New Generation Service Manual
755A/981A/985A and 1201A
The iNetVu™ brand and logo are registered trademarks of C-COM Satellite Systems, Inc. ©
Copyright 2006 C-COM Satellite Systems, Inc.
1-877-iNetVu6
Revision 003 May 25, 2014
Page 1: ...rvice Manual 755A 981A 985A and 1201A The iNetVu brand and logo are registered trademarks of C COM Satellite Systems Inc Copyright 2006 C COM Satellite Systems Inc 1 877 iNetVu6 www c comsat com Revision 003 May 25 2014 ...
Page 2: ...sion is prohibited except as followed under the copyright laws Both the iNetVu and C COM names and logos are registered trademarks of C COM Satellite Systems Inc Intel Pentium is a registered trademark of Intel Corporation Microsoft Windows Windows NT and MapPoint are registered trademarks of Microsoft Corporation All other product names mentioned in this manual may be trademarks or registered tra...
Page 3: ... that prevents human exposure to potential radiation hazards For large vehicles with roof mounts the height of the bottom lip of the earth station when fully deployed must be at least six feet above the ground at all times or six feet above a surrounding surface which a person may easily access If a roof access ladder or any other means of access to the roof is installed on the vehicle then the la...
Page 4: ...r characteristics of the earth station supplied to them by C COM or C COM s authorized representatives Note 1 This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of FCC rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential installation This equipme...
Page 5: ...1 613 745 4110 Fax 1 613 745 7144 General Inquiries info c comsat com Dealer Information dealer c comsat com Support Services support c comsat com Phone 1 613 745 4110 OPT2 Toll Free 1 877 463 8886 OPT2 Monday Friday 8 30am 6 00pm EST After Hours Support Tel 1 613 656 3723 Toll Free 1 800 233 0218 Monday Friday 6 00pm 9 00pm EST Weekends and Canadian Holidays 8 30am 9 00pm EST ...
Page 6: ...iNetVu New Generation Service Manual Page 6 of 53 C COM Satellite Systems Inc This page is left Blank intentionally ...
Page 7: ...lt Removal Installation 23 3 4 Replacing the Polarization Assembly for a 1201 Platform 26 3 5 Replacing the Polarization Assembly for a 981 Platform 29 3 6 Replacing and or Adjusting the Azimuth Sensor s 30 3 6 1 Azimuth Encoder 30 3 6 2 Azimuth Home or Away Sensor 31 3 6 3 For the 1201 Home Away Sensor 31 3 6 4 For the 981 755 Home and Away Sensors 32 3 7 Replacing and or Adjusting the Elevation ...
Page 8: ...ems Inc 1 INTRODUCTION 1 1 About This Manual This service manual explains how to fully maintain the iNetVu Drive Away System s and repair replace certain product components An electronic version of this manual is included on the iNetVu USB Drive that came with your system ...
Page 9: ...ments Under normal operating conditions it is recommended to maintain your iNetVu Drive Away Platform every three 3 months 2 1 2 Harsh Operating Environments It is recommended to perform maintenance to your iNetVu Drive Away Platform at least every one 1 month when subjected to snow and ice dirt grime road spray sand salt spray or extreme heat or cold Immediately perform maintenance after exposure...
Page 10: ... chemicals contaminants or mechanical blockages that can be harmful and damaging to the operation and finish of the iNetVu product After any exposure to contaminants or periodically after general use the iNetVu outdoor product should be cleaned with warm soap and water or low pressure wash rinsed then dried thoroughly for the best ongoing operation reliability and maintenance of fit and finish 2 1...
Page 11: ...tor and Coax cables on the side of the unit Remove any obstructions such as snow ice or dirt from the exterior and interior if any or the Motor Control Sensor and Coaxial Ports Use a can of compressed air if necessary Fig 1 iNetVu Drive Away Platform Connector Location Military Style Connectors and Coax cables 1201A Ku Drive Away 981A Ku Drive Away 755A Ka Drive Away 985A Ka Drive Away ...
Page 12: ...belts from overspray and remove overspray from neighboring surfaces after application I AZ gear reducer end face with shaft and high speed input shaft extension II EL gear reducer end face of output shaft Belleville Washers and torque limiter nut 1201 only and high speed input shaft extension III Keyless locking bushing on primary EL reduction driveshaft exposed face and fasteners If no Hex Socket...
Page 13: ...iNetVu New Generation Service Manual Page 13 of 53 C COM Satellite Systems Inc 1201 Torque Limiter Nut 1201 Belleville Washers Keyless Bushing ...
Page 14: ...iNetVu New Generation Service Manual Page 14 of 53 C COM Satellite Systems Inc 3 REPAIRS AND REPLACEMENTS ...
