ViaSat 8116 Series, 8118 Series Installation And Operation Manual
Series 8116/8118
16-/18-Meter Earth Station Antenna
Installation and Operation Guide
Manual Part No.42S183D
April 2004
Notice
All Rights Reserved
The information contained in this document is proprietary to ViaSat, Inc.
This document may not be reproduced or distributed in any form without
the consent of ViaSat, Inc.
The information in this document is subject to change without notice.
ViaSat, Inc. assumes no responsibility for any errors 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:
Publication Number: 42S183D
Copyright ® 2002 ViaSat, Inc.
All rights reserved. No part of this book may be reproduced in any form
or by any means without permission in writing from ViaSat, Inc.
____________________________________________________________________________________________
TABLE OF CONTENTS
NOTE
For a further or more detailed breakdown of section
contents, refer to the title page of each section.
SECTION 1
1-1
1-1
1-3
1-4
SECTION 2
2-1
2-1
2-1
2-2
2-2
2-3
2-4
2-4
2-5
2-5
2-9
2-10
2-10
2-10
2-12
2-13
2-14
2-15
2-17
2-21
2-22
2-24
2-32
2-32
2-33
2-33
GENERAL INFORMATION
Introduction to Manual
Description
Wind Load Options
Specifications
LOWER MOUNT INSTALLATION PROCEDURES
General
What to do About Visible Loss or Damage
What to do About Concealed Damage
How to Inventory Equipment Received
How to Return Equipment
General Mechanical Safety Summary
Emergency Plan
General Electrical Safety Summary
Resuscitation
Recommended Tools and Equipment
Recommended Installation Sequency
Recommended Torque Values
Site Preparation
Assembly of Lower Mount
Azimuth Bearing Ring Assembly
Leg Installation
Bottom Skin Plate Installation
Mezzanine Installation (Optional)
Ships Ladder Assembly and Installation (Optional)
Middle and Top Skin Plate Installation
Torquing Lower Mount Fasteners
Door Assembly and Installation
Grouting Baseplate and Skin Plate to Foundation
Hot Weather Grouting
Cold Weather Grouting
Grouting Procedures
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42S183D
SERIES 8116/8118 16/18-METER EARTH STATION ANTENNA iii
TABLE OF CONTENTS
____________________________________________________________________________________________
SECTION 3
UPPER MOUNT INSTALLATION PROCEDURES
3-1
3-1
3-1
3-14
3-19
3-22
3-22
3-23
3-29
3-29
3-29
3-30
General
Azimuth Drive Anchor Installation
Rotating Frame Installation
Azimuth Drive Installation
Elevation Drive Installation
Hub Assembly and Installation
Hub Assembly
Hub Installation
Installing Guardrails and Ladders
Ladders Installation
Guardrails Installation
Miscellaneous Platform Hardware
SECTION 4
INSTALLATION OF REFLECTOR, SPARS,
SUBREFLECTOR, AND FEED
4-1
4-1
4-1
General
Installation of Reflector
Installation of Panel Mounting Ring and Optional LNA
Enclosure
4-4
4-15
4-23
4-29
4-31
4-37
4-37
4-40
Installation of 18M Truss Assemblies
Installation of 16M Truss Assemblies
Installation of Panels
Final Alignment of Panels
Installation of Spars and Subreflector
Installation of Model 8118 Feed
Installation of Feed
Installation of Waveguide
SECTION 5
OPERATION
5-1
5-1
5-1
5-2
5-5
General
Satellite Pointing Procedure
Feed Polarization
Subreflector Adjustment
Azimuth Sector Change Procedure
____________________________________________________________________________________________
iv
SERIES 8116/8118 16/18-METER EARTH STATION ANTENNA 42S183D
TABLE OF CONTENTS
____________________________________________________________________________________________
SECTION 6
6-1
6-1
6-1
6-1
6-2
6-5
6-5
SECTION 7
7-1
7-1
7-1
APPENDIX A
APPENDIX B
APPENDIX C
MAINTENANCE
General
Periodic Maintenance
Weekly Maintenance
Monthly Maintenance
Bi-Monthly Maintenance
Yearly Maintenance
Corrosion Protection
OPTIONS
General
Feed Options
Lightning Protection
INSTALLATION CHECKLIST WITH MANUAL PAGE
REFERENCES
MECHNCIAL ALIGNMENT SPECIFICATION AND REPORT
FOR 16/18-METER LIMITED MOTION ANTENNA
(479820A)
CONTOUR ALIGNMENT SPECIFICATION AND RECORD
FOR 16/18-METER ANTENNA (479821B)
____________________________________________________________________________________________
42S183D
SERIES 8116/8118 16/18-METER EARTH STATION ANTENNA v
SECTION 1
1-1 Introduction to Manual
1-1 Description
1-3 Wind Load Options
1-4 Specifications
GENERAL INFORMATION
42S183D Series 8116/8118 16-/18-Meter Earth Station Antenna
____________________________________________________________________________________________
SECTION 1 GENERAL INFORMATION
INTRODUCTION TO
MANUAL
DESCRIPTION
This manual contains information needed to properly install,
operate, and maintain the 16-/18-Meter (16/18M) Earth Station
Antenna. This section contains general information on the 16/18M
antenna. Sections 2 through 4 contain information pertaining to
16/18M antenna installation. Sections 5 and 6 contain information
pertaining to operation and maintenance. Section 7 describes the
different configurations available for the 16/18M antenna.
Appendix A contains a complete antenna installation checklist with
page references for the detailed procedures. Appendix B and
Appendix C contain mechanical and contour alignment
specifications and report information for the antenna, respectively.
All warnings and cautions should be reviewed before any
procedures are performed. Failure to do so may result in personal
injury or equipment damage.
Periodic maintenance and corrosion protection procedures are
contained in Section 5. For replacing components of the antenna,
refer to the installation and assembly drawings contained in
Sections 2, 3, and 4.
The 16/18M Earth Station Antenna provides a high-quality antenna
designed specifically for the INTELSAT-A station market. The
antenna is designed with many standard and optional features to
provide maximum user and application flexibility. Figure 1-1
shows an outline drawing of the 16M/18M antenna. The following
list identifies the main features of the antenna:
• Cassegrain feed for high-efficiency performance
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42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 1-1
• Designed for minimum maintenance
• Locked-in surface accuracy through precision tooling
• Frequency reuse feed
• Minimum site preparation required
• Full 360° azimuth travel in six over-lapping sectors
• Internal access for a clean, elegant look.
The 16/18M antenna is a Cassegrain design with a reflector and
subreflector that are shaped for maximum efficiency and low
sidelobes. The circularly polarized, four-port, frequency reuse feed
assembly includes a corrugated horn, orthomode transducer,
diplexers, and connecting waveguide. The transmit frequency
band is from 5.850 to 6.425 GHz and the receive frequency band is
from 3.625 to 4.200 GHz. All the performance specifications are
in full compliance with INTELSAT-A specifications.
GENERAL INFORMATION
____________________________________________________________________________________________
Figure 1-1. 16-/18-Meter Motorized Antenna
____________________________________________________________________________________________
1-2
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
GENERAL INFORMATION
____________________________________________________________________________________________
The mount for both the 16- and 18-meter antennas is the same
elevation-over-azimuth pedestal. The elevation travel limits can be
set at any points between 0 and 90 degrees. The azimuth travel
range is a full 360 degrees covered in six overlapping sectors. Size
11 resolvers are supplied for position readout. Both axes are
equipped with 75 ton (667 kN) jack screws drives. As an option,
100 ton (890 kN) jack-screws can be provided to address additional
demands imposed by very high wind conditions on the 18M
antenna. Access to the drives and the reflector is gained from
inside the mount rather than from external ladders. The feed
electronics can be accessed at any elevation angle through the rear
of the hub.
The motorized package features variable-speed ac motors to
provide higher motor speeds for rapid stowing or slewing in
addition to the slow speeds required for satellite tracking. The
drives are equipped with variable-speed ac motors having a low
speed of about 0.010 degrees per second and a high speed slew rate
of about 0.1 degrees per second. The normal operational rate of
each axis is typically 0.01 to 0.015 degrees per second.
CAUTION
__________________________________________
No buildings, walls, fences, or other permanent
fixtures should be planned for installation any
closer than two meters from the antenna and
foundation envelope without consultation with
the factory.
Wind Load Options
__________________________________________
The 18-meter antenna will operate or drive to stow in winds up to
90 miles per hour (145 km/h) with the standard 75 ton (667 kN)
actuators. It will survive in any position in winds up to 105 miles
per hour (170 km/h). In the stow position (elevation axis at 90
degrees), the antenna will survive winds up to 140 miles per hour
(225 km/h). Under worst-case conditions, when the antenna is at 0
degrees elevation angle, it will take about 30 minutes to stow the
antenna using the variable speed motors. While the elevation axis
is being stowed, the azimuth axis can be turned to a more favorable
direction relative to the wind, if necessary. The azimuth axis never
needs to be stowed during adverse winds once the elevation axis is
at 90 degrees.
With the optional 100 ton (890 kN) actuators, the antenna will
operate or drive to stow in winds up to 90 miles per hour (145
km/h) but will survive in any position in winds up to 125 miles per
hour (200 km/h). In the stow position, the antenna will survive
winds up to 165 miles per hour (265 km/h).
____________________________________________________________________________________________
42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 1-3
GENERAL INFORMATION
____________________________________________________________________________________________
The 16-meter antenna will operate or drive to stow in winds up to
110 miles per hour (175 km/h). It will survive in any position in
winds up to 125 miles per hour (200 km/h). In the stow position,
the antenna will survive winds up to 175 miles per hour (280
km/h).
SPECIFICATIONS
Function/Item Specification
General
Antenna Type Cassegrain, dual-reflector
Antenna Diameter 16 Meters
18 Meters
Reflector Construction
16-Meter Antenna 120 precision aluminum panels
18-Meter Antenna 168 precision aluminum panels
Mount Configuration Elevation-over-azimuth
Antenna Pointing Range
Azimuth 6 overlapping 90° sectors for a full 360°
Elevation 0 to 90° continuous
Antenna System Weight (Approximate)
16 Meter 124,000 lbs (56,233 kg)
18 Meter 127,000 lbs (57,594 kg)
Reflector Weight
16 Meter 39,000 lbs (17,686 kg)
18 Meter 42,000 lbs (19,047 kg)
Elevation Balance Angles
16 Meter 67°
18 Meter 69°
Drive Rates Variable over the range of:
Azimuth 0.0075 to 0.1125 degrees per second
(average)
Elevation 0.0044 to 0.0660 degrees per second
(average)
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1-4
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
GENERAL INFORMATION
____________________________________________________________________________________________
SPECIFICATIONS
Continued
Function/Item Specification
Electrical
Operating Frequency
Receive 3.625 to 4.200 GHz
Transmit 5.850 to 6.425 GHz
Feed Type Corrugated horn, frequency-reuse
Polarization Dual Circular
Gain at Midband (referenced to diplexer output ports)
Receive 55.2 + 20 log (f/4.0) dBi, 16-Meter
56.4 + 20 log (f/4.0) dBi, 18-Meter
Transmit 58.8 + 20 log (f/6.175) dBi, 16-Meter
60.1 + 20 log (f/6.175) dBi, 18-Meter
VSWR 1.25:1, Maximum
Axial Ratio
Receive 1.06:1
Transmit 1.06:1
Isolation Between Ports
Transmit 85 dB, Minimum
Receive 85 dB, Minimum
Beamwidth at Midband (nominal)
-3 dB Receive 0.32°, 16-meter
0.23°, 18-meter
-3 dB Transmit 0.21°, 16-meter
0.17°, 18-meter
First Sidelobe Level -14 dB, Maximum
Typical Antenna Noise Temperature
(Maximum @ 4 GHz referenced at output of OMT,
25°C (77°F), 50% RH, clear sky)
Elevation
5° 48
10° 41
20° 34
40° 32
60° 30
Power Handling Capability 5 kW continuous, 20 kW peak
(per port)
Feed Interface
Receive CPR-229G flange
Transmit CPR-137G flange
Voltage Requirements (actuators) 120/208V ac, 3-phase, 5-wire, 60 Hz or
220/380V ac, 3-phase, 5-wire, 50 Hz
(standard - others available)
Temperature (K)
____________________________________________________________________________________________
42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 1-5
GENERAL INFORMATION
____________________________________________________________________________________________
SPECIFICATIONS
Continued
Function/Item Specification
Electrical - continued
Pointing Error 0.028° rms [with winds of 30 mi/h (48
km/h)gusting to 45 mi/h (72km/h) (1ß)]
0.040° rms [with winds of 45 mi/h
(72km/h)gusting to 60 mi/h (95 km/h)
(1ß)]
Tracking Error 0.02° rms with winds of 30 mi/h (48
km/h)gusting to 45 mi/h (72km/h)
Environmental
Feed Pressurization Leak Rate 500 cc/hr, Maximum
Feed Pressurization Relief Valve 0.5 psig
Ambient Temperature -40 to +60°C (-40 to +140°F)
Rainfall 100 mm/h (4 in/h)
Relative Humidity 0 to 100 % with condensation
Altitude Above Sea Level 0 to 10,000 feet (0 to 3048 m)
Sand and Dust As in desert regions
Salt Spray As in coastal regions
Fungi As in tropical regions
Solar Radiation 1.14 kW sq meter (360 Btu/h/sq ft)
Vertical Shock (survival) 0.1 G
Horizontal Shock (survival) 0.3 G
Earthquake Survival Per grade 11, Mercalli scale
Wind Survival (16M)
Operate Drives 110 mi/h (175 km/h)
Any Position 125 mi/h (200 km/h)
Stow Position 175 mi/h (280 km/h)
Wind Survival (18M)
Operate Drives 90 mi/h (145 km/h) (standard or optional
actuators)
Any Position 105 mi/h (170 km/h) (standard 75 ton
actuators)
125 mi/h (200 km/h) (optional 100 ton
actuators)
Stow Position 140 mi/h (225 km/h) (standard 75 ton
actuators)
165 mi/hr (265 km/h) (optional 100 ton
actuators)
________________________________________________________________
____________________________________________________________________________________________
1-6
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
SECTION 2
2-1 General
2-1 What to do about Visible Loss or Damage
2-1 What to do about Concealed Damage
2-2 How to Inventory Equipment Received
2-2 How to Return Equipment
2-3 General Mechanical Safety Summary
2-4 General Electrical Safety Summary
2-5 Recommended Tools and Equipment
2-9 Recommended Installation Sequency
2-10 Recommended Torque Values
2-10 Site Preparation
2-10 Assembly of Lower Mount
2-33 Grouting Baseplate and Skin Plate to Foundation
LOWER MOUNT INSTALLATION
PROCEDURES
42S183D Series 8116/8118 16-/18-Meter Earth Station Antenna
SECTION 2 LOWER MOUNT INSTALLATION PROCEDURES
GENERAL
WHAT TO DO ABOUT
VISIBLE LOSS OR
DAMAGE
WHAT TO DO ABOUT
CONCEALED
DAMAGE
This section contains general procedures for unpacking all of the
antenna hardware. This section also contains procedures for
installing the lower mount of the 16-/18-Meter Earth Station
Antenna. The installation of the upper mount (including rotating
frame, azimuth/elevation drives, hub, and optional work platform)
is contained in Section 3. The installation of the reflector, spars,
subreflector, and feed is contained in Section 4. General safety
precautions and procedures for the entire installation are also
described at the beginning of this section.
ViaSat thoroughly inspects and carefully packs all equipment
before shipment. At the time of shipment, the carrier assumes
responsibility for its safe delivery; therefore, do not return damaged
units to ViaSat. Instead, file a claim with the carrier as noted in the
paragraphs following the initial unpacking procedure given below:
1. Inspect shipping carton for visible damage.
2. Open the shipping carton.
3. Remove all packing material.
4. Inspect unit for visible damage.
5. Using packing list, check for missing items (see "How To Inventory
Equipment Received" below).
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.
Concealed damage means damage which does not become
apparent until the unit has been unpacked. The contents may be
damaged in transit due to rough handling, even though the carton
may not show external damage. If you discover damage after
unpacking the unit, make a written request for inspection by the
carrier's agent within 15 days of the delivery date, then file a claim
with the carrier since such damage is the carrier's responsibility. If
you follow these instructions carefully, ViaSat guarantees its full
support of your claims to protect you against loss from concealed
damage.
____________________________________________________________________________________________
42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-1
LOWER MOUNT INSTALLATION PROCEDURES
HOW TO INVENTORY
EQUIPMENT
RECEIVED
HOW TO RETURN
EQUIPMENT
Check off each item received against that list on the packing slip
included with the shipment, and verify that this list matches the
purchase order. If any items are missing, please notify ViaSat
immediately and return a copy of the packing slip with the missing
item(s) circled.
For a current list of telephone and email contract information
please refer to the Contact Information section of the ViaSat
internet site (http://www.viasat.com
). Select Products, Satellite
Ground Systems and Contact Us.
ViaSat’s Satellite Ground Systems division makes every
reasonable effort to ensure that all items arrive safely and in
working order. When equipment is received, which is not in
working order, return the equipment to the factory for repair or
replacement. Return the equipment according to the following
procedure. This procedure will apply whenever equipment is
returned for warranty or other services.
a) Notify ViaSat of the problem and request a Return Material
b) Tag or identify the defective equipment and note defect and
c) Reship equipment in original shipping container or use a strong
d) Package equipment using shock-absorbing material around all sides
e) Seal container securely and mark outside of container FRAGILE.
Authorization (RMA) number and shipping instructions.
circumstances, if any. If known, reference sales order, purchase
order and date equipment was received.
shipping container to protect equipment during shipment.
of equipment.
NOTE
Absence of the RMA number will cause a delay in processing
your equipment for repair. Be sure to include the RMA
number in all correspondence.
NOTE
ViaSat Inc will not accept freight collect. Be sure to ship all
items freight prepaid.
____________________________________________________________________________________________
2-2
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
GENERAL
MECHANICAL
SAFETY SUMMARY
LOWER MOUNT INSTALLATION PROCEDURES
WARNING
__________________________________________
Electrical shock from voltages used in this
system can cause injury or death. Prior to
making any electrical connections or performing
maintenance and repair, ensure power is
removed. Electrical connections should be made
only by qualified personnel in accordance with
local regulation.
__________________________________________
These are general mechanical safety precautions that are not related
to any specific procedure. They are recommended precautions that
personnel must understand and apply.
WARNING
__________________________________________
Installation or maintenance of antennas may
require persons to work at elevated work
stations. Whenever persons are working at eight
or more feet above ground and not on a guarded
platform, they should wear safety belts with at
least one, and preferably two, lanyards, with the
exception that trained and qualified persons may
work up to 25 feet (7.6m) if on an approved
ladder. In the sentence above, approved usually
means that the ladder is tied off once the person
has climbed but before work begins.
__________________________________________
____________________________________________________________________________________________
42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-3
LOWER MOUNT INSTALLATION PROCEDURES
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 anything while it is
being hoisted.
2. Always wear a hard hat, especially if
someone is above you.
__________________________________________
WARNING
__________________________________________
Ensure that all electrical tools and equipment
are properly grounded.
__________________________________________
Emergency Plan
Have an emergency plan. Know the procedures for obtaining firstaid and fire-fighting assistance. Plan your work and maintain good
housekeeping; the safety and quality of the product are at stake.
GENERAL
ELECTRICAL SAFETY
SUMMARY
These are general electrical safety precautions that are not related
to any specific procedure. These are recommended precautions
that personnel must understand and apply.
____________________________________________________________________________________________
2-4
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
Resuscitation
RECOMMENDED
TOOLS AND
EQUIPMENT
LOWER MOUNT INSTALLATION PROCEDURES
WARNING
__________________________________________
Avoid shorting circuits when using metal tools.
Some circuits have high current capability
which, when shorted, will flash and may cause
burns and/or eye injury.
Remove all jewelry and exposed metal objects
from body and clothing before performing
maintenance, adjustments, 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 power
connected. Extreme caution must be exercised
during these procedures.
Death or severe injury may result if personnel
fail to observe safety precautions.
__________________________________________
Personnel working with or near hazardous chemicals or voltages
should be familiar with modern methods of resuscitation.
Tables 2-1 through 2-4 list the tools and equipment needed for
installing ViaSat’s 16 or 18 meter antenna. Table 2-1 is a list of
hand tools. Table 2-2 is a list of on-site requirements such as
cranes, steel chokers, and an air compressor. Table 2-3 is a list of
precision items required such as a theodolite and level. Table 2-4
is a list of installation aids, rigging, and expendable items such as
air wrenches, slings, ladders, and safety items, some of which may
be available at the site.
____________________________________________________________________________________________
42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-5
LOWER MOUNT INSTALLATION PROCEDURES
Table 2-1. Hand Tools Required for Installation
Quantity Description
1 Set* Combination wrenches up to 1 inch size
1 Each* 3/4 inch combination wrench
1 Each* 7/8 inch combination wrench
1 Each* 1 1/16 inch combination wrench
1 Each 1 1/8 inch combination wrench
1 Each* 1 1/4 inch combination wrench
1 Each* 1 5/8 inch combination wrench
1 Each* 1 7/8 inch combination wrench
1 Each* 2 inch combination wrench
1 Each 18 inch adjustable (Crescent) wrench
1 Each 24 inch adjustable (Crescent) wrench
1 Each 24 inch pipe wrench
1 Each* 1 1/16 inch spud wrench
1 Each* 1 1/4 inch spud wrench
1 Each* 1 5/8 inch spud wrench
1 Set 3/8 inch drive ratchet, extensions, and sockets from 3/8 to 7/8
1 Set* 1/2 inch drive ratchet, extensions, and sockets from 7/16 to 1
1 Each* 3/4 inch x 1/2 inch drive socket
1 Each* 7/8 inch x 1/2 inch drive socket
1 Each* 1 1/16 inch x 1/2 inch drive socket
1 Each* 1 1/4 inch x 1/2 inch drive socket
1 Each Socket adapter, 1/2 inch female to 3/4 inch male
1 Set* 3/4 inch drive ratchet, extensions, and sockets from 7/8 to 2
1 Each* 1 1/4 inch x 3/4 inch drive socket
1 Each* 1 5/8 inch x 3/4 inch drive socket
1 Each* 1 7/8 inch x 3/4 inch drive socket
1 Each* 2 inch x 3/4 inch drive socket
1 Each Socket adapter, 3/4 inch female to 1/2 inch male
1 Each 3/4 inch drive torque wrench, 250-300 ft-lbs capacity
1 Each 3/4 inch drive torque wrench, 600 ~-lbs capacity
2 Sets Screwdrivers, flat blade and Phillips
1 Set Hex keys (Allen wrenches) up to 1/2 inch size
1 Set* Nut drivers
2 Pairs Mechanic's pliers
1 Each Wire crimping tool
2 Pairs Lineman's pliers
2 Pairs Needle-nose pliers
1 Pair 12 inch channel lock pliers
2 Pair 10 inch vise grips
1 Each 4 pound sledge hammer
1 Each 8 pound sledge hammer
1 Each 24 ounce ball peen hammer
1 Each* Rawhide hammer
2 Each Claw hammer
2 Each 1 inch bull pin
2 Each 2 inch bull pin
1 Each Small slaver bar
inch size
1/4 inch size
inch size
____________________________________________________________________________________________
2-6
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
LOWER MOUNT INSTALLATION PROCEDURES
Table 2-1. Hand Tools Required for Installation - continued
Quantity Description
2 Each Large slaver bar
2 Each Crow (wrecking) bar
1 Each Pry bar
1 Each Band cutter
1 Each Hacksaw
6 Each Hacksaw blade
1 Each Automatic center punch
1 Each Drill index, 1/16 through 1/2 inch
6 Each 3/16 inch drill bits (for panel targets)
1 Each Tap and die set up through 3/8-16 size
1 Each 12 inch machinist's flat file
1 Each 12 inch round file
3 Each 6 inch C-clamp
1 Each Wire brush, stainless steel
1 Each Grease gun with cartridges
2 Rolls Electrical tape
1 Each Angle finder or magnetic base inclinometer
1 Each 24 inch carpenter's level
1 Each 12 inch machinist's scale with square head, 1/100 graduation
1 Each Feeler gage set
1 Each 12 foot tape
1 Each 25 foot tape
1 Each Chalk line reel (full of chalk)
1 Each 1 inch putty knife
1 Each 3 inch putty knife
1 Each 4 x 12 inch finishing trowel
1 Each 6 inch pointing trowel
4 Each 3/4 - 10 shoulder eye bolts (4-6 inch)
* Doubling the quantity of this item will enable a larger crew to install the
antenna more quickly.
______________________________________________________
____________________________________________________________________________________________
42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-7
LOWER MOUNT INSTALLATION PROCEDURES
Table 2-2. On-Site Machinery and Equipment Required for
Quantity Description
1 Each* 45 ton crane with a 100 foot boom
4 Each 15 foot steel choker, 3/4 inch wire diameter
2 Each 20 foot steel choker, 1 inch wire diameter
4 Each Small, medium, and large shackles
1 Each Electric generator [or power hook-up point]
1 Each Air compressor with hoses and fittings, 600 cfm capacity
1 Each 20 foot scaffold [Not needed if mezzanine option is included
1 Each 50 foot high platform lift or bucket truck [Optional, but very
1 Each 5 gallon bucket (for grouting)
* Adding another crane will enable a larger crew to install the antenna more
quickly. [About 20 ton capacity with as much boom as possible to be used for
assembling trusses and intercostals.]
______________________________________________________
Table 2-3. Precision Tools Required for Installation
Quantity Description
1 Each
Machinist's level, 0.005 inch/foot graduation
1 Each
Wild Heerburg T2 theodolite with tribrach
1 Each
GV01 short focus lens for T2 theodolite
1 Each
GV02 short focus lens for T2 theodolite
1 Each
GV03 short focus lens for T2 theodolite
1 Each
Battery pack and light kit for T2 theodolite
1 Each
90 degree eyepiece set for T2 theodolite
1 Each 16/18 meter reflector alignment kit [Part number 479609]
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Table 2-4. Installation Aids, Rigging, and Expendable Items
Quantity Description
1 Each 6 foot step ladder
1 Each 12 foot step ladder
2 Each 50 foot extension cord
2 Each Trouble light with 25 foot cord
1 Each* Transformer with duplex receptacle, 220 Volt to 110 Volt
1 Each Q-beam spotlight, 200,000 candle-power, 120 volt
1 Each 12 volt power supply for Q-beam spotlight
2 Each Flashlight, 2 D cell battery type
6 Each Flashlight battery, D cell
1 Each* 1/2 inch drive electric impact wrench
Installation
with mount]
useful]
Required
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2-8
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
RECOMMENDED
INSTALLATION
SEQUENCY
LOWER MOUNT INSTALLATION PROCEDURES
Table 2-4. Installation Aids, Rigging, and Expendable Items
Required - continued
Quantity
1 Each * 3/4 inch drive electric impact wrench
1 Each* 1/2 inch drive air impact wrench (if a compressor is available)
1 Each* 3/4 inch drive air impact wrench (if a compressor is available)
1 Each Cordless 3/8 inch drive drill motor with charger
1 Each 7 1/4 inch circular saw
3 Each Plywood blade for circular saw
4 Each 20 foot nylon sling
4 Each 15 foot nylon sling
4 Each 10 foot nylon sling
1 Each 50 foot nylon rope (1/2 inch)
4 Each Moving quilts
4 Each Safety belt with 2 D-rings
4 Each Safety lanyard
3 Each Tool belt
3 Each Bolt bag with tool holder
4 Each Hard hat
2 Pair Safety glasses
6 Pair Ear plugs
12 Pair Cloth gloves
6 Pair Leather palm gloves
1 Each First aid kit
1 Box Garbage bags
1 Can Hand Cleaner
6 Rolls Toilet paper
1 Each Ice Chest
1 Each Water Cooler
1 Each Umbrella
* Doubling the quantity of this item will enable a larger crew to install the antenna more
quickly.
