2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
4096-859
Revision A
August 7, 2012
ASSEMBLY MANUAL
2.4M SERIES 1241 ANTENNA
GENERAL DYNAMICS
SATCOM Technologies
1500 Prodelin Drive
Newton NC 28658USA
Phone 828-464-4141
www.gdsatcom.com
ProdelinCorporationPage18/17/2012
2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
2.4M SERIES 1241 ANTENNA
ASSEMBLY MANUAL
Legal Notice
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application programs, operating systems, software design implementation, tests, test results, operation, diagnosis,
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Uniform Trade Secrets Act, by the Uniform Trade Secrets Act and by any other states'/countries' Trade Secrets Acts
regardless if some of the information or documents that were incorporated into such drawings, sketches, computer
programs, plans, specifications, technical data, prototype products, blueprints,
models, formulae, tables, engineering designs, diskettes, tapes, software, other electronic media (defined to include, but
not be limited to, the system functional design, logic flow, algorithms, application programs, operating systems, software
design, implementation, tests, test results, operation, diagnosis repair...) and/or documents or other information that was
incorporated into the Proprietary Materials came from a customer or third party and whether such Proprietary Materials do
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photographs, instructions, diagrams,
A
- Original Release 8/8/2012 JWL
Revision
Released for
production.
Description Date Approved By
8/17/12 R.F.
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2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
TABLE OF CONTENTS
LIST OF FIGURES .......................................................................................................................... 4
LIST OF TABLES ............................................................................................................................ 4
2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
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Figure 1: 2.4m Series 1241 Antenna
2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
1. INTRODUCTION
1.1. General Information
This manual describes the assembly and installation of General Dynamics’ 2.4m Rx/Tx
antenna. These instructions cover all areas of assembly and installation. Additional
sections are included in the manual to provide information on antenna pointing and
maintenance. General Dynamics recommends that these instructions be followed closely, and in the order shown, for proper antenna performance.
1.2. 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 packing list for each major
component is supplied.
1.3. Freight Damage
Any damage to materials while in transit should be immediately directed to the freight
carrier. They will instruct you on matters regarding any freight damage claims.
1.4. Materials – Missing or Damaged
Any questions regarding missing or damaged materials that are not due to the freight carrier
should be directed to General Dynamics’ Customer Service Department at:
General Dynamics
SATCOM Technologies
1500 Prodelin Drive
Newton NC 28658
USA
(828) 464-4141
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2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
1.5. Mechanical Installation Tools
Required Tools:
• Wrenches (see Table 1)
Other Recommended Tools:
• Compass
• Inclinometer
• Adjustable wrench 10”
• 3/8” drive Ratchet with Sockets and 6” extension (see
Table 1)
Table 1: Wrench and Socket Sizes Required
HARDWARE SIZE SAE WRENCH SIZE
METRIC WRENCH
SIZE
MAX RECOMMENDED
TORQUE (±10%)
5/16” 1/2” 13mm
3/8” 9/16” 14mm
1/2” 3/4” 20mm
3/4” 1-1/8” 24mm
1” 1-1/2” 38mm
NOTE: The Minimum Torque applied should not be less than 10% of maximum
recommended torque.
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15 ft-lbs
(20.3 n-m)
20 ft-lbs
(27.1 n-m)
45ft-lbs
(61 n-m)
145ft-lbs
(196.6 n-m)
220 ft-lbs
(298.3 n-m)
2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
1.6. Site Selection
In order to achieve maximum performance of your antenna system, it is important to select the correct
location for the antenna. The following guidelines should be observed when selecting a site for the
installation.
1. The line of site to the satellite should be clear of any obstructions, such as trees or buildings.
2. The site should be relatively flat and level for ease of installation and access to the antenna.
3. The site should be checked for underground obstruction, such as buried cables or pipes.
4. All local building codes should be adhered to (i.e. grounding, foundation requirements, zoning
rules, setbacks, etc.).
1.7. Suggested Mast & Foundation
6” SCH 40 PIPE
(6.625” OD)
TYP 2
2-5
54.0
54.0
SEE NOTE #7
A A
24.0
SECTION A-A
NOTES:
1. 2 x 2 x 1/4 HRS Angle and schedule 40 pipe should conform with ASTM A36 and ASTM A53
Type E and S Grade B.
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.)