Page 15: ...ench sockets Loctite Threadlocker 222 Low Strength Removable Loctite Threadlocker 248 Medium Strength Removable 1 Remove the azimuth cover Please keep track of all screws and their original location after removal 2 Locate and remove 2 mounting screws securing the azimuth encoder in place 3 Loosen the 2 set screws from the encoder Disconnect the cable and you should be able to lift away the encoder...
Page 16: ...4 Remove 3 screws and lift away the Encoder mounting plate 5 Remove 4 reducer mounting screws The azimuth motor should be free and you will be able to remove it from the azimuth chassis NOTE Please keep track of all parts and their original location Remove 3 Screws Remove 4 Screws ...
Page 17: ...operly aligned on the pulley and bearing groves Install 4 reducer mounting screws applying loctite Do not fully tighten these screws until the motor had been properly tensioned 7 To set tension correctly on the Azimuth Motor Belt please follow the following procedure 3 1 2 Azimuth Belt Tension 8 Once the belt is in place pull back on the motor thus applying tension onto the belt NOTE Adjustment mu...
Page 18: ...tighten 3 screws 12 Install the Encoder ensuring the cables are pointing towards the center of the base casting Tighten the 2 set screws If you are unable to insert the encoder you can loosen the set screws to release tension 13 Install and tighten the 2 mounting screws securing the azimuth encoder in place 14 Connect the Azimuth Encoder and Azimuth Motor to the internal wiring harness 15 Congratu...
Page 19: ...emovable Loctite Threadlocker 248 Medium Strength Removable 1 Disconnect the Elevation Motor from internal wiring harness Remove the tension wedge screw While lifting up on the elevation motor tap the tension wedge towards the rear of the antenna to release tension allowing for removal 2 There should be enough slack to slid the belt out Once the belt is free we can lift the motor freely and remove...
Page 20: ...pin can now be removed 2 Locking Pin Clips Motor Mounting Pin 4 The Elevation Motor can now be removed 3 2 1 Installing the Elevation Motor 5 If the motor you receive does not have the Mounting Plates installed they must be transferred from the failed motor 6 Assemble the EL Motor mounting plates Install one plate on each side of the motor Fasten the 4 screws on each side ...
Page 21: ...ion wedge below the motor mounting plate Insert screw but do not tighten until belt tension is set 9 Slide the Belt onto the EL Reducer out put shaft Slide the belt onto lower Pulley making sure the belt teeth are aligned in the grooves The tension wedge can be moved further to the rear providing additional slack for the belt 10 Proceed to tension the belt Motor Mounting Pin ...
Page 22: ...r 1201 and 380 20 Hz for 981 985 and 755 Use positioning of the Wedge to increase or decrease belt tension Sliding Wedge in will increase tension while sliding out will decrease it 12 Lift the bottom of the motor up applying tension onto the belt pushing Wedge in will hold tension in place 13 Tighten screw applying Loctite torque as specified in Appendix 1 NOTE Adjustment must be completed within ...
Page 23: ... adjust the tension 2 Adjust tension using the tension screw and ensure that the EL Pulley Clamps are at the maximum distance from each other This will release tension from the EL Belt 3 Remove the top 4 screws from the EL Pulley Clamp and remove the top plates 4 Loosen the remaining 4 screws from the EL Pulley Clamp farthest from the elevation motor 5 Remove the belt to be replaced Tension Screw ...
Page 24: ...st belt tooth is placed on the last groove Place top clamp and tighten into place 2 Wrap belt over EL shaft continuing around the Pulley assembly until belt reaches the bottom clamp plate on the other side 3 Ensure last belt tooth is placed on the last groove place top clamp and tighten into place 4 Tighten the 4 bottom clamp screws on the clamp that is furthest away from the EL motor Last Groove ...
Page 25: ...t on the belt 6 Insert and tighten the remaining 4 screws from the EL Pulley Clamp farthest from the elevation motor 7 Set the belt tension by adjusting the tensioning screw Set the tension on the Pulley belt to 485 24 Hz for the 1201 and 330 10 Hz for the 755 981 985 Platforms 8 To complete the replacement tighten the 4 bottom screws closest to the elevation motor Tension Screw Install 4 Screws a...
Page 26: ...mbly 1 Remove cover and disconnect all cable from the POL Cage Assembly 2 Install Feed Rotator Arm Assembly onto POL Cage Assembly Ensure the Rotator Feed Arm is facing in the opposite direction as that from the Feed Horn Tighten specified screws 3 Install POL cage assembly onto Feed Arm Insert side with Rotator Arm first into top Feed Boom Pivot and ensure its pointing away from reflector Feed Ho...
