Series 8116/8118 16-/18-Meter Earth Station Antenna Installation ...

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.

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TABLE OF CONTENTS

NOTE For a further or more detailed breakdown of section contents, refer to the title page of each section.

SECTION 1 GENERAL INFORMATION

1-1 1-1 1-3 1-4

Introduction to Manual Description Wind Load Options Specifications LOWER MOUNT INSTALLATION PROCEDURES SECTION 2 General 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

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

____________________________________________________________________________________________ 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 ____________________________________________________________________________________________

____________________________________________________________________________________________ 42S183D SERIES 8116/8118 16/18-METER EARTH STATION ANTENNA v

SECTION 6 MAINTENANCE

6-1 6-1 6-1 6-1 6-2 6-5 6-5

General Periodic Maintenance Weekly Maintenