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Series 8345

4.5-Meter Prime Focus Motorized Antenna

Installation Manual

Manual 42S199F

March 2003

Summary of Contents for Series 8345

Page 1: ...Series 8345 4 5 Meter Prime Focus Motorized Antenna Installation Manual Manual 42S199F March 2003 ...

Page 2: ... Equipment 2 2 2 6 General Mechanical Safety Summary 2 3 2 6 1 Emergency Plan 2 3 2 7 General Electrical Safety Summary 2 4 2 7 1 Resuscitation 2 4 2 8 Recommended Tools And Equipment 2 5 2 9 Recommended Installation Sequence 2 6 2 10 Recommended Torque Values 2 6 2 11 Assembly of Mount 2 8 2 11 1 Adjustment of Eccentric Cam Followers 2 21 2 11 2 Installation of Azimuth Actuator 2 21 2 11 3 Instal...

Page 3: ...3 1 3 2 Satellite Pointing Procedure 3 1 3 3 Focal Length Inspection And Adjustment 3 1 3 3 1 Adjustment Procedure 3 2 3 4 Equipment Required For Transmit Patterns 3 3 Maintenance 4 1 4 1 General 4 1 4 2 Periodic Maintenance 4 1 4 2 1 Weekly Maintenance 4 1 4 2 2 Monthly Maintenance 4 2 4 2 3 Bi Monthly Maintenance 4 2 4 2 4 Yearly Maintenance 4 4 4 3 Corrosion Protection 4 5 42S199F iv ...

Page 4: ...trings for Rib Adjustment 2 30 Figure 2 12 Feed and Feed Housing Assembly C Band 2 33 Figure 2 13 Attachment of Spars to Support Brackets 2 33 Figure 2 14 Installation of Feed Housing and Orthomode Transducer 2 34 Figure 2 15 Installation of LNAs LNBs 2 36 Figure 2 16 Installation of LNA LNB Cover 2 37 Figure 2 17 Feed Window Installation 2 39 Figure 2 18 Feed and Feed Housing Assembly Ku Band 2 4...

Page 5: ... Table 2 1 Tools and Equipment Required For Installation 2 5 Table 2 2 Torque Values For Antenna Fasteners High Strength Grade 5 Zinc or Galvanized Steel 2 6 Table 2 3 Torque Values For Antenna Fasteners Stainless Steel 2 7 42S199F vi ...

Page 6: ...d equipment or to obtaining desirable results from the equipment This symbol warns of electrical shock hazards to personnel Failure to comply with the instructions of such a warning may result in severe injury or death resulting from electrical shock This symbol warns of non electrical hazards to personnel Failure to comply with the instructions of such a warning may result in severe injury or dea...

Page 7: ...s that may appear in this document and does not warranty any specific application Any product names mentioned herein are used for identification purposes only and may be trademarks and or registered trademarks of their respective companies In all correspondence with ViaSat Inc regarding this publication please refer to the Manual Part No on the title page Copyright 2003 ViaSat Inc All rights reser...

Page 8: ...Blank Page ...

Page 9: ...ance for a wide range of applications combining the following features Ease of Installation Minimum maintenance design Minimum shipping and installation costs design Minimum site preparation requirements Full satellite arc coverage from any location in the contiguous United States 2 to 90 continuous elevation 180 continuous azimuth Elevation over azimuth Mount for ease of operation Interchangeable...

Page 10: ...the optional feeds offered with the Series 8345 4 5M Prime Focus Motorized Antenna provides consistent high quality and unusual economy in a mid sized antenna system The Ku band feed provides dual polarization receive only capability in the 10 9 to 12 75 GHz range The C band feed provides dual polarization receive only capability in the 3 7 to 4 2 GHz range Both are available in motorized polariza...

Page 11: ...to do About Visible Loss or Damage Make a note of any loss or evidence of external damage on the freight bill or receipt and have it signed by the carrier s agent Failure to adequately describe such external evidence of loss or damage may result in the carrier refusing to honor a damage claim The form required to file such a claim will be supplied by the carrier 2 3 What to do About Concealed Dama...

Page 12: ...nd shipping instructions For a current list of telephone and email contact information please refer to the Contact Information section of the ViaSat internet site http www viasat com Select Products and Technologies Satellite Ground Systems and Contact Us b Tag or identify defective equipment and note defect and circumstances if any If known reference sales order purchase order and date equipment ...

Page 13: ...pproved ladder In the sentence above approved usually means that the ladder is tied off once the person has climbed but before work begins WARNING Overhead hazards either because items may fall or because a person may strike them unintentionally are typical around construction sites or during installation of large antennas It is prudent to adopt the following rules 1 Never stand underneath anythin...

Page 14: ...nts and or troubleshooting Before working inside the equipment remove all power unless power is required to perform procedures Do not replace parts with power on Replacement of fuses or other parts must be done using identical types and ratings Substitution of non identical parts may cause safety and fire hazards Servicing this equipment may require working with protective covers removed and ac po...

Page 15: ...4 inch to 3 8 inch drive 1 Each Torque wrench 150 ft lbs 203 Nm 1 Each Torque wrench 250 300 ft lbs 333 400 Nm 3 4 inch drive 1 Each Small Allen wrench set 1 Each Medium Allen wrench set 1 Each Large Allen wrench set 1 Each 1 2 inch Allen wrench 1 Each Torpedo level 1 Set Electrical tools screw drivers nut drivers pliers crimp tool line man pliers needle nose pliers channel lock pliers 1 Set 3 8 i...

Page 16: ...r all 4 5M antenna fasteners Refer to Table 2 2 for galvanized fasteners and Table 2 3 for stainless steel fasteners CAUTION Do not torque any fasteners until specifically directed to torque a fastener As fasteners are installed tighten finger tight only Table 2 2 Torque Values For Antenna Fasteners High Strength Grade 5 Zinc or Galvanized Steel Fastener Size Torque ft lb tolerance 10 1 4 20 6 8 N...

Page 17: ...a Fasteners Stainless Steel Fastener Size Torque ft lb tolerance 10 1 4 20 6 8 Nm 5 16 18 12 16 Nm 3 8 16 20 26 Nm 1 2 13 45 60 Nm 3 4 10 130 except as noted 173 Nm NOTE The required torque value for the foundation anchor bolts is 100 lb ft 136 Nm 42S199F 2 7 ...

Page 18: ... attached to a foot of the foundation according to local grounding codes See NOTES in Figures 2 2 2 3 or 2 4 NOTE For the following procedure tighten all fasteners in steps 1 through 8 only finger tight then follow step 9 a through e for tightening sequence 1 As shown in Figure 2 1 place one end of a leg onto a leg juncture maintaining proper orientation of bend in leg Bolt in place with 3 4 10 x ...

Page 19: ...ges down on top of the previously assembled leg junctures Bolt leg support bracket in place at the two inboard holes of each leg juncture using 3 4 10 x 2 1 4 inch bolt washer and nut in six places 4 Attach short extension of each support arm to the center hole at the underside of each leg juncture using 3 4 inch bolt washer and nut in three places Refer to Figure 2 3 5 Before fastening the suppor...

Page 20: ...d nut in three places 9 Using the following sequence as shown in Figure 2 5 torque all 3 4 inch fasteners to 250 ft lbs 333 Nm a Torque the two inboard bolts of each leg juncture b Torque the six outboard bolts of each leg juncture which connect the azimuth ring to the leg junctures NOTE Using a carpenters level make sure that the azimuth ring remains level during steps c and d c Torque the two bo...

Page 21: ...Chapter 2 Installation Figure 2 2 Installation of Leg Support Bracket 42S199F 2 11 ...

Page 22: ...Chapter 2 Installation Figure 2 3 Installation of Support Arms 42S199F 2 12 ...

Page 23: ...Chapter 2 Installation Chapter 2 Installation 42S199F 2 13 Figure 2 4 Installation of Azimuth Ring 42S199F 2 13 ...

Page 24: ...Chapter 2 Installation Chapter 2 Installation 42S199F 2 14 Figure 2 5 Tightening Sequence for Pedestal 42S199F 2 14 ...

Page 25: ...2 inch bolt washer and nut in six places NOTE Orientation of the torque arm will establish the azimuth travel Position torque arm as shown with reference to the center of azimuth travel 13 Locate load frame three cam followers one eccentric cam follower three 1 inch washers one 1 3 8 washer four 1 14 nuts and four grease fittings 14 Install cam followers and hardware in top four holes of load fram...

Page 26: ...e 2 6 20 Bolt pivot arm to load frame using 3 4 10 x 2 1 2 inch bolt washer and nut in four places 21 Install eccentric cam followers 1 3 8 washers 1 14 nuts and grease fittings in the four bottom holes of load frame Figure 2 6 AZ EL Assembly 4 5 Meter Motorized Sheet 1 of 5 482045B 42S199F 2 16 ...

Page 27: ...Chapter 2 Installation Figure 2 6 AZ EL Assembly 4 5 Meter Motorized Sheet 2 of 5 482045B 42S199F 2 17 ...

Page 28: ...Chapter 2 Installation Figure 2 6 AZ EL Assembly 4 5 Meter Motorized Sheet 3 of 5 482045B 42S199F 2 18 ...

Page 29: ...Chapter 2 Installation Figure 2 6 AZ EL Assembly 4 5 Meter Motorized Sheet 4 of 5 482045B 42S199F 2 19 ...

Page 30: ...Chapter 2 Installation Figure 2 6 AZ EL Assembly 4 5 Meter Motorized Sheet 5 of 5 482045B 42S199F 2 20 ...

Page 31: ...tallation of Azimuth Actuator Refer to Figure 2 6 and perform the following procedure to install the azimuth actuator 1 Locate the azimuth actuator assembly two azimuth pivot pins 1 4 20 x 5 8 screws and washers 2 Position the azimuth actuator on the load frame and apply a small amount of grease to the pivot pins CAUTION Be sure not to damage grease fittings when installing pivot pins 3 Install pi...

Page 32: ...muth stabilizer guide bracket to torque arm and bolt in place using 3 8 16 x 2 inch bolt washer and nut in two places NOTE Field adjustment is required on stabilizer guide bracket at zero azimuth angle 4 Allow guide bracket to touch both cam followers then push bracket into the cam followers an additional 1 8 inch 5 Torque fasteners CAUTION Use care not to damage grease fittings during installatio...

Page 33: ...is not available 1 The elevation actuator can be driven manually when electrical power is not available Manually release the motor brake by rotating the brake release level 90 2 Attach a 1 inch socket to the manual drive adapter located on the elevation jack and rotate as required 3 Position the elevation actuator to the load frame and install the lower clevis pin and spiral retaining rings in two...

Page 34: ...pivot pins are designed with grease fittings and are installed on the mount with grease fittings positioned toward the inside of elevation pivot ears This allows for proper installation of elevation LSR drive bracket Use care not to damage grease fittings during installation 4 Position right hand and left hand elevation pivot brackets over load frame ears and install pivot pins and spiral retainer...

Page 35: ... looking at zenith NOTE Loosely install all hardware unless otherwise instructed until assembly of the reflector is completed The recommended screw tightening procedure is provided at the appropriate stage of installation Install spring pins in the Hub top and bottom and the straight end of the Panel Braces where they will be attached to the Ribs 2 Attach the bent end of a Panel Brace flat side do...

Page 36: ...Repeat STEPs 2 through 4 above until all Panel Braces and Ribs have been installed Note that the bolt and nut for six of the Panel Brace attachment points at the bottom of the Hub will already be in place holding the Hub to the Pivot Brackets and Upper Actuator Bracket 5 To ensure that the Ribs are properly set for the most accurate reflector surface a Rib Setting Template is supplied a Place the ...

Page 37: ... template holes aligned laterally inspect the longitudinal alignment If they are not aligned push the rib to the left or right to slightly bend it at the location shown in Figure 2 9 This will lengthen or shorten the rib allowing alignment of the rib and template holes longitudinally but it will cause a lateral misalignment of the holes Repeat STEPs 5b and 5c until the holes in the template and Ri...

Page 38: ...lector Center Plate and spacers and install the Plate into the center of the Hub The surface of the Plate should be even with the Panels once the Panels are installed 7 Place two overlapping reflector Panels onto Ribs Use a 1 4 20 x 1 3 4 inch panel mounting screw to attach the panels to the center of the Hub Use a 1 4 20 x 5 8 inch panel mounting screw washer and nut eight places along the common...

Page 39: ...at the panels maintain their accuracy during the shipping and installation process Refer to Figure 2 10 a Place the template into the concave side of the Panel surface with the ends of the template curve at the corners of the wide end of the Panel The template should be positioned perpendicular to the panel surface b If a gap of more than 1 32 0 03 is observed at the mid position of the panel temp...

Page 40: ...Figures 2 11A and 2 11B Proceed as follows a Choose three Ribs equally spaced around the reflector 120 degrees apart Attach a length of 8 10 lb fishing line 010 012 inch diameter across the reflector between two of the three chosen points Seat the line in the left side of the corner notch between two Panels Fasten the line to the rib below using strapping tape Figure 2 11A Stringing the Reflector ...

Page 41: ...m of the reflector should lie in an almost perfect plane 10 Torque all panel fasteners to 7 9 lb ft if using a torque wrench or 1 2 2 3 turn past snug tight if no torque wrench is available To avoid distortion of the reflector during tightening use the following sequence a Starting at any reflector Panel tighten each of the bolts at Location 1 the bolts which hold the Panels to the Hub b Tighten t...

