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Summary of Contents for General Dynamics 500-0646
- Page 1 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. Description 600-1046 Antenna Feed System Maintenance Manual PLEASE DISCARD THIS PAGE BEFORE BINDING MANUAL...
- Page 2 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 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.
- Page 3 SATCOM TECHNOLOGIES CONFIDENTIAL AND PROPRIETARY 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.
- Page 4 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...
- Page 5 CAUTIONARY NOTICE Although SATCOM Technologies has attempted to detail in this document all areas of possible danger to personnel in connection with the use of this equipment, personnel should use caution when installing, operating and servicing this equipment. Care should be taken to avoid electrical shock, whether the hazard is caused by design or malfunction.
- Page 6 POTENTIAL DAMAGE TO ANTENNA The antenna limit switches and resolvers have been pre-set to allow for maximum antenna performance. Any subsequent adjustment may jeopardize antenna performance and/or result in damage to the antenna. SAFETY NOTICE The following safety procedures are listed to remind those performing any work on the antenna system that safety rules must be observed.
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Page 7: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ......................1 General ..........................1 INSTALLATION....................... 2 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 Installation Procedure ......................5 2.2.1 Pedestal Structure ......................6 2.2.2 Azimuth Jack Assembly.................... - Page 8 LIST OF TABLES Table 1. Tool List ......................... 3 500-0646A...
- Page 9 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.
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Page 10: Introduction
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... -
Page 11: Installation
INSTALLATION 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. -
Page 12: Tools Recommended For Installation
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. - Page 13 Awl (1/8" Diameter) Pliers Flat File Machinist (10”) Adjustable Spud Wrench Striking Wrench 500-0646A...
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Page 14: Installation Procedure
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. -
Page 15: Pedestal Structure
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). -
Page 16: Azimuth Jack Assembly
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. -
Page 17: Figure 4. Installing The Azimuth Jack
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. 500-0646A... -
Page 18: Hub
2.2.3 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]. -
Page 19: Figure 6. Installing The Hub
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. -
Page 20: Figure 8. Installing The Elevation Jack
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). -
Page 21: Radial Beam Structure
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. - Page 22 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.
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Page 23: Figure 11. Radial Beam Installation
Figure 11. Radial Beam Installation 500-0646A... -
Page 24: Figure 12. Reflector Lacing Assembly
Figure 12. Reflector Lacing Assembly 500-0646A... -
Page 25: Reflector Lacing Members
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"... -
Page 26: Figure 13. Reflector Panel Assembly
Figure 13. Reflector Panel Assembly 500-0646A... -
Page 27: Reflector Panels
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. -
Page 28: Figure 14. Reflector Panel Assembly Order
Figure 14. Reflector Panel Assembly Order 500-0646A... -
Page 29: Feed Boom Structure
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. -
Page 30: Figure 15. Rotating Antenna For Feed Boom Installation
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). -
Page 31: Figure 16. Feed Boom Assembly
Figure 16. Feed Boom Assembly 500-0646A... -
Page 32: Subreflector Assembly
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”... -
Page 33: Figure 17. Feed Boom Assembly Supports
Figure 17. Feed Boom Assembly Supports 500-0646A... -
Page 34: Feed Boom Alignment
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”. -
Page 35: Feed Horn
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"... - Page 36 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.
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Page 37: Figure 20. Feed Assembly
Figure 20. Feed Assembly Figure 21. Feed Alignment 500-0646A... -
Page 38: Figure 22. Install Feed Support Kit
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... -
Page 39: Overview For Installing Waveguide
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. -
Page 40: Installing The Elevation Limit Switch
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... -
Page 41: Azimuth Limit Switch Installation
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. -
Page 42: Figure 27. Elevation Resolver Assembly
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. -
Page 43: Installing The Azimuth Transducer
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. -
Page 44: Figure 29. Azimuth Resolver With Bracket
Figure 29. Azimuth Resolver with Bracket Figure 30. Azimuth Resolver (side view) 500-0646A... -
Page 45: Electrical Installation
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. -
Page 46: Figure 31. Antenna Position
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). -
Page 47: Figure 32. Rf Pattern
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). -
Page 48: Figure 33. Feed Port Polarization
• 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 •... -
Page 49: Maintenance
MAINTENANCE 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. -
Page 50: Replacing The Elevation Jack Boot
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. -
Page 51: Warranty
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. -
Page 52: Appendix A. Hardware Charts
APPENDIX A. HARDWARE CHARTS (Figures of hardware are shown actual size for convenient reference). 500-0646A... - Page 53 NOTE: TORQUE HARDWARE TO VALUE STATED UNDER FIGURE UNLESS 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 110 lb-ft (150 Nm) 200 lb-ft (272 Nm) 5/8 X 1 3/4 HEX BOLT HDG 110 lb-ft (150 Nm)
- Page 54 500-0646A...
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Page 55: Appendix B. Site Selection
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. -
Page 56: Appendix C. Reporting Loss Or Visible Damage
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"... -
Page 57: Appendix D. Mounting Considerations
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...
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