2 x 2 1/4 HRS ANGLE
12 INCHES LONG
TYPICAL 2 PLACES
12.0
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2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
2. ANTENNA INSTALLATION
Table 2: Reflector and Mount Parts List
ITEM PART NO. DESCRIPTION QTY
1 0179-447
2 0179-448
3 0179-444
4 0179-445
Reflector, 2.4m RT 4pc Quad #1
Reflector, 2.4m RT 4pc Quad #2
Reflector, 2.4m RT 4pc Quad #3
Reflector, 2.4m RT 4pc Quad #4
1
1
1
1
5 0185-3607
6 0168-415
7 0211-1265
8 0211-1266
9 0211-1267
10 0211-1268
11 0211-1269
AZ / EL Positioner
Elevation Adjustment Block
Reflector BTM Bracket LH
Reflector BTM Bracket RH
Reflector Top Bracket LH
Reflector Top Bracket RH
Reflector Center Bracket
1
1
1
1
1
1
2
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2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
Parts List Continued
12 0490-1010
2.4m 4pc Reflector Support Weldment
13 0247-445
2.4m 4pc Crossarm
14 0490-1014
Weldment, El Rod – 2.4m
0200-948 Reflector Spacer Kit
15 0159-265
Reflector Spacer #65
1
2
1
4
16 8110-007
17 8201-052
18 8202-068
19 8036-016
20 8036-024
21 8201-049
22 8202-046
23 8317-106
Nut, 7/8-9 Hex Jam
Flat washer, 7/8 USS STD
Lock washer, 7/8 Internal Tooth
0200-1865 AZ / EL Hardware Kit
Bolt, 1-8 x 2.00 Hex
Bolt, 1-8 x 3.00 Hex
Flat Washer, 1” SAE STD
Lock washer 1” STD
Screw Assy, 5/8-11 x 1.50
4
4
4
2
3
6
4
6
24 8107-007
25 8031-012 Bolt, 5/16-18 x 1.50 Hex 24
26 8201-071
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Nut, 1-8 Hex
0200-1828 Reflector Seam Hardware Kit
Flat washer, 5/16” SAE Narrow
5
48
2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
Parts List Continued
27 8202-041 Lock washer, 5/16” STD 24
28 8101-009
29 8032-010
30 8201-042 Flat washer, 3/8” USS STD 28
31 8202-042
32 8102-007
33 8033-010
Nut, 5/16-18 Hex
0200-1829 Reflector Support Hardware Kit
Bolt, 3/8-16 x 1.25 Hex
Lock washer 3/8” STD
Nut, 3/8-16 Hex
Bolt, 1/2-13 x 1.25 Hex
24
14
14
14
4
34 8201-043
35 8202-043
Flat washer, 1/2 USS STD
Lock washer, 1/2" STD
4
4
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2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
2.1. AZ / EL POSITIONER INSTALLATION
CAUTION: During the assembly procedure, the sequence of instructions
must be followed. DO NOT TIGHTEN ANY HARDWARE UNTIL
INSTRUCTED.
STEP 1:
Insert the 5/8” Set Screws (ITEM 23) into the canister and slip AZ/EL positioner (ITEM 5) over the mast
pipe. Tighten the set screws snug against the mast pipe.
STEP 2:
Insert elevation tube (ITEM 6) using 1” hardware (ITEMS 19, 21, 22). Lightly tighten at this time.
STEP 3:
The positioner must be oriented correctly to the center of the satellite orbital arc. Loosen the set screws
and rotate the canister on the mast pipe to the required position. Tighten the set screws then tighten the
5/8” lock nuts against the canister.
19, 21, 22
To Satellite
(within 10 deg.)
5
6
23
Mast Pipe
Figure 2: AZ / EL POSITIONER
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2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
2.2. REFLECTOR QUADRANT ORIENTATION
The series 1244 reflector quadrants are labeled #1, #2, #3 and #4. These
numbers may be found molded into the back of each quadrant at the inside
corner. Note that each quadrant has a longer side (major axis) and a shorter side
(minor axis). In the standard upright position, the antenna elevation angle range
is between 5 and 90 degrees. When viewed from behind in the standard position
(feed support at the bottom), quadrant #1 should be in the upper left; #2 is lower
left; #3 is lower right and #4 in the upper right position. See Figure 3.
However, to allow a lower profile installation or in areas of high snow
accumulation, the reflector can be assembled in the inverted position (feed
support at the top). In this position, quadrant #1 would be in the lower right; #2
upper right; #3 in upper left and #4 in lower left position. See Figure 4.
When assembling for the inverted position, the Back Frame (item 14) must be turned 180
degrees from its standard position prior to its mounting to the Az/El positioner – see Step 2. Also note that the optional feed stabilization kit cannot be used when the reflector is used in the
inverted position.
