DOCUMENT 500-0646, 3.8M VX Antenna O&M, Installation Manual
Important: In addition to this manual, the following manuals must be provided
to ensure adequate information:
Document No.
600-1046 Antenna Feed System Maintenance Manual
PLEASE DISCARD THIS PAGE BEFORE BINDING MANUAL
Description
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
FOR
MODEL 3.8 METER VX ANTENNA
500-0646
Revision A
July 25, 2006
General Dynamics SATCOM Technologies
2600 N. Longview St., Kilgore, TX USA 75662-6842
Phone (903) 984-0555 y FAX (903) 984-1826
www.gdsatcom.com
"EXPORT CONTROL WARNING - the disclosure of this document or its contents to non-U.S. persons,
or the transmission of its contents outside the United States must be in compliance with U.S. Export Laws
and Regulations. The bearer of this document is under obligation to know the applicable restrictions for
the dissemination of its contents that relate to U.S. Export Laws and Regulations or any other U.S.
government approvals".
All computer software, technical data or other information pertaining to the equipment covered
by this document is considered proprietary by SATCOM Technologies. Such information
transmitted in this document or related documents is for the benefit of SATCOM Technologies
customers and is not to be disclosed to other parties verbally or in writing without prior written
approval of SATCOM Technologies. Additionally, this document may not be reproduced in
whole or in part without written consent from SATCOM Technologies.
SATCOM TECHNOLOGIES CONFIDENTIAL AND PROPRIETARY
A Original release 7/25/06 JDT LJI SPK
REV. DESCRIPTION DATE WRITER CHK. APPR.
500-0646A i
Use of WARNINGS, CAUTIONS, etc.
Warnings, Cautions and other notes are included throughout this document to provide
necessary information. IGNORING WARNINGS, CAUTIONS AND OTHER NOTES
MAY RESULT IN DAMAGE TO THE PRODUCT, INJURY, OR IN EXTREME CASES,
DEATH. You should know the use of Warnings, Cautions and other markings.
Definitions are:
WARNING! HIGHLIGHTS AN INSTALLATION, OPERATING OR MAINTENANCE
PROCEDURE, PRACTICE, CONDITION, STATEMENT, ETC., WHICH,
IF NOT STRICTLY OBSERVED, COULD RESULT IN INJURY TO OR
DEATH OF PERSONNEL.
CAUTION! HIGHLIGHTS AN INSTALLATION, OPERATING OR MAINTENANCE
PROCEDURE, PRACTICE, CONDITION, STATEMENT, ETC., WHICH,
IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO OR
DESTRUCTION OF EQUIPMENT OR THE LOSS OF MISSION
EFFECTIVENESS OR LONG TERM HEALTH HAZARDS TO
PERSONNEL.
Important: Highlights an essential installation, operating or maintenance
procedure, practice, condition or statement, which, if heeded, will
ensure efficiency and/or safety of said procedures.
Note: Highlights an installation, operating or maintenance procedure, practice,
condition or statement, which, if heeded, could enhance efficiency and/or
safety of said procedures.
ESD: The Electrostatic Sensitive Device (ESD) appears at the beginning of
any procedure or procedural step that includes the handling of
equipment sensitive to damage from electrostatic discharge.
General Warnings and Cautions are also provided at the front of the document. These
Warnings and Cautions should be read by anyone who is involved with installation, has
access to the equipment or is assigned to perform maintenance on the equipment.
500-0646A ii
Although SATCOM Technologi es has attemp t ed to detail in this docum ent all areas of possib le
danger to personnel in connection with the u se of this equipm ent , per sonne l should use caution
when installing, operating and servicing this equipment. Care should be taken to avoid electr ical
shock, whether the hazard i s caused by design or malfunction. SATC OM Technologies is
specifically not liable for any damage or injury arising from a technician’s failure to follow the
instructions contained in this document or his failure to exercise due care and caution in the
installation, operation and service of this equipme nt. SAT C OM Technologies shall not be
responsible for injury or damag e resultin g from im proper procedures or from the use of
improperly trained or inex perienced pers onnel performing such tasks.
This document is intended as a general guide for train e d and qualifie d per sonn el w ho are aware
of the dangers of handling potentially hazardous electrical and electron ic circuits. This
document is not intended to contain a complete statement of all safety precautions that should
be observed by personne l in using this or other electronic equipment.
The antenna and feed system supp lied by SATCOM Technologies is designed to be integrated
with various types of electronic equipment. This system, if integrated with high power amplifiers
or traveling wave tubes, will be capable of transmitting microwave ener gy at varying power
levels. If transmitting microwave pow er, SATCOM T ec hnolog ies cauti ons the end-user to review
all applicable local, federal and internati onal regu lations and to comply with all such regulations
in the operation and maintenance of the integrated system.
CAUTIONARY NOTICE
ELECTRICAL HAZARDS
The electrical currents an d volt ages ass o ciated with this equipment, whether supplied by
SATCOM Technologies or others, are dangerous . P ersonnel must at all times observe safety
regulations.
• It is recommended that a lockout/tagout process be utilized while servicing the antenna
system. In the United States, see OSHA 1910.147.
• Always disconnect power before opening covers, doors, enclosures, gates, panels or
shields.
• Always use grounding sticks and short ou t high volt age p oints bef ore serv ic in g.
• Do not remove, short-circuit or tamper with interlock swit ches on access covers, doors,
enclosur e s, gates, panels o r sh i e l d s.
• Keep away from live circuits.
• Know your equipment and do not take risks.
• Always remove all power to the system prior to working on the antenna, the reflector
assembly, the reflector backup a ssem b ly or the feed ass em bly.
• Always tag all circuits noting that the power is OFF, the dat e and y our name, prior to
commencing any work on th at sy stem.
In case of emergency, be sure that power is disconnected .
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The antenna limit switche s and res olver s hav e be en pr e- set to allow for m ax imum a ntenna
performance. Any subsequent adjustment may jeopardize antenna p erformance and/or result in
damage to the antenna.
The following safety procedures are listed to remind those performing any work on the anten n a
system that safety rules must be observed. Failure to observe safety rules may result in serious
injury or death. Always work safely and in accordance w ith established procedures.
• It is recommended that a lockout/tagout process be utilized while servicing the antenna
system. In the United States, see OSHA 1910.147.
• Care shall be taken in all operations to safeguard other people as well as property and
to comply with all local safety procedures as establi shed by the cu stom er’ s site
representative, as well as local building codes and fire protection standards.
• All persons performing work on the antenna sy stem shall also comply with the
Occupational Safety and Health Act (OSHA) standards an d a ll other federal state and
local laws, ordinances, regu latio ns and codes relating to designated work.
• Unless the customer’s repre sentative on site specifically designate s an individual
responsible for site safety, the SATCOM Technologies Site Supervisor shall be
responsible for and establish a site safety program for the SAT C O M Technologies
installation work. The site safety program shall incorpora te all SAT COM Technologies
safety procedures and requirem e nts
POTENTIAL DAMAGE TO ANTENNA
SAFETY NOTICE
• Never make internal adjustments or perfor m m ai ntenanc e or servi ce when alone or
fatigued.
