS LIST ITEM# PART# DESCRIPTION QTY 1 0490-353 CANISTER 1 2 0600-044 REFLECTOR SUPPORT TUBE 1 3 0247-135 CHANNEL, ELEVATION 1 4 0490-202 ROD, ELEVATION ADJUSTMENT 1 5 0179-245 0179-180 REFLECTOR, WHITE REFLECTOR, WHITE W/SHC 1 6 8317-109 ASSEMBLY, SET SCREW, 3/8-16 x 1.00" (W/ NUTS) 6 7 8032-008 BOLT, 3/8-16 x 1.00" 3 8 8201-043 FLATWASHER, NARROW, 1/2" 2 9 8201-042 FLATWASHER, 3/8" 4 10 8202-042 LOCKWASHER, 3/8" 3 11 8102-007 NUT, HEX, 3/8-16 3 12 8319-006 SCREW, 27-64-13 x 1-3/8" HI-LO THREAD 4 13 8033-026 BOLT, 1/2-13 x 3.25" 1 14 8201-030 FLATWASHER, 1/2" 2 15 8202-043 LOCKWASHER, 1/2" 1 16 8104-007 NUT, HEX, 1/2-13 2 17 8115-003 NUT, COUPLING, 1/2-13 1 18 8031-008 BOLT, 5/16-18 X 1.00 1 19 8101-009 NUT, HEX, 5/16-18 1 20 8201-041 FLATWASHER, 5/16 2 21 8202-041 LOCKWASHER, 5/16 1 SELECTED SATELLITE LOW END HIGH OPTIONAL GROUND STRAP MAST PIPE FIGURE 2.0-1 9
FIGURE 2.0-2 10
SECTION III ANTENNA ALIGNMENT 3.0 ALIGNMENT TO SATELLITE The 1.2 meter offset reflector contains a 22.6 deg. elevation offset look angle. Therefore, when the reflector aperture is perpendicular to the ground, the antenna is actually looking 22.6 deg. in elevation. All electrical connections need to be properly completed before antenna alignment. STEP 1: Attach an inclinometer to the support tube as shown in figure 3.0-1. Subtract 22.6 deg. (see paragraph above) from the elevation angle of the desired satellite. This is the desired adjusted elevation angle. STEP 2: STEP 3: STEP 4: STEP 5: Raise or lower the antenna to find the desired elevation angle by turning the 1/2" nuts located at the elevation channel. Position the top hex nut so it will not interfere with adjustment. Turn the bottom coupling nut clockwise to increase elevation and counterclockwise to decrease elevation. After the correct elevation angle is set, loosen the 3/8" set screws just enough to allow the antenna system to be rotated around the mast pipe. Sweep the antenna through azimuth until the signal is found and then lost. Mark this point and sweep back through azimuth until the signal is found and lost again. Center azimuth between the two points where signal is lost. Peak the antenna signal by fine adjustments made in both elevation and azimuth. Tighten all hardware used for adjustment. 11
INCLINOMETER ELEVATION HARDWARE FIGURE 3.0-1 12
SECTION IV MAINTENANCE 4.0 MAINTENANCE OVERVIEW After installation, the antenna requires only periodic inspection. It is anticipated that maintenance, if required, will be minimal and easily handled by a local or inhouse maintenance staff. The materials used in the construction of this Earth Station Antenna virtually eliminate any maintenance repairs. 4.1 PERIODIC INSPECTION It is suggested that a periodic inspection be performed at least every six months. NOTE: After any severe weather conditions, inspection of the antenna should be performed to determine if foreign objects have caused damage or if survival specifications have been exceeded. This inspection should include the following: STEP 1: STEP 2: STEP 3: STEP 4: Check all bolting locations - all bolts should be tight. Check all structural members - repair or replace if damaged. Check the foundation anchor bolts, if any - they must be secure and no failure signs in foundation. Check for corrosion - on the reflector structure and the mount. 4.2 REFLECTOR Prodelin's reflector does not require any maintenance. The composite construction of the reflector is virtually impervious to any damages that could be caused by weather or atmospheric conditions. It is only necessary to inspect for any physical damage done by vandalism or very severe weather conditions. Should any damage be detected to a portion of the reflector, contact the Customer Service Department at Prodelin for recommendations involving reflector repair. 13
4.3 MOUNT AND REFLECTOR SUPPORT STRUCTURE The mount and reflector support structure supplied with this antenna is of steel construction and has a hot-dip galvanized finish. If inspection shows any signs of structural failure, the mount members that are damaged should be repaired or replaced. CORROSION: Any corrosion on steel members may be repaired with a cold, zinc-rich galvanizing paint. 4.4 FEED AND FEED SUPPORT The feed support and feed rods should be inspected to insure that all hardware is secure. The feed/radio mounting bolts should be tight. The feed horn window should be inspected to insure that it is intact so that no moisture can collect inside the feed horn. Replace if damaged. 14