Center Line
of Reflector
Feed Rod
Holes
Feed Support at Bottom
Figure 3: Reflector Orientation Standard
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2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
Feed Support at Top
Feed Rod
Holes
Center Line
of Reflector
Figure 4: Reflector Orientation Inverted
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2.4M SERIES 1241 ANTENNA 4096-859
STEP
1
STEP
2
ASSEMBLY MANUAL REVISION A
2.3. REFLECTOR SUPPORT ASSEMBLY
Reflector
Petal
16, 17, 18
15
Locate quadrant #1 and insert threaded insert
(item 15) thru the hole on the face of the
reflector. Secure insert with 7/8” hardware (items
16, 17, 18). Snug only to allow freedom of
movement for the back frame assembly. Repeat
step for quadrants #2, #3 & #4.
Figure 5: Reflector Spacer Installation
STEP1:
12
INSTALL
21, 22, 24
180° FOR
INVERTED
MOUNTING
19, 21
19, 21
21, 22, 24
Figure 6: Reflector Support Assembly
Straddle the tabs of the reflector
support (item 12) over the holes in
the positioner and secure using 1”
bolts and hardware (items 19, 21,
22, 24). Tighten snug only and let
the tube fall back upon the
positioner.
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2.4M SERIES 1241 ANTENNA 4096-859
STEP
3
ASSEMBLY MANUAL REVISION A
11
7
13
29, 30
11
9
11
13
8
30, 31, 32
12
Shown with 1240
series positioner for
illustration only
(A) Place the cross arms (item 13) on the reflector support (item 12) as shown. Place the RH
and LH top brackets (items 9, 10) on the top cross arm and secure with 3/8 hardware (items 29,
30, 31, 32) as shown. Snug hardware by hand only at this time.
(B) Place the RH and LH bottom brackets (items 7, 8) on the bottom cross arm and secure with
3/8 hardware (items 29, 30, 31, 32) as shown. Snug hardware by hand only at this time.
(C) Place the two center brackets (item 11) on the reflector support as shown and secure with 3/8
hardware (items 29, 30, 31, 32) as shown. Snug hardware by hand only at this time.
Note: If installing with an inverted reflector, the locations of brackets (items #7,8 and
items #11,13) will be reversed from location shown.
Figure 7: Reflector Support Brackets
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2.4M SERIES 1241 ANTENNA 4096-859
STEP
4
(See table 1).
ASSEMBLY MANUAL REVISION A
See Note
8
12
7
30, 31, 32
30, 31, 32
29, 30
29, 30
Figure 8: Reflector BTM Support Brackets
Note:
are fully seated against the reflector support with no gaps between any of the
components before completing the next procedure.
Insert 3/8” hardware (items 29, 30) thru the reflector support (item 12) and the BTM
brackets (item 7, 8) as shown. Secure with 3/8” washers and hex nuts (items 30, 31,
32). Tighten this hardware to recommended torque to secure the BTM brackets.
Make sure the BTM brackets (items 7, 8), and the cross arm (item 13),
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2.4M SERIES 1241 ANTENNA 4096-859
STEP
5
ASSEMBLY MANUAL REVISION A
DETAIL VIEW
Shown with 1240
series positioner for
illustration only
2
11
11
2
25
Note location of
feed support
mounting hole
33, 34, 35
2
8
DETAIL VIEW
Figure 9: Quad #2 Installation
Note: Installing the lower quads (#2, #3) first will ease installation.
(A) Place Quad #2 on the cross arm (item 13) with the seam ribs between the reflector brackets
(items 7, 8, 11). Note that the longer side should be aligned with the major axis. Note the
location of the feed support mounting hole at the bottom of the reflector in Figure 9.
(B) Insert a 5/16 bolt (item 25) thru the seam rib and the center bracket (item 11) to temporarily
hold the petal.
(C) Insert the ½” bolt and washers (item 33, 34, 35) thru the cross arm and into the reflector
spacer. Hand snug only at this time.
7
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2.4M SERIES 1241 ANTENNA 4096-859
STEP
6
ASSEMBLY MANUAL REVISION A
3
26, 27, 28
25, 26
Shown with 1240
series positioner for
illustration only
33, 34, 35
Figure 10: Quad #3 Installation
(A) Place Quad #3 on the cross arm (item 13) with the seam rib against the seam rib of quad 32
and between the reflector brackets (items 2, 7, 8, 11). Note that the longer side should be aligned
with the major axis.
(B) Insert 5/16” bolts with washers (items 25, 26) thru the brackets and the major seam ribs as
shown. Secure with 5/16” hex nuts and washers (items 26, 27, 28). Hand snug only.
(C) Insert the 1/2” bolt and washers (item 33, 34, 35) thru the cross arm and into the reflector
spacer. Hand snug only at this time.
(D) Remove the temporary 5/16” bolt placed thru the center bracket in STEP 5 after Quad #3 is
supported by the major seam bolts and the 1/2” hardware.