ELECTROMAGNETIC RADIATION
• It is recommended that a lockout/tagout process be utilized while servicing the antenna
system. In the United States, see OSHA 1910.147.
• Do not stand in the direct path of the feed system when the system is transmitting!
• Do not work on the feed system when the system is on!
ALWAYS WORK SAFELY!
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TABLE OF CONTENTS
INTRODUCTION .............................................................................................................1
1.0
1.1 General............................................................................................................................1
2.0 INSTALLATION...............................................................................................................2
2.1 Before Beginning .............................................................................................................2
2.1.1 Antenna Foundation ........................................................................................................2
2.1.2 Shipment Inspection........................................................................................................2
2.1.3 Unpacking Instructions ....................................................................................................2
2.1.4 Tools Recommended for Installation...............................................................................3
2.2 Installation Procedure......................................................................................................5
2.2.1 Pedestal Structure...........................................................................................................6
2.2.2 Azimuth Jack Assembly...................................................................................................7
2.2.3 Hub..................................................................................................................................9
2.2.4 Radial Beam Structure...................................................................................................12
2.2.5 Reflector Lacing Members.............................................................................................16
2.2.6 Reflector Panels ............................................................................................................18
2.2.7 Feed Boom Structure.....................................................................................................20
2.2.8 Subreflector Assembly...................................................................................................23
2.2.9 Feed Boom Alignment...................................................................................................25
2.2.10 Feed Horn......................................................................................................................26
2.2.11 Overview for Installing Waveguide ................................................................................30
2.2.12 Installing the Elevation Limit Switch...............................................................................31
2.2.13 Azimuth Limit Switch Installation ...................................................................................32
2.2.14 Installing the Elevation Transducer................................................................................32
2.2.15 Installing the Azimuth Transducer .................................................................................34
2.2.16 Electrical Installation......................................................................................................36
2.2.17 Positioning the Antenna on the Satellite........................................................................36
2.2.18 Adjustment of Elevation Axis.........................................................................................36
2.2.19 Adjustment of Azimuth Axis...........................................................................................36
2.2.20 Repositioning the Azimuth Rotating Jack Arm...............................................................36
2.2.21 Peaking the Antenna on the Satellite.............................................................................36
3.0 MAINTENANCE ............................................................................................................40
3.1 General..........................................................................................................................40
3.1.1 Antenna Surface Cleaning.............................................................................................40
3.1.2 Electrical Device Cleaning.............................................................................................40
3.1.3 Mechanical Maintenance...............................................................................................40
3.1.4 Pedestal Turning Head And Bearing Plates..................................................................40
3.1.5 Feed Window Inspection ...............................................................................................40
3.1.6 Replacing the Elevation Jack Boot................................................................................41
3.1.7 Replacing the Azimuth Jack Boot..................................................................................41
4.0 WARRANTY..................................................................................................................42
APPENDIX A. HARDWARE CHARTS..................................................................................... A-1
APPENDIX B. SITE SELECTION ............................................................................................B-1
APPENDIX C. REPORTING LOSS OR VISIBLE DAMAGE.................................................... C-1
APPENDIX D. MOUNTING CONSIDERATIONS.....................................................................D-1
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LIST OF TABLES
Table 1. Tool List .........................................................................................................................3
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LIST OF FIGURES
Figure 1. Fully Assembled 3.8m VX Antenna..............................................................................5
Figure 2. Pedestal Assembly.......................................................................................................6
Figure 3. Installing the Azimuth Trunnion ....................................................................................7
Figure 4. Installing the Azimuth Jack...........................................................................................8
Figure 5. Installing the Elevation Lugs..........................................................................................9
Figure 6. Installing the Hub........................................................................................................10
Figure 7. Installing the Elevation Jack Support..........................................................................10
Figure 8. Installing the Elevation Jack .......................................................................................11
Figure 9. Antenna Rotated to 90° Elevation...............................................................................12
Figure 10. Radial Alignment Pins...............................................................................................12
Figure 11. Radial Beam Installation...........................................................................................14
Figure 12. Reflector Lacing Assembly.......................................................................................15
Figure 13. Reflector Panel Assembly.........................................................................................17
Figure 14. Reflector Panel Assembly Order ..............................................................................19
Figure 15. Rotating Antenna for Feed Boom Installation...........................................................21
Figure 16. Feed Boom Assembly...............................................................................................22
Figure 17. Feed Boom Assembly Supports...............................................................................24
Figure 18. Subreflector Assembly..............................................................................................25
Figure 19. Feed Boom Alignment..............................................................................................26
Figure 20. Feed Assembly.........................................................................................................28
Figure 21. Feed Alignment.........................................................................................................28
Figure 22. Install Feed Support Kit ............................................................................................29
Figure 23. Install Feed Support Kit ............................................................................................30
Figure 24. Install Feed Support Kit ............................................................................................30
Figure 25. Elevation Limit Switch Installation.............................................................................31
Figure 26. Azimuth Limit Switch Installation ..............................................................................32
Figure 27. Elevation Resolver Assembly...................................................................................33
Figure 28. Elevation Resolver Assembly...................................................................................34
Figure 29. Azimuth Resolver with Bracket.................................................................................35
Figure 30. Azimuth Resolver (side view) ...................................................................................35
Figure 31. Antenna Position.......................................................................................................37
Figure 32. RF Pattern ................................................................................................................38
Figure 33. Feed Port Polarization..............................................................................................39
500-0646A vii
1.0 INTRODUCTION
1.1 General
The 3.8-meter VX antenna is designed to work at various radio frequencies and to be
assembled easily in the field by the user. This dual offset antenna is composed of the
main reflector, subreflector, supporting structures and pedestal structures. After being
properly assembled, this antenna will achieve high gain and exceptional pattern
characteristics.
This manual is designed to guide the user through a logical sequence of procedures
starting with the foundation and continuing on to the pedestal installation. Next, the
optional strut kit (or jack kit) and motor kits are discussed. The reflector is addressed,
followed by the feed and integration kits. Finally, positioning on the satellite is covered to
finalize antenna setup.
This antenna can be fitted with AZ/EL struts or it can be equipped with jacks, screws and
motors. The motorization package can be retrofitted to an existing antenna that has
struts. Throughout this manual, both of these options are referenced. Follow the
appropriate steps for your particular configuration. The antenna can also be retrofitted
with a full line of integration options directly on the feed boom. Options include: transmit
waveguide runs, SSPAs, TWTAs and receive. Also, LNAs, LNBs and block down
converters can be configured.
The 3.8-meter VX antenna is compatible with a full range of control options from jog
control to step track and memory track. Also available for this antenna is a full anti-icing
system for cold weather applications.