Page 42: ...his procedure is only applicable to installation of the C band feed 1 Apply a thin coat of grease to the ridge surface and the groove surface of each half of the feed housing Place the feed horn into the feed housing and bolt the two halves of the feed housing together using 10 24 x 1 3 8 inch bolt washer and nut two places and 10 24 x 3 4 inch bolt washer and nut two places Snap feed window into ...

Page 43: ...Chapter 2 Installation Figure 2 12 Feed and Feed Housing Assembly C Band Figure 2 13 Attachment of Spars to Support Brackets 42S199F 2 33 ...

Page 44: ...Chapter 2 Installation Figure 2 14 Installation of Feed Housing and Orthomode Transducer 42S199F 2 34 ...

Page 45: ... 2 inch screw 8 Attach coaxial cable to each LNA or LNB and secure with cable tie as shown in Figure 2 15 Make loop approximately 5 inch radius in both cables and braided shield Route coaxial cables and braided shield down along the groove in the support spar and secure cables to support spar using cable ties equally spaced Coaxial cables and braided shield should be draped over outside edge of re...

Page 46: ...Chapter 2 Installation Figure 2 15 Installation of LNAs LNBs 42S199F 2 36 ...

Page 47: ...Chapter 2 Installation Figure 2 16 Installation of LNA LNB Cover 42S199F 2 37 ...

Page 48: ...le holding the window near the point it was first inserted slowly work the remainder of the window into the groove Work away from the starting point in both directions using both hands all the way around the periphery of the window to the opposite side When almost all the window is in the groove it will be buckled near the part which isn t in the groove d While holding the window against the face ...

Page 49: ...ttach a terminal lug to the outside edge of the feed using 1 4 20 x 3 4 inch screw and washer 7 Insert braid shield into slot in terminal lug and fasten in place using 1 4 20 x 1 2 inch screw 8 Place the feed horn into the feed housing making sure that the ridge of the feed housing is between the feed and the clamp ring and bolt the two halves of the feed housing together using 10 24 x 1 1 2 inch ...

Page 50: ...spar support brackets to the outside edge of reflector using 1 4 20 x l inch hex socket head screws previously installed See Figure 2 19 11 Attach each of four support spars to spar support bracket using 1 4 20 x 1 1 4 inch bolt washer and nut six places See Figure 2 19 11 Attach each of four support spars to spar support bracket using 1 4 20 x 1 1 4 inch bolt washer and nut six places See Figure ...

Page 51: ...ducer to feed horn using 6 32 x 5 8 pan head screw in four places See Figure 2 20 14 Install LNAs LNBs as applicable to orthomode transducer using M4 x 7 pitch x 14 mm metric bolt washer and nut See Figure 2 20 15 Attach coaxial cable to each LNA or LNB and secure with cable tie as shown in Figure 2 20 16 Make loop approximately 5 inch radius in both cables and braided shield Route coaxial cables ...

Page 52: ...ided shield to terminal lug using 1 4 20 x 1 2 inch screw NOTE Be sure to allow enough slack in the coaxial cables between the LNAs LNBs and the support spar so that the feed can be rotated 18 Install LNA LNB cover on the feed housing using 10 24 x 3 4 inch bolt washer and nut in four places refer to Figure 2 21 Figure 2 21 Installation of LNA LNB Cover 42S199F 2 42 ...

Page 53: ... technical drawings required for installation of the 4 5M antenna The list is given in the order the drawings appear on the following pages Part No Rev Title 367733 B Motorized 4 5 Meter Ku Band Feed Installation 367730 D Motorized 4 5 Meter Ku Band Feed Assembly 42S199F 2 43 ...

Page 54: ...ST 205 16 73270 Washer Flat No 6 SST 204 12 174555 Washer lock No 6 SST 203 4 75446 Nut Hex 6 32 SST 202 27 88711 Nut Hex 20 zinc 201 54 88536 Washer Flat Zinc 200 22 88524 Screw Hex HD 20 x 1 14 1 364651 Waveguide 13 1 364548 Waveguide 12 4 364522 Spacer 11 4 364527 Bracket SPAR 10 4 301892 SPAR Feed 5 5 369764 Spacer 4 2 301817 Lug Ground ATCH 3 2 87544 Terminal Lug 2 1 300936 HDW Grounding Kit ...

Page 55: ...Chapter 2 Installation Figure 2 22 Motorized 4 5 Meter Ku Band Feed Installation Sheet 2 of 3 367733 42S199F 2 45 ...

Page 56: ...Chapter 2 Installation Figure 2 22 Motorized 4 5 Meter Ku Band Feed Installation Sheet 3 of 3 367733 42S199F 2 46 ...