Page 27: ...tator Arm Note The objective of the washers is to take up free play such that the Feed Horn Assy does not have free play from side to side but provide a mild spring pressure If required fewer or additional washers may be used with the same number on each side to preserve the symmetry 5 Insert same amount of spring washers on the other end of the POL Cage shaft and install retaining ring 3 Washers ...
Page 28: ...cing away from the feed arm 7 Use low strength loctite 222 on M3 set screw and insert into place This set screw will be used for final ABCD adjustments if POL requires tilting 8 Insert shoulder screw into piston end of gas spring using small plastic bushing as a spacer and applying loctite 242 9 Apply jam nut on the other end of the screw and tighten into place ...
Page 29: ...ss etc 12 You have successfully installed the 1201 Polarization Assembly 3 5 Replacing the Polarization Assembly for a 981 Platform 1 Install POL Assembly onto feed using specified fasteners and mounting bushings Install positioning screws and tighten 2 Insert mounting screws into place and tighten to specified torque 3 Remove cover and connect cables in POL Cage Tilt Sensor Motor Compass etc 4 Yo...
Page 30: ...l harness Locate and remove 2 mounting screws securing the azimuth encoder in place 3 Loosen the 2 set screws from the encoder You should be able to lift away the encoder at this point 4 Install the new encoder in reverse order 5 Connect all cables Power up the 7024 controller and attempt to stow the platform If you are able to stow the platform you may now continue as normal 6 Congratulations you...
Page 31: ...m the sensor and begin to unscrew the sensor out to fully remove it 3 6 3 For the 1201 Home Away Sensor 1201 Home Away Sensor Location a Screw the AZ AW sensor all the way until it hits the bearing and then roll it back half a turn Use of a 24mm feeler gauge is recommended for sensor distance setting Tighten the bolt Torque the M5 sensor to a maximum of 5Nm b Connect the sensor to the internal har...
Page 32: ...onnect the sensor to the internal harness and place the antenna down Move the antenna to the home position and if the Home Sensor is properly aligned with the target the LED should be ON c From the iNetVu Software Controls screen the Azimuth ST should be active Attempt to auto stow the platform d To test the Away Sensor move the platform to roughly 180 or 180 degrees If the Away Sensor is properly...
Page 33: ...ip Ensure the wire is looped correctly and is routed clear of any obstructions during full motion of the EL Axis Reconnect the cable to the harness Platform 1201 Platform 981 755 3 Congratulations you have successfully replaced the elevation tilt sensor 3 7 2 Elevation Stow and UP Sensor Note To perform these steps you will be required to move the antenna on Elevation 1 Lower or raise the antenna ...
Page 34: ... the sensor target Roll back and use a 0 35mm feeler gauge to set the distance Tightening the nut in place 4 Congratulation you have successfully replaced the EL ST UP limit sensor 3 7 3 Elevation Down Sensor 1 Raise the antenna so that the EL Down Limit Sensor lines up with a solid part of the EL Down flag Elevation UP Limit Sensor Elevation Stow Sensor ...
Page 35: ...ssfully replaced the Down Limit Sensor 3 8 Replacing and or adjusting the Polarization Sensor s 981 1201 only 3 8 1 Polarization Stow Sensor 1 Remove the Polarization assembly cowling and locate the polarization limit sensor 2 Disconnect the sensor from the internal wiring and loosen the nut 3 Unscrew the sensor out until completely removed 4 Screw the replacement sensor in until it touches a soli...
Page 36: ...tVu New Generation Service Manual Page 36 of 53 C COM Satellite Systems Inc 6 Congratulations you have successful replaced the polarization limit sensor Target is a blank space Polarization Home Switch LED ...
Page 37: ...ace and slide the cable out of the opening 2 Slide one grommet over the new compass cable feed cable through opening in Feedboom bracket and slide second grommet over the cable Compass cable tail end should face away from reflector 3 Push grommets into place 4 Install compass on BUC mounting plate Ensure logo on compass is facing out so it s viewable 5 Connect compass cable to internal harness con...
Page 38: ...rough the feed arm bar and connect to the internal wiring coming from the Pol assembly 3 9 3 Platform Model Ka 755 985 1 Locate and disconnect the compass from the internal wiring removing 2 screws securing the compass in pace 2 Install the new compass label facing out on the feed horn protection bracket Ensure cable end is opposite to metal ear Connect the compass cable to external cable coming o...
Page 39: ...o replace the Base Bearing Assembly on 755 981 and all 985 platform types Required Materials Base Bearing Assembly Misc Metric Hand Tools for fasteners Thread Locker Medium Thread Locker High Procedure Warning It is recommended 2 people perform this procedure to avoid serious damage or harm to both operator and equipment 1 Remove AZ EL cowling and set aside 2 Remove Cable Clip ...