It is very important to understand the entire installation procedure to avoid any mistakes
that could result in permanent damage to the antenna. Therefore, SATCOM
Technologies strongly suggests the antenna user 1) read this manual thoroughly before
starting the installation and 2) follow the steps precisely. SATCOM Technologies
disclaims any liability or responsibility for the results of improper or unsafe installation,
operation and maintenance practices. Should any installation, operation or maintenance
questions arise that are not answered within this document, please contact:
General Dynamics SATCOM Technologies
2600 N. Longview St.
Kilgore, Texas USA 75662-6842
Tel: (903) 984-0555
Fax: (903) 984-7597
Note: All personnel installing or working with this equipment should become
thoroughly familiar with the instructions in this manual before starting
work.
500-0646A 1
2.0 INSTALLATION
2.1 Before Beginning
2.1.1 Antenna Foundation
Prior to the installation of the antenna, the antenna foundation must be complete. Refer
to VertexRSI foundation structure drawing 034372 as well as 039304 for conduit, if an
antenna control system such as 7134/7200 will be used. Recommendations for site
selection are presented in Appendix B.
2.1.2 Shipment Inspection
The VertexRSI 3.8-meter VX antenna is packaged in four basic packages with two
optional packages and one customer-dependent package. Once received, the antenna
shipping packages should be inspected for exterior damage. If damage is found, please
contact SATCOM Technologies for correction. See Appendix C for “Reporting Loss or
Visible Damage.”
Prior to the installation process, it is recommended that the components be inventoried
against the parts list for each antenna. A hardware kit is part of the shipment. A Bill of
Material (BOM) is included inside each hardware kit and may be used to inventory the
hardware. Use the Work Order Bill Of Material "Unit Qty" and "Catalogue Number" to
inventory the hardware. Should any part be missing or if damage is apparent, please
refer to Appendix C, "Reporting Loss or Visible Damage." A complete 3.8-meter VX
antenna shipment contains the following:
Package #
Description
1 Hub
2 Radial Beams
3 Reflector
4 Motorizable Pedestal (open skid)
5 Hardware Kits
6 Jack or Strut Kit
7 Foundation Installation [optional]
8 Feed Installation [customer dependent]
2.1.3 Unpacking Instructions
Care should be exercised when uncrating and unpacking the equipment. Each package
should be inspected as it is opened. The contents of each package should be checked
against the work-order packing list inside each package or against the parts list to verify
correct part numbers and quantities.
If a claim for shipping damages is to be made, save the packing material, the container
and the accompanying paperwork to substantiate the claim with the carrier. Notify
SATCOM Technologies as soon as possible. Do not return any unit, subassembly or
assembly until authorization and shipping instructions are received from the
factory.
500-0646A 2
2.1.4 Tools Recommended for Installation
This 3.8-meter VX antenna is designed for assembly by a crew of three with the
assistance of a lifting device such as a forklift. The following is only a partial list of
recommended hand tools. Refer to VertexRSI document 500-0321 for a complete listing
of recommended tools for installation.
Table 1. Tool List
Tool Name and Size Quantity
Open End/Box End wrench (each size) 2
5/16", 3/8", 7/16", 1/2”, 9/16", 3/4", 1-1/16"
1/2” Drive Ratchet 15” Long 2
1/2” Drive Extension 10” Long 2
1/2” Drive Extension 6” Long 2
1/2” Drive Sockets (each size) 2
5/16", 3/8", 7/16", 1/2”, 9/16", 3/4", 7/8”, 1-1/16", 1-1/8", 1-1/4"
3/8” Drive Ratchet 15” Long 2
3/8” Drive Extension 6” Long 2
3/8” Drive Extension 10” Long 2
3/8” Drive Sockets (each size) 2
7/16", 1/2”, 9/16"
3/8” Drive (Female) to 1/2” Drive (Male) Adapter 1
Allen Wrench Set (1/16” thru 3/8”) 2
Phillips Screw Driver (+) 2
Regular Flat Screw Driver (-) 2
25 Ft. Measuring Tape 1
Claw Hammer 2
2 lb. Hammer 2
Inclinometer 1
Level (Alum. 18”) 1
Step ladder 6 Ft. (2m) and 16 Ft. (5m) 1
12" Pipe Wrench 1
Cordless drill (must have a clutch) 1
Drill Set (1/16” thru 1/2”) 1
Spade Lug Crimper 2
Caulking Gun 1
Nylon Slings – 2” W x 20’ L 4
Utility Belt 2
Bolt Bag 2
Torque Wrench, 0-250 in–lb (0-30 Nm) 1
Torque Wrench, 90-600 ft-lb (122-814 Nm) 1
Torque Wrench, 10-80 ft–lb (14-109 Nm) 1
500-0646A 3
Awl (1/8" Diameter) 1
Pliers 2
Flat File Machinist (10”) 1
Adjustable Spud Wrench 1
Striking Wrench 1
500-0646A 4
2.2 Installation Procedure
Note: Refer to Figure 1 during installation. This figure is an overall view of the
assembled antenna and can assist the installer with locating parts and
understanding the relationship between the components.
Note: Refer to Appendix A for hardware torque values unless otherwise
indicated within a step.
Figure 1. Fully Assembled 3.8m VX Antenna
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2.2.1 Pedestal Structure
The pedestal assembly is shipped pre-assembled and is comprised of the V-frame
weldment pinned to the pedestal weldment in two places.
Figure 2. Pedestal Assembly
Step 1. Determine the desired antenna orientation and place the pedestal on the foundation
anchor bolts with the V-frame pointing in the desired direction (foundation hardware is
shipped with the foundation kit). The antenna will typically face south in northern
latitude installations and north in southern latitude installations.
Note: One inch of grout may be used in tracking configurations.
Note: The pedestal assembly should be lifted into place as an assembly using
adequate lifting equipment such as a forklift or hoist.
Step 2. Locate the four 1” x 4” x 4” plate washers and place them on each of the four anchor
bolts. Use a bubble level positioned on the top and sides of the pedestal to ensure
that it is level, both horizontally and vertically.
Step 3. Install one washer and one nut (included in the foundation kit) on each of the four
anchor bolts. Torque the anchor bolt nuts to 740 ft. lbs. ± 10% dry or 560 ft. lbs. ±
10% lubricated.
500-0646A 6
2.2.2 Azimuth Jack Assembly
Step 1. Install the azimuth trunnion to the pedestal. Install one retaining ring on the pin and
slide one flat washer onto the pin. Place the thrust washer above the bottom azimuth
trunnion attachment point and then, while holding the azimuth trunnion in place, insert
the pin from the bottom. Secure the pin by sliding a flat washer onto it and attaching
the second retaining ring. The azimuth trunnion should easily swing right and left at
this point.
Figure 3. Installing the Azimuth Trunnion
Step 2. Attach the azimuth jack to the azimuth trunnion. Slide the azimuth jack tube through
the hole on the azimuth trunnion and secure the jack to the trunnion using 5/8” x 2”
bolts, 5/8” nuts and 5/8” flat washers (four places).