Page 57: ...Chapter 2 Installation Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 1 of 10 367730 42S199F 2 47 ...

Page 58: ...Chapter 2 Installation Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 2 of 10 367730 42S199F 2 48 ...

Page 59: ...Chapter 2 Installation Chapter 2 Installation 42S199F 2 49 Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 3 of 10 367730 42S199F 2 49 ...

Page 60: ...Chapter 2 Installation Chapter 2 Installation 42S199F 2 50 Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 4 of 10 367730 42S199F 2 50 ...

Page 61: ...Chapter 2 Installation Chapter 2 Installation 42S199F 2 51 Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 5 of 10 367730 42S199F 2 51 ...

Page 62: ...Chapter 2 Installation Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 6 of 10 367730 42S199F 2 52 ...

Page 63: ...Chapter 2 Installation Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 7 of 10 367730 42S199F 2 53 ...

Page 64: ...Chapter 2 Installation Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 8 of 10 367730 42S199F 2 54 ...

Page 65: ...Chapter 2 Installation Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 9 of 10 367730 42S199F 2 55 ...

Page 66: ...Chapter 2 Installation Chapter 2 Installation 42S199F 2 56 Figure 2 23 Motorized 4 5 Meter Ku Band Feed Assembly Sheet 10 of 10 367730 42S199F 2 56 ...

Page 67: ...dicator held across the actuator bracket of the hub move antenna to the required elevation angle by turning the elevation actuator on until the required angle is obtained 3 Rotate the antenna in azimuth until the satellite signal has been picked up 4 Peak up the signal by jogging the elevation and azimuth actuators as necessary until the signal strength is at maximum 3 3 Focal Length Inspection An...

Page 68: ...e screw in the hole near the end of the spar 3 Set each spar screw so that it is located a distance D above the mark on the spar bracket and tighten Refer to Figure 3 1 Figure 3 1 Focal Length Inspection and Adjustment 4 Re measure the feed location and verify that its new distance L from the reflector is given by the equation L 62 12 1 5 x D If not incrementally adjust all spars by equal amounts ...

Page 69: ... transmit capability 70 MHz IF Source stable C Band Ku Band upconverter whichever is applicable stable Cooperating earth station with spectrum analyzer and chart recorder HP 8566B preferred and voice link with earth station under test Satellite transponder time must be acquired on a satellite that is viewable from both the station under test and the cooperating earth station 42S199F 3 3 ...

Page 70: ...Chapter 3 Operation Blank 42S199F 3 4 ...

Page 71: ...bricant as required Grease fittings are supplied to lubricate azimuth lead screw support bearings Boots are supplied on each actuator which require inspection The prime focus polarization drive mechanism requires no lubrication but must be inspected to ensure proper operation Structural fasteners used on the mount actuators reflector and prime focus feed may require additional corrosion protection...

Page 72: ...ING Remove electrical power from antenna system prior to performing bi monthly maintenance 1 Remove LSR covers inspect mechanical operation and check for condensation accumulation If moisture exists open all drain holes Apply a spray type lubricant WD 40 or equivalent to all moving parts Secure covers 2 Remove hub cover Inspect polarization drive assembly apply a spray type lubricant WD 40 or equi...

Page 73: ...g low temperature greases is not used on the actuator machine screw damage to the screw or motor could occur Texaco Low Temperature 2346 Shell Aeroshell 7 Mobil Low Temperature 28 7 Inspect azimuth and elevation boots Replace as required 8 The antenna rotates in azimuth on rollers rotating about the azimuth ring Inspect rollers and apply a thin uniform coationg of grease to the contact surfaces of...

Page 74: ...tener SizeTorque ft lb tolerance 10 1 4 20 6 8 Nm 5 16 18 15 20 Nm 3 8 16 30 40 Nm 1 2 13 75 100 Nm 3 4 10 250 except as noted 333 Nm 1 8 600 except as noted 813 N _____________________________________________________________________ Torque Values For Antenna Fasteners Stainless Steel Fastener Size Torque ft lb tolerance 10 1 4 20 6 8 Nm 5 16 18 12 16 Nm 3 8 16 20 26 Nm 1 2 13 45 60 Nm 3 4 10 130 ...

Page 75: ...ion protection on the mount actuators and related hardware If the protective finish is damaged clean with a wire brush remove all rust and apply a coat of Rust Oleum or equivalent spray on cold galvanizing compound 2 Evaluate the corrosion protection on the reflector surface spars feed potentiometer brackets and related hardware If the paint is scratched chipped beginning to flake or just wearing ...

Page 76: ...Chapter 4 Maintenance Blank 42S199F 4 6 ...

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