Page 40: ...revent unit from tipping forward or sliding on the parent base plate assembly 4 Tip Lay mount on its side supporting the elevation arms You may want to consider removing the reflector to avoid damaging it 5 Snip cable ties and disconnect sensor connections 6 Pull coax cables out through the center AZ EL base assembly AZ Away Sensor EL Stow Sensor Cable AZ Home Sensor ...
Page 41: ... of 53 C COM Satellite Systems Inc 7 Pull the remaining harness cables also through center of AZ EL base assembly 8 Tip mount back on its base make sure sensor cables are tucked up and away to avoid getting pinched by the AZ EL machined base edge ...
Page 42: ...tor fasteners keep in mind the base is not fastened down and it may slide on you 10 Push AZ motor inwards to loosen AZ belt 11 Loosen outer Bearing Slewing Ring screws Caution as this step will leave the EL Arm and Feed Arm unsupported causing it to tip forward Second person must support mount top level as screws are being removed ...
Page 43: ...ley and disengage at the front end of AZ motor gear shaft as second person continues to support mount 13 Lift top level assembly off base assembly leaving Pulley and Bearing assembly 14 Remove faulty old AZ Base Bearing assembly and place new AZ Base Bearing replacement part assembly on parent base assembly ...
Page 44: ... AZ travel stop is over AZ home sensor location Base cable feature should also be positioned as shown here 16 Place 2 screws to one at the front and the other at the back temporarily hold down Base Bearing to parent base assembly 17 Place belt over Base Bearing assembly Location of Ball Bearing Slot Location of Cable Exit Opening AZ Home Sensor Location Travel Stop ...
Page 45: ...he Bearing 19 Apply thread locker and fasten screws loosely until all have been inserted Once all screws are inserted fasten as per torque table which can be found at end of this article 20 Slide belt onto AZ Reducer Shaft Belt at the back end should be above Pulley for easy installation 21 Slide belt onto Pulley ensure belt teeth align in grooves on the Pulley AZ Reducer Shaft Belt Pulley ...
Page 46: ...ws Set tension to 285 Hz 15 Hz DO NOT OVER TENSION THIS BELT If no tension meter exists use trial and error by pressing down on belt for tension check and testing using iNetVu software to see current reading 23 Remove 2 screws that were temporarily holding chassis to base 24 Tip antenna on its side 25 Feed motor and sensor cables through center ...
Page 47: ...r from bottom end of chassis in order to connect the sensors 27 Connect EL Stow sensor it s the one coming from top through center of chassis 28 Connect AZ Home also referred to as AZ Stow from the bottom view it s the sensor on the left Note Ensure pins of sensor line up with connector holes to avoid bending pins Home Away ...
Page 48: ...tion Service Manual Page 48 of 53 C COM Satellite Systems Inc 29 Connect AZ Away sensor 30 Clean up cables by applying cable ties so they are tucked away 31 Feed 2 coax cables through center of chassis Home Away EL Stow ...
Page 49: ...s Inc 32 Set system in the upright position holding the cables underneath chassis opening 33 Align mount holes on base and chassis 34 Apply thread locker and insert fasteners hand tighten leaving them loose until all have been inserted and Feed Arm aligned for proper stowing ...
Page 50: ...form iNetVu A0981A 981 Ku iNetVu 7024B C Controller Allen Key Set 1 Connect motor and sensor cables between antenna and controller 2 Power up controller and wait until menu is displayed on LCD 3 Stow antenna with controller Stop the stowing once arm touches down on stow block This will determine how much adjustment will be required to center the azimuth be prepared to press the stop button if Feed...
Page 51: ...e Feed Arm until visually centered Equal distance should exist on either side between Feed Arm and edge of stow plate Note Manually moving the elevation up a few degrees may be required in order to shift and center the azimuth axis 5 Tighten base hold down bolts 6 Deploy and verify system stows with proper centering 7 Install cable clip ...
Page 52: ...form use a 14mm Hex Socket wrench or any tool with a Hex attachment Place wrench on Hex Socket and rotate in the desired direction This method of manual movement is valid on 755A 981A 985A and 1201A If your system did not ship with the Hex Sockets installed on the motor reducer shafts contact C COM Satellite Systems Inc Fig 38 Using a Hex Socket Wrench to operate AZ EL motors Note A drill is NOT r...
Page 53: ...edium 10 medium M12 75 medium 39 medium 20 medium applies for A2 A4 70 grade stainless steel plain or non lubricated threads µtotal 0 20 Threadlocker strength Threadlocker strength Thread diameter Threadlocker strength Socket Button Head ISO 7380 Socket Flat Head DIN 7991 Socket Low Head DIN 7984 Torque Nm Socket Head ISO 4762 DIN 912 Hex Head ISO 4014 4017 DIN 931 933 Torque Nm Torque Nm Socket S...