Step 3. Attach the end of the azimuth jack screw to the appropriate lug on the V-frame (see
Figure 4). The appropriate lug is determined depending on the antenna’s azimuth
travel requirements. Use a flat washer and a retaining ring on each end of the pin.
Note: It may be necessary to extend the jack screw to reach the V-frame lug.
This can be accomplished by driving the jack in azimuth using an electric
drill and a 1/2” socket.
500-0646A 7
Figure 4. Installing the Azimuth Jack
Step 4. Install the key on the jack input shaft.
Step 5. Ensure that the motor face sits flush against the flange face.
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2.2.3 Hub
Step 1. Before installing the elevation lugs, insert the 5/8” x 1-3/4” [15.875mm x 44.45mm]
hot-dip galvanized hardware for feed booms into the first hole in the flat bottom of the
hub (see Figure 5).
Step 2. Install the elevation lugs parallel to the bottom floor of the hub and torque them to 200
ft-lbs [271 Nm].
Back
of Hub
of Hub
Elevation Lug
Feed Boom
Hardware
Figure 5. Installing the Elevation Lugs
Right Side
Step 3. Mount the hub on the T-head by aligning the holes on the hub brackets with the holes
on the T-head lugs and inserting the pins. Secure the pins with flat washers and
retaining rings.
CAUTION! AS A SAFETY PRECAUTION, THE HUB SHOULD BE HELD IN PLACE
WITH ADEQUATE LIFTING EQUIPMENT (SUCH AS A FORKLIFT OR
HOIST) UNTIL THE ELEVATION JACK SUPPORT AND ELEVATION
JACK ARE INSTALLED.
500-0646A 9
Figure 6. Installing the Hub
Step 4. Install the elevation jack support assembly to the bottom of the hub with 3/4" [19.05]
hardware and brackets as shown in Figure 7.
Note: The bolted connection of the jack support assembly should face toward
the front of the hub.
Figure 7. Installing the Elevation Jack Support
500-0646A 10
Step 5. Install the elevation drive assembly to the pedestal base by installing the rod-end pin
and cotter pin.
Step 6. Secure the elevation jack drive assembly to the elevation jack support by installing
the shoulder screws.
Step 7. Install the elevation jack motor following the steps used to install the azimuth jack
motor (see Section 2.2.2).
CAUTION! IF THE MOTOR IS USED ON THE ELEVATION JACK, POSITION IT SO
THAT THE CONDUIT BOX HOLE IS FACING DOWN TO PREVENT
WATER FROM SEEPING INTO THE CONDUIT BOX. THE MOTOR
MAY NEED TO BE ROTATED BACK AND FORTH UNTIL BOTH
COUPLING HALVES LINE UP AND MESH TOGETHER.
Figure 8. Installing the Elevation Jack
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2.2.4 Radial Beam Structure
Step 1. Run the antenna up to 90° in elevation to ease assembly of the reflector.
Figure 9. Antenna Rotated to 90° Elevation
Step 2. Using a hammer, insert and tap the radial alignment pins into the factory-drilled holes
in the hub. There is one alignment pin hole near each pair of bolt holes in the radial
mounting bands. Do not drive the pins all the way into the holes. Each pin must
protrude out from the hub 1/2” [12.7mm] (see Figure 10).
Figure 10. Radial Alignment Pins
500-0646A 12
Note: There may be factory-installed, adhesive-backed shims on the hub. Do
not remove these shims or misalignment may occur.
Step 3. Identify the radial beams from #1 to #4. Each should have identification from the
factory. Improper location will create problems during panel installation.
CAUTION! DO NOT PUSH OR TWIST THE RADIAL BEAMS AT ANY TIME
DURING THE INSTALLATION PROCESS. ANY DAMAGE TO THESE
MEMBERS WILL RESULT IN DISTORTION OF THE REFLECTOR
SURFACE.
Note: To prevent galling of hardware, lubricate threads and torque as noted in
Appendix A.
Note: Prior to assembly, ensure that mating surfaces are free of dirt and debris
by wiping with a clean cloth.
Step 4. Attach the radial beam to the hub with 1/2" x 2" [12.7 mm x 50.8 mm] stainless steel
hardware. The radials must be seated on the machined step of the hub and against
the alignment pins. Do not tighten the hardware beyond hand-tight until the next step.
Step 5. Inspect and verify that the radial beam T-bar is properly seated on the machined step
at the rear of the hub weldment. The edge of the radial "T" should also be contacting
the alignment pins to the side of each radial. When each radial is correctly in place,
fully tighten all hardware holding the radial to the hub as shown in Figure 11.
500-0646A 13
Figure 11. Radial Beam Installation
500-0646A 14
Figure 12. Reflector Lacing Assembly
500-0646A 15
2.2.5 Reflector Lacing Members
Note: All lacing members, clips, etc. need to be assembled with the bolts
completely loose. This will allow the radials to move as necessary to
facilitate panel installation. The lacing hardware will be tightened later
also.
Install the reflector lacing braces and 2" x 2-1/2" [50.8mm x 63.5mm] angle clips (2-1/2"
[63.5mm] leg pointed away from the web of the radial) between the installed radial
beams at the lacing hole locations with 1/2" x 1-1/2" [12.7mm x 38.1mm] stainless steel
hardware. Bolt loosely (see Figure 12). The lacing will be tightened in Section 2.2.6,
Step 7, after installing reflector panels.
Note: There is a left and a right diagonal lacing tube brace between the #3 and
#4 radial beams
CAUTION! DO NOT PUSH OR TWIST THE LACING BRACES OR DAMAGE TO
THE REFLECTOR STRUCTURE MAY OCCUR. ONLY ROTATE THEM
SLOWLY UNTIL FINDING THE RIGHT PLANE IN WHICH ALL THE
SURFACES BECOME FLUSH AND ARE EASILY BOLTED
TOGETHER.
500-0646A 16
Figure 13. Reflector Panel Assembly
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2.2.6 Reflector Panels
Step 1. Working from ladders or scaffolding, start installing the reflector panels from the
center outward in each direction according Figure 14.
CAUTION! DO NOT STAND OR LIE ON THE PANELS DURING INSTALLATION
AS THIS WILL CAUSE PERMANENT DISTORTION TO THE
REFLECTOR SURFACE. DO NOT PUSH OR PULL ON THE RADIALS
WITH MORE THAN MINIMAL EFFORT TO LINE THE HOLES UP WITH
THOSE IN THE PANELS.
500-0646A 18
Figure 14. Reflector Panel Assembly Order
500-0646A 19
Step 2. Place the first two upper panels between #1 and #2 radial beams, and insert the #10
screws in each hole. Tighten the screws along radial #1 (center radial) only.
CAUTION! IN ORDER FOR THE PANEL AND THE RADIAL BEAM CONTOURS
TO FIT EACH OTHER CORRECTLY, BE SURE THAT THERE ARE NO
GAPS OR FOREIGN MATTER BETWEEN THE TOP OF THE RADIAL
AND THE BOTTOM OF THE PANEL.
Note: Ensure that lubricant has been applied to all hardware to prevent galling
and to ease disassembly.