Description
______________________________________________________
In order to ensure proper and trouble-free installation, the following
installation sequence is recommended:
1. Site Preparation (contained in manual #42S182)
2. Assembly of Lower Mount (contained in this section)
3. Assembly of Upper Mount (contained in Section 3)
4. Installation of Reflector (contained in Section 4)
5. Assembly of Spars and Subreflector (contained in Section 4)
6. Installation of Feed, Spars, and Subreflector (contained in Section 4)
7. Electrical Installation (contained in manual #42S197)
Appendix A provides a checklist with manual page number
references. The checklist follows the recommended sequence listed
above.
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42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-9
LOWER MOUNT INSTALLATION PROCEDURES
RECOMMENDED
TORQUE VALUES
The following list contains the recommended torque values for all
antenna fasteners.
__________________________________________
Do not torque any fasteners until specifically
directed to torque a fastener. As fasteners are
installed, tighten finger tight only.
__________________________________________
1 1/4-inch Fasteners 1100 ft-lbs (1491 Nm)
1-inch Fasteners 600 ft-lbs (813 Nm)
3/4-inch Fasteners 260 ft-lbs (353 Nm)
5/8-inch Fasteners 150 ft-lbs (203 Nm)
1/2-inch Fasteners 76 ft-lbs (103 Nm)
3/8-inch Fasteners 31 ft-lbs (42 Nm)
5/16-inch Fasteners 24 ft-lbs (33 Nm)
1/4-inch Fasteners 9 ft-lbs (12 Nm)
SITE PREPARATION
Refer to 16-/18-Meter Earth Station Antenna Site Preparation
Technical Manual #42S182 for information needed to properly
locate and install the foundation for the 16-/18-Meter (16/18M)
Earth Station Antenna.
ASSEMBLY OF
LOWER MOUNT
The following procedure describes the complete assembly of the
lower mount for the 16- or 18-meter antenna. The completed
lower and upper mount assembly is identified in Figure 2-1. A
crane will be required during the entire assembly of the 16- or 18meter antenna. (The crane is required during the entire installation
process except for the site preparation and electrical installation.)
CAUTION
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2-10
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
LOWER MOUNT INSTALLATION PROCEDURES
Figure 2-1. Completed Mount Assembly With Hub
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42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-11
LOWER MOUNT INSTALLATION PROCEDURES
Azimuth Bearing Ring
Assembly
The platform plate is assembled on the ground and then installed
on the top of the mount after the columns are erected during the
frame installation procedure. Assemble the azimuth bearing ring
assembly in accordance with the following procedure.
__________________________________________
The following assemblies weigh from 870 lbs
(395 kg) to 9300 lbs (4218 kg). Use extreme care
when hoisting these assemblies into position.
__________________________________________
__________________________________________
Mount damage can occur if the platform plates
are not properly aligned. Ensure proper
alignment is maintained as described in the
following procedure.
__________________________________________
1. Block up 2 piece tapped plate (item 3 in Figure 2-2) with ends 0.125
inches apart forming a hexagon (access underneath for installation of
top skin mounting angle is required).
2. Using hoist set 2 piece mounting plate (item 2 in Figure 2-2) in place
rotating ends 60° from ends of item 3.
3. Using hoist set 2 piece top plate (item 1 in Figure 2-2) in place rotating
ends 60° from ends of item 2 and item 3.