2
13
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2.4M SERIES 1241 ANTENNA 4096-859
STEP
7
5/16”
Seam Bolts
ASSEMBLY MANUAL REVISION A
1/2" Reflector
Bolts
Shown with 1240
series positioner for
illustration only
(A) Install Quad #1 and Quad #4 using the same procedures as outlined in STEP 6. After all the
seam bolts are installed, begin tightening the 5/16” seam bolts from the center out until all the
seam bolts are tightened to the recommended torque. (See table 1)
Note:
are fully seated against the reflector support with no gaps between any of the components
before completing the next procedure.
(B) Next tighten the 3/8” cross arm and center bracket hardware to the recommended torque.
(See table 1)
(C) To complete the reflector assembly, tighten the four reflector insert nuts and the four 1/2"
reflector bolts to the recommended torque. (See table 1)
Make sure the Reflector brackets (items 7, 8, 9, 10, 11), and the cross arm (item 13),
1
2
Figure 11: Complete Reflector
4
3
3/8” Cross Arm
Hardware
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2.4M SERIES 1241 ANTENNA 4096-859
STEP
9
STEP
8
STEP
10
ASSEMBLY MANUAL REVISION A
Locate the elevation rod (item 14)
and install the 1” hex nut and washer
14
21, 24
(items 21, 24).
Figure 12: Elevation Rod Assy 1
Carefully swing the reflector up into a vertical
position. Insert the elevation rod assembly
Adjustment
Tube
(item 14) thru the elevation adjustment tube at
the back of the positioner. Install the 1” hex
nut and flat washer (items 21, 24).
21, 24
Figure 13: Elevation Rod Assy 2
24
14
Secure the elevation rod (item 14) to the reflector
support (item 12) with 1” hex bolt, lock washer,
and hex nut (items 20, 22, 24) as shown.
Reflector Support
Figure 14: Elevation Rod Assy 3
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20
14
2.4M SERIES 1241 ANTENNA 4096-859
r on
ASSEMBLY MANUAL REVISION A
3. FEED SUPPORT
This antenna will accept a variety of feed supports and feed systems. For Feed support installation
instructions, refer to the manuals supplied with the feed support.
4. ANTENNA ALIGNMENT
4.1. Alignment to Satellite
The 2.4M offset reflector contains a 17.35° elevation offset angle. Therefore, when the reflector
aperture is perpendicular to the ground, the antenna is actually looking 17.35° in elevation. The
following alignment procedure is intended only as a general reference guide for this antenna. For
proper antenna performance, accurate alignment is critical. Therefore, it is recommended that your
own detailed procedure be used or contact General Dynamics' Technical Support Department for
additional recommendations.
4.2. Initial Alignment
1) Place an inclinometer on the reflector support as shown in Figure 4. Remember to add 17.35
degrees to the reading to allow for the reflector’s offset angle (or subtract 17.35 degrees if
inverted)
2) Raise or lower the antenna to find the desired elevation by turning the 1" nuts located at the
elevation block. Position the top nut so that it will not interfere with adjustment. Turn the bottom
nut clockwise to increase elevation and counterclockwise to decrease elevation.
3) After the correct elevation angle is set, rotate the antenna in azimuth by loosening the canister
set screws and spinning the entire reflector assembly until the satellite is located. Tighten the
canister set screws securely.
4) Peak the antenna signal by adjusting elevation and azimuth until optimal signal is achieved.
5) To fine adjust azimuth, loosen the four ¾” bolts in the az/el assembly and turn the 1" nuts
located at the azimuth adjustment.
6) Once optimal signal is obtained, tighten all of the hardware used for adjustments.
Place inclinomete
reflector support
Elevation
Azimuth
Adjustment
Figure 15: Antenna Alignment
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2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
5. MAINTENANCE
5.1. 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 in-house
maintenance staff.
5.2. Periodic Inspection
It is suggested that a periodic inspection be performed at least every six months.
NOTE: After any very 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:
1) Check all bolting locations - all bolts should be tight.
2) Check all structural members - repair or replace if damaged.
3) Check the foundation anchor bolts - they must be secure and with no failure signs in foundation.
4) Check for corrosion - on the reflector structure and mount.
5.3. Reflector
General Dynamics' 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 other
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 General Dynamics for recommendations involving
reflector repair.
5.4. Mount and Reflector Support Structure
The mount and reflector support structure supplied with this antenna is of steel construction and
has a hot-dipped 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 zinc-rich cold galvanizing paint.
5.5. Repair and / or Replacement
Any questions or issues regarding repair or replacement parts should be addressed to General
Dynamics’s customer service department at:
General Dynamics
SATCOM Technologies
1500 Prodelin Drive
Newton NC 28658
USA
(828) 464-4141
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