Note: Holes in the panels should line up with the holes in the radials when the
parts are in their correct positions. An awl may be useful in assisting
alignment.
Step 3. Place the next two lower panels between #1 and #2 radial beams (below the panel in
Step 2) and insert the #10 screws in each hole. Tighten the screws along the radial
#1 (center radial) only.
Step 4. Insert and tighten the screws that join the upper and lower panels together
(see Figure 13).
Step 5. Starting from the top and working in sequence toward the hub, tighten the remaining
screws on the outer and lower panel installed in Step 2 and Step 3.
Step 6. Repeat the installation procedure from Step 2 through Step 5 above for each panel
section. Work from the middle toward the outer edge of the reflector. See Figure 14
for order of installation.
Step 7. Completely tighten all the stainless steel hardware on the previously installed lacing
members from Section 2.2.5. Be sure that there are no twists to the radial beam
structures while tightening the lacing members.
CAUTION! DO NOT PUSH OR TWIST THE LACING BRACES OR DAMAGE TO
THE REFLECTOR STRUCTURE MAY OCCUR. ONLY ROTATE THEM
SLOWLY UNTIL FINDING THE RIGHT PLANE IN WHICH ALL THE
SURFACES BECOME FLUSH AND ARE EASILY BOLTED
TOGETHER.
CAUTION! TIGHTEN THE HARDWARE CONNECTING THE ANGLE CLIPS TO
THE RADIALS FIRST, THEN TIGHTEN THE HARDWARE
CONNECTING THE LACING THE ANGLE CLIP.
2.2.7 Feed Boom Structure
Note: All hardware in this section is to be loosely installed. They will be
tightened after the feed boom alignment.
Step 1. Rotate the antenna upright by turning the elevation jack until the antenna is rotated
about 90° as indicated in Figure 15.
Step 2. Attach the left and the right feed booms to the bottom of the hub weldment with six
5/8" x 1-3/4" [15.875mm x 44.45mm] hot-dip galvanized bolts and tighten them. (see
Figure 16).
Step 3. Install the two feed boom gussets to the hub and feed boom with 1/2" x 1-1/2"
[12.7mm x 38.1mm] stainless steel hardware (see Figure 16).
500-0646A 20
Step 4. Loosely attach two feed boom standard mount channels to the top of the feed booms
with 3/8" x 1-3/4" [9.525mm x 44.45mm] stainless steel hardware and install the 1/2"
[12.7mm] plastic shims between the top of the boom and the bottom of the
standard-mount channel (see Figure 16).
Figure 15. Rotating Antenna for Feed Boom Installation
Step 5. Loosely attach the other two feed boom standard-mount channels and long feed
boom diagonal braces to the bottom of the feed booms with 3/8" x 1-1/4" stainless
steel hardware, (see Figure 17).
Step 6. Loosely install the short feed boom diagonal brace inside the rear section of the feed
booms. It attaches underneath the hub weldment with 3/8" x 1-1/4" [9.525mm x
31.75mm] stainless steel hardware between the feed booms and the angle clips, and
1/2" x 1-1/2" [12.7mm x 38.1mm] stainless steel hardware between the angle clip and
brace. (This member is only for manual pedestal models). (See Figure 17).
500-0646A 21
Figure 16. Feed Boom Assembly
500-0646A 22
2.2.8 Subreflector Assembly
Step 1. Identify a notch at the top of the subreflector. Make sure the subreflector is properly
mounted with the notch toward the topside.
Step 2. The subreflector has been factory assembled to the two subreflector brackets using
the four subreflector clips with 1/4” x 3/4” [6.35mm x 19.05mm] stainless steel
hardware. The subreflector brackets are mounted to the subreflector seat with
3/8” x 1” [9.525mm x 25.5mm] stainless steel hardware (See Figure 18).
Step 3. Place the factory-assembled subreflector on the end of the feed boom and secure it
using the 3/8” x 1-1/4” [9.525mm x 44.45mm] stainless steel hardware. (see Figure
18).
500-0646A 23
Figure 17. Feed Boom Assembly Supports
500-0646A 24
2.2.9 Feed Boom Alignment
Step 1. Use a tape measure long enough to measure the distances between the outer panel
tips and the ends of each feed boom on both sides. Make sure the measurement is
taken from the exact opposite point on each side of the main reflector. The difference
between the distances on both sides should be no more than 1/8”. If it is, loosen the
5/8" bolts at the hub feed boom connection and adjust the feed boom until it is 1/8” or
less. See Figure 19.
Figure 18. Subreflector Assembly
500-0646A 25
Step 2. Torque the six 5/8" [15.875mm] hot-dip galvanized connection bolts between the feed
booms and the hub weldment. Next, tighten all 3/8" [9.525mm] stainless steel
hardware for the feed boom members identified in Section 2.2.7. If the difference is
more than 1/8" ensure that there is no binding in the feed boom lacing connections or
the feed boom-to-hub connections.
Figure 19. Feed Boom Alignment
2.2.10 Feed Horn
Step 1. Bolt the feed horn bracket onto the installed feed boom standard-mount channels with
four 1/4" x 2" [6.35mm x 50.8mm] stainless steel hardware (see Figure 20 and Figure
21). Check the distances from the top of the feed horn to the subreflector topside
tooling holes. Distances A and B should be equal to within 1/8" [3mm]. Repeat the
above and check from the bottom of the horn to the bottom side tooling holes.
500-0646A 26
Note: The subreflector and feed alignment are located during the
manufacturing process. Do not modify the mounting surfaces or hole
locations.
Note: Each feed ships separately with specific installation instructions,
drawings and mounting hardware. Refer to these as well as the general
instructions of this section. With some feeds, additional holes may be
required.
500-0646A 27
Figure 20. Feed Assembly
Figure 21. Feed Alignment
500-0646A 28
Step 2. Attach one end of a feed support bar to the standard mount channel using the
existing hole as shown in Figure 22.
Step 3. Match-drill a hole in the feed boom arm and attach the other end of the feed support
bar to the feed boom arm using one (1) ¼ x 7/8” hardware as shown in Figure 22.
Repeat for other side.
Step 1
Step 2
Figure 22. Install Feed Support Kit
Note: If you are using a standard feed, use two (2) ¼ x 7/8” hardware included
in the kit to fasten the feed support bars to the standard mount channel as
shown in Figure 23; or, if you are using a motorized feed, use the existing
hardware to fasten the feed support bars to the standard mount channel
as shown in Figure 24.
500-0646A 29
Figure 23. Install Feed Support Kit
Figure 24. Install Feed Support Kit
2.2.11 Overview for Installing Waveguide
Waveguide kits provided by SATCOM Technologies include documentation and
installation drawings. Certain amplifiers, converters, etc. are provided with
documentation that is included in their appropriate boxes. Refer to individual documents
for instructions regarding these items.
Note: For Strut Option Antennas, skip to Section 2.2.17 at this time.