4. Secure all three layers together through bolt holes indicated in Figure 22 using screws and washers (items 100 and 101). Note that only 6 bolts
are used in one segment of the hexagon. This is where the azimuth drive
pivot frame is installed at a later time.
5. Torque bolts to 600 ft-lbs (813 Nm).
6. Attach six top skin mount angles (item 8 in Figure 2-3) to underside of
azimuth bearing ring assembly using screw, two flat washers, and nut
(items 102, 103 and 104 in Figure 2-3). Hand tighten nuts.
The azimuth bearing ring assembly is now ready to be set on
top of the columns in accordance with the next procedure.
WARNING
CAUTION
NOTE
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2-12
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
LOWER MOUNT INSTALLATION PROCEDURES
Leg Installation
The leg assembly must be properly aligned and installed for all
assemblies to properly fit together. Install the legs and associated
frame assemblies in accordance with the following procedure.
WARNING
__________________________________________
The following assemblies weigh from 135 lbs
(61 kg) to 15355 lbs (16965 kg). Use extreme
care when hoisting these assemblies into position.
__________________________________________
1. Install one hex nut (item 100, Figure 2-3) on each of the 24 leg anchor
bolts (six sets of four) and one hex nut (item 104) on each of 38 skin
bottom angle anchor bolts. Locate top of the nut 1-inch above the pad.
2. Place one flat washer (items 101 or 103, Figure 2-3) on each hex nut.
3. Using hoist, lift leg (item 1) into position over one set of column anchor
bolts (weight = 2790 lbs, 1265 kg).
4. Align column bottom plate holes with anchor bolts so the column leans
inward toward center of mount and secure with four flat washers and
nuts (item 100 and 101). Hand tighten nuts.
5. Using ladder remove hoist from leg.
6. Install remaining 5 legs as described in steps 3 through 5.
7. Attach hoist to azimuth bearing ring assembly (item 2).
8. Lift azimuth bearing ring assembly to rest on top of 6 legs.
9. Align azimuth bearing ring assembly corner holes with holes in top
mounting plate of legs. (It may be necessary to lower some of the legs
using nuts on leg base in order to properly align the holes.)
10. Secure azimuth bearing ring assembly to top plate of legs with screw,
two flat washers, and nut (item 102, 103, and 104). Hand tighten.
11. Remove hoist from azimuth bearing ring assembly.
12. Torque azimuth bearing ring assembly bolts to 1100 ft-lbs
(1491 Nm). Azimuth bearing ring assembly bearing mounting surface
(top of item 2 in Figure 2-2) should be leveled now by adjusting leg
anchor nuts up or down as required.
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42S183D
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-13
LOWER MOUNT INSTALLATION PROCEDURES
Bottom Skin Plate
Installation
The bottom skin angles, door skin angles, lower skin tees, lower
door tees, lower skins, and lower door skins (items 3, 4, 5, 7, 11,
and 13 in Figure 2-3) are installed prior to installation of the
optional mezzanine and stairway.
1. Attach lower skin tee (item 5, Figure 2-3) to inside surface of lower
skin (item 11) with bolt, two flat washers, and nut (item 105, 103, and
104). Hand tighten. (Five of these assemblies are required.)
2. Lift lower skin into position on outside of two legs which do not have
the foundation bolt pattern for the access door between the legs.
3. Align plate side holes with holes in leg and secure to leg with bolt, two
flat washers, and nut (item 105, 103, and 104) in each skin plate side
hole. Hand tighten.
4. Install bottom skin angle (item 3) on skin bottom angle anchor bolts
using the following procedure.
a. Align holes in vertical leg of bottom skin angle with holes in
bottom skin.
b. Secure angle to skin with bolt, two flat washers, and nut (item
105, 103, and 104).
c. Secure angle to anchor bolts using washer and nut (item 103
and 104).
d. Hand tighten fasteners.
5. Remove hoist from bottom skin plate.
6. Install remaining four bottom skin plates as described in steps 1 through
5.
7. Attach lower door tee (item 7) to inside surface of lower door skin (item
13) with bolt, two flat washers, and nut (item 105, 103, and 104). Make
sure slanted side of skin is to the right.
8. Attach lower door tee in the same manner as step 7 except place angled
side of lower door skin on the left side.
9. Lift left lower door skin assembly into position on outside of left leg.
10. Align plate angled side holes with holes in leg and secure to leg with
bolt, two flat washers, and nut (item 105, 103, and 104) in each skin
plate side hole. Hand tighten.
11. Install door skin angle same as step 4 above.
12. Install right lower door skin assembly as described in steps 9, 10, and
11.
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2-14
SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
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