500-0646A 30
2.2.12 Installing the Elevation Limit Switch
Step 1. Install the pivot plate to the hub tooling boss with supplied hardware.
Step 2. Install the bracket on the elevation lug and attach the switch to the bracket so that it
lays flat.
CAUTION! IT IS POSSIBLE TO INSTALL THIS BRACKET INCORRECTLY,
WHICH WILL CAUSE IMPROPER ALIGNMENT OF THE LIMIT
SWITCH. SEE FIGURE 25 FOR CORRECT POSITIONING.
Step 3. Slip one stop collar onto the rod and tighten it close to the hub. After threading the
end of the stop rod through the limit switch arm, secure it with a retaining nut and
attach the stop rod to the pivot plate.
Step 4. Slip the other collar over the rod near the end and tighten it.
Step 5. Adjust the length of the switch arm until the rod rides without binding. Drive the jack
to its retracted and extended lengths and adjust the stop collars so that the switch is
tripped before the mechanical stop is reached
Figure 25. Elevation Limit Switch Installation
500-0646A 31
2.2.13 Azimuth Limit Switch Installation
CAUTION! TO PREVENT DAMAGE TO THE JACK, OR INJURY TO THE
OPERATOR, CARE SHOULD BE TAKEN TO DRIVE THE JACK
SLOWLY AS IT APPROACHES THE STOP COLLAR AT THE LIMITS
OF AZIMUTH TRAVEL.
Step 1. Install limit switch to the underneath side of top pivot on V-frame (Figure 26)
Step 2. Install stop plate to upper azimuth pin with “U” bolt and adjust height so stop
hardware will hit switch lever arm when attached to switch.
Step 3. Adjust switch arm and stop plate so that it will contact the tripping hardware when
limits are reached. Drive the antenna to its retracted and extended length to adjust
the switch so it trips before the jack stop is reached. Reference drawing 035881
located in your print pack for further installation information.
Figure 26. Azimuth Limit Switch Installation
2.2.14 Installing the Elevation Transducer
CAUTION! TO PREVENT DAMAGE TO THE JACK OR INJURY TO THE
OPERATOR, CARE SHOULD BE TAKEN TO DRIVE THE JACK
SLOWLY AS IT APPROACHES THE STOP COLLAR AT THE LIMITS
OF ELEVATION TRAVEL.
Step 1. Drive the elevation jack until it is fully retracted
Step 2. Attach the swing arm weldment to the hub tooling boss and secure it using the nut as
shown in Figure 27 and Figure 28.
500-0646A 32
Step 3. Install the swing arm clamp to the #11 resolver shaft using the supplied setscrew and
tighten.
Note: Additional adjustment may be necessary when installation is complete.
Step 4. Insert the resolver into the resolver bracket until the setscrews line up with the groove
in the resolver and tighten.
CAUTION! DO NOT OVER-TIGHTEN THE SETSCREWS AGAINST THE
RESOLVER OR DAMAGE MAY OCCUR.
Step 5. Place the resolver assembly onto the elevation lug and install hardware in the bracket
before tightening.
Step 6. Attach the swing arm to the swing arm clamp with the setscrew. Adjust the length of
the arm so it does not slip off rod bolt weldment.
Step 7. Hand-tighten all setscrews and bolts to 25 lb-in.
Figure 27. Elevation Resolver Assembly
500-0646A 33
Figure 28. Elevation Resolver Assembly
2.2.15 Installing the Azimuth Transducer
CAUTION! TO PREVENT DAMAGE TO THE JACK OR INJURY TO THE
OPERATOR, CARE SHOULD BE TAKEN TO DRIVE THE JACK
SLOWLY AS IT APPROACHES THE STOP COLLAR AT THE LIMITS
OF ELEVATION TRAVEL.
Step 1. Drive the azimuth jack until it is fully retracted.
Step 2. Attach the mount bracket to the lower pintle shaft of the pedestal with the bolt. See
Figure 30.
CAUTION! DO NOT OVER-TIGHTEN THE SETSCREWS AGAINST THE
RESOLVER OR DAMAGE MAY OCCUR.
Step 3. Insert the resolver into the resolver bracket and secure with cleats.
Step 4. Line up the bracket as shown in Figure 29 and Figure 30 and attach the swing arm
clamp to the resolver shaft using the setscrew and tighten.
Note: Additional adjustment may be necessary when installation is complete.
Step 5. Attach the swing arm to the swing arm clamp with the setscrew. Adjust the length of
the arm to properly fit the pivot hardware as seen in Figure 29 and Figure 30. Adjust
the length of the arm so that it lines up.
Note: Swing arm should be parallel with mount when adjusted.
500-0646A 34
Figure 29. Azimuth Resolver with Bracket
Figure 30. Azimuth Resolver (side view)
500-0646A 35
2.2.16 Electrical Installation
The electrical installation should be conducted by referring to the appropriate Electrical
Installation Drawing included in the print pack.
Controller installation and configuration should be in accordance with the individual
Antenna Control System Manual provided with the controller.
2.2.17 Positioning the Antenna on the Satellite
To position the antenna, the elevation and azimuth pointing angles must be known.
These angles are specific for each site location and satellite. This information can be
obtained from the satellite operator and mapping data of the antenna location.
2.2.18 Adjustment of Elevation Axis
The elevation look angle can easily be found by using the bottom of the feed boom as
the reference datum. The bottom of the feed boom is parallel to the RF axis, hence, use
of an inclinometer on the bottom of the feed boom will give the elevation look angle of
the antenna. Adjust the antenna in elevation using the adjustment nuts on the elevation
strut (or by driving the jack), until the inclinometer is at the desired look angle. See
Figure 31.
2.2.19 Adjustment of Azimuth Axis
Step 1. Use a compass to sight along the feed boom to locate the desired azimuth angle.
Note: When using a compass note that true north varies from magnetic north
depending on the site location. The compass reading can also be
affected by steel structures in close vicinity to the compass.
Step 2. If the desired angle is near the end of, or beyond the azimuth travel for that position of
the rotating jack arm, the arm can be repositioned as explained below. Otherwise
skip to Section 2.2.21.
2.2.20 Repositioning the Azimuth Rotating Jack Arm
CAUTION! THIS PROCEDURE MAY ONLY BE PERFORMED IN WINDS LESS
THAN 20 MPH. ATTEMPTING TO DO THIS IN STRONGER WINDS
CAN CAUSE SERIOUS DAMAGE TO THE ANTENNA STRUCTURE
OR OTHER STRUCTURES IN CLOSE PROXIMITY TO THE
REFLECTOR AND COULD CAUSE BODILY HARM.
Step 1. Loosen hardware and remove from the V-frame lug.
Step 2. Manually move the pedestal to the desired position and re-attach the opposite V-
frame lug. Tighten the hardware to the specified torque values.
2.2.21 Peaking the Antenna on the Satellite
Note: When peaking the antenna on the satellite a spectrum analyzer should
be used with the following instructions.
500-0646A 36
Step 1. After locating the position of the satellite with the inclinometer and compass, look for
a signal on one of the satellite transponder frequencies.
Step 2. Scan back and forth in the azimuth to locate the maximum (greatest amplitude)
transponder signal (see Figure 32).
Note: Two turns of the nuts on the azimuth strut equal approximately 1° of
azimuth rotation. Approximately 4 to 5 turns of the jack input shaft is
equal to 1° of azimuth rotation.
Note: The antenna will not need to rotate more than ± 1.5° from the maximum
level or the antenna may receive a signal from a different satellite.
Step 3. With the antenna positioned at the maximum signal level in azimuth, scan back and
forth in elevation using the nuts on the elevation strut (or by driving the jack) until the
maximum (greatest amplitude) transponder signal is found.
Note: Three turns of the nuts on the elevation strut is equal to approximately 1°
of azimuth rotation. Approximately 6 turns of the jack input shaft is equal
to 1° of azimuth rotation.
Figure 31. Antenna Position
500-0646A 37
Step 4. When the antenna is being peaked to the maximum copolar signal level, it is
necessary to make sure that the antenna is on the main beam and not a sidelobe of
the signal (see Figure 32).
• If the antenna is on a side lobe the signal on the spectrum analyzer will diminish and
not return or will decrease and return to a higher level as the antenna is rotated in
azimuth and/or elevation (see Figure 33).
• If the signal diminishes and does not return, position the antenna back to the original
starting point. Rotate the antenna in the opposite direction. The signal will decrease
then increase to a higher level on the spectrum analyzer. The increased signal level
is the main signal beam.
• Using this higher signal level repeat Step 2 through Step 4 to get the antenna
peaked to the maximum transponder signal level.
Figure 32. RF Pattern
Step 5. When using a linearly-polarized system always check the feed polarity. Rotate the
feed to the optimum polarization setting after the antenna has been peaked on the
satellite.
• When receiving true vertical polarization the receive port at the rear of the feed
should be in the horizontal position (see Figure 33). This corresponds to 0° on an
angular scale relative to the feed support. In this configuration the antenna will
receive true vertical polarization and transmit horizontal polarization. To achieve the
opposite polarization, in both receive and transmit, the feed must be rotated 90° by
loosening the feed clamps and rotating the entire feed. This will correspond to 90°
on an angular scale relative to the feed support.
• In general, the incoming (Rx) /outgoing (Tx) signal polarization on the antenna will
not always be perpendicular or parallel to the Earth's surface. Because of this it will
be necessary to optimize polarization of the antenna feed by aligning it to the satellite
polarization. This is achieved by carefully rotating the feed until the feed and the
satellite are in the same polarization.
500-0646A 38
• Rotate the feed as required to receive and maximize the appropriate receiver signal
levels.
Step 6. Once the antenna is positioned at the peak signal level, check or tighten the following
bolts and/or nuts:
• Elevation jackscrew nuts
• Azimuth fine adjust collar and turning head bolts
• Elevation axis bolts
Step 7. Once the polarity is set, secure the feed clamps. The system is now completed and
no more adjustments need to be made.
Figure 33. Feed Port Polarization
500-0646A 39
3.0 MAINTENANCE
3.1 General
Proper maintenance will keep the antenna in good working condition and ensure the
antenna meets or exceeds the designed life expectancy. Follow a protective
maintenance program that routinely cleans, inspects, lubricates and implements
corrective measurement as required on all mechanical, structural, electrical and
electronic components on the antenna. If there are any discrepancies beyond your ability
to remedy, please contact SATCOM Technologies to acquire the information of how to
deal with them before you proceed.
3.1.1 Antenna Surface Cleaning
A periodic surface cleaning is recommended to remove the excessive accumulation of
dust, dirt and contaminants. A mild detergent solution, soft cloth and soft brushes can
be used to clean the exterior of the antenna.
3.1.2 Electrical Device Cleaning
For electrical and electronic parts, visual inspection of the wires, cables, waveguides,
switches, relays, etc. is required to prevent any bad insulation or loose connections. To
remove dust or loosen foreign particles on the electrical and electronic equipment, use of
a vacuum and soft brush or cloth is recommended. Some electrical and electronic parts
require cleaning using special cleaning solvents. In this case, the parts cleaned need to
be dried for 10-15 minutes before placing them back into operation. Always disconnect
power and use lock-out tags to prevent shock hazards to personnel when servicing any
electrical component.
3.1.3 Mechanical Maintenance
The antenna mechanical and structural parts such as reflector, pedestal, drive system,
anti-icing system (if installed) and hardware need to be periodically inspected in order to
ensure proper operation. Where there are no established wear limits, perform a visual
inspection to identify worn or damaged parts to avoid the improper functioning of the
earth station. Periodically, check all hardware to make sure it is properly tightened.
Motorized antenna lubricants need to be checked every six months at each jack and
bearing location.
3.1.4 Pedestal Turning Head And Bearing Plates
Lubricate with medium-grade white lithium grease by inserting the nozzle in the space
between the pedestal turning-head’s front and rear sections then between the clamping
bolts of the pedestal turning head (see Figure 2).
3.1.5 Feed Window Inspection
A visual inspection of the feed window should be performed periodically to prevent
contaminates from entering the feed. Look to make sure the feed window is tight on the
feed horn and has no cracks or splits.
500-0646A 40
3.1.6 Replacing the Elevation Jack Boot
Replacement of the elevation jack boot should only be attempted in winds less than 20
mph. Rotate the antenna to the 90° position while placing a wooden block between the
“T-head” and the hub. “Lock” the antenna in place with a come-along, cables or ropes.
Ensure that after removing the jack rod-end pin from the pedestal base, it is still possible
to reconnect the rod end. Remove the rod-end pin at the pedestal and swing the jack
screw downward. Loosen the clamps and remove the boot. (It may be necessary to cut
the old boot to remove it.) Install a new boot over the jack and tighten the clamps to
secure it. (It may be necessary to fold the boot on the end of the rod that connects to the
pedestal base.)
3.1.7 Replacing the Azimuth Jack Boot
Replacement of the jack boot should only be attempted in winds less than 20 mph. Drive
the jack until it is fully extended. “Lock” the antenna in place with a come-along, cables
or ropes. Remove the rod-end pin and the swing-jack screw outward. Loosen the clamps
and the remove boot. (It may be necessary to cut the old boot to remove it.) Install the
new boot over the jack and tighten the clamps to secure it. (It may be necessary to fold
the boot on the end of the rod that connects to pedestal base.)
500-0646A 41
4.0 WARRANTY
SATCOM Technologies warrants the items ordered hereunder at the time of shipment to
be free from defects in material, workmanship, and to conform to the contract
specification. SATCOM Technologies’ liability under this Warranty shall terminate one
(1) year after date of acceptance or eighteen (18) months from the date of shipment,
whichever comes first. Some individual products include extended warranties as stated
in brochure(s) and extended warranties may be purchased as requested and quoted.
Written notice of any defects shall be given SATCOM Technologies upon discovery and
SATCOM Technologies shall promptly correct such defects by repair or replacement, at
its option, without charge, either FCA SATCOM Technologies’ plant or service in the
field.
IN NO EVENT SHALL SATCOM TECHNOLOGIES’ LIABILITY UNDER THIS
WARRANTY EXCEED THE COST OF REPAIR OR REPLACEMENT OF SUCH
DEFECTIVE ITEM AND UNDER NO CIRCUMSTANCES SHALL SATCOM
TECHNOLOGIES BE LIABLE FOR SPECIAL OR CONSEQUENTIAL DAMAGES.
Specifically excluded from this Warranty are:
a. Defects or nonconformance caused by and resulting from improper operation,
maintenance, or storage of the equipment.
b. Items of characteristically indeterminate life, such as bulbs, fuses, etc.
THIS WARRANTY CONSTITUTES SATCOM TECHNOLOGIES’ SOLE AND
EXCLUSIVE LIABILITY HEREUNDER AND BUYER'S SOLE AND EXCLUSIVE
REMEDY FOR DEFECTIVE OR NONCONFORMING ITEMS AND IS IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS IMPLIED OR STATUTORY (INCLUDING THE
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE).
500-0646A 42
APPENDIX A. HARDWARE CHARTS
(Figures of hardware are shown actual size for convenient reference).
500-0646A A-1
NOTE: TORQUE HARDWARE TO VALUE STATED UN DER FIGURE UN LESS
OTHERWISE INDICATED. THESE ARE LUBRICATED VALUES.
LUBRICANT MAY BE ANY WAX, OIL OR GREASE PRODUCT.
5/8 X 2 1/4 HEX BOLT HDG
3/4 X 2 1/2 HEX BOLT HDG
200 lb-ft (272 Nm)
3/4 X 3 1/4 HEX BOLT HDG
200 lb-ft (272 Nm)
110 lb-ft (150 Nm)
5/8 X 1 3/4 HEX BOLT HDG
110 lb-ft (150 Nm)
1 X 1 1/2 HEX BOLT HDG
440 lb-ft (597 Nm)
1 X 2 1/4 HEX BOLT HDG
440 lb-ft (597 Nm)
1 X 4 HEX BOLT HDG
440 lb-ft (597 Nm)
1/2 X 2 HEX BOLT SS
20 lb-ft (27.2 Nm)
1/2 X 1 1/2 HEX BOLT SS
20 lb-ft (27.2 Nm)
3/8 X 1 3/4 HEX BOLT SS
100 lb-in (11.3 Nm)
3/8 X 1 1/4 HEX BOLT SS
100 lb-in (11.3 Nm)
1/4 X 2 HEX BOLT SS
30 lb-in (3.4 Nm)
1/4 X 1 1/2 HEX BOLT SS
30 lb-in (3.4 Nm)
#10 X 1/2 SS
PAN HEAD MACHINE SCREW
A54.DWG
500-0646A A-2
500-0646A A-3
APPENDIX B. SITE SELECTION
There are several antenna-mounting methods selected by users. There are some
general requirements that need to be followed:
• The antenna should have a clear line of sight to the satellite arc, clear of any trees,
buildings or other structures.
• If a ground mount is chosen, the site should be relatively level, free of underground
obstructions and not be subject to excessive rainfall runoff.
• If a roof mount is being selected, the roof structure should be designed or verified by
a certified professional to withstand the antenna load and forces imposed by wind
loads. A foundation interface loads document is available from SATCOM
Technologies to aid in the structural analysis.
500-0646A B-1
APPENDIX C. REPORTING LOSS OR VISIBLE DAMAGE
Some damage may occur to the parts during the shipping process. A claim should be
filed with the carrier upon receipt of the equipment or after completion of parts
verification. Follow the "Reporting Loss or Visible Damage", "Reporting Concealed
Damage", and "Reporting Missing Parts" when filling a claim with the carrier.
• Reporting Loss or Visible Damage
Make a note of any loss or damage on the freight bill or receipt signed by the carrier's
agent. Failure to adequately claim such loss or damage may result in the carrier refusing
to honor a damage claim. The form for such a claim can be acquired from the carrier.
• Reporting Concealed Damage
The contents may be damaged in transit due to rough handling, but the package may
not show any external damage. For any concealed damage discovered after unpacking
the unit, make a written request for an inspection by the carrier's agent, and file a claim
with the carrier.
• Reporting Missing Parts
After opening the shipment, an inventory of the parts should be completed. Check items
received in the shipment. If there is any item missing, please notify SATCOM
Technologies immediately by contacting Project Managing Department.
• Returning
Thorough consideration has been taken by SATCOM Technologies to ensure that all
antenna items arrive in safe working order. Occasionally, equipment may be received
that is not in working condition due to reasons beyond manufacturer's control. Upon
review of the completed claim forms, SATCOM Technologies will determine disposition
as to return, repair and/or replacement. The return process can be expedited by
following this procedure:
1. Notify SATCOM Technologies Project Managing Department by call or fax, giving a
short description about the missing items or damaged components. (Phone -(903)
984-0555, Fax -(903) 984-1826.
2. Tag or identify the defective equipment, noting the defect or circumstance. Pack the
equipment in a sturdy shipping container with some protective packing materials, and
return to SATCOM Technologies.
3. When returning items to SATCOM Technologies, please include all available
information regarding sales order number, purchase order number, delivery date and
other pertinent information to properly identify the antenna. Also, please include the
following information:
• Your company name
• Your address with city, state and country
• Your telephone and fax numbers
• The individual's name SATCOM Technologies should contact
500-0646A C-1
APPENDIX D. MOUNTING CONSIDERATIONS
There are two basic mounting approaches for small antennas: ground mount and roof
mount. For ground mounting, the user should build a qualified antenna foundation and
consult a structural professional for the foundation soil structures. For roof mounting,
some special considerations should be taken as follows:
The antenna system should be properly supported to provide transfer of all the antenna
loads into the main building structures, sustaining all the wind loading exerted on the
antenna along with the antenna self-weight. The designed roof-mounting frame must
distribute loads from the antenna interface location to the building’s roof beams and
columns.
The structural concepts that will be incorporated to achieve an effective frame
configuration are as follows:
• At each foundation interface location, provide a direct load path for each load vector
component.
• Where feasible, align axes of framing members to the vector direction of the applied
loads. This can reduce bi-axial bending and torsional effects.
• Eccentricity between the applied load vector and the framing member centroid can
produce large torsional forces. These torsional effects require more complex joint
details to transfer forces properly and introduce increased structural deflection.
• Reinforcing members are required where the antenna structure is bolted to a beam.
The reinforcement should be designed to prevent flange bending and web crippling
under concentrated load.
• Use correct anchors in concrete surface.
• Avoid use of double-nutting (one nut on top and one nut on bottom of the plate) to
provide leveling. This will induce undesirable anchor bolt bending conditions.
• Use friction type connections where it is possible to provide 100% load reversal
capacity.
500-0646A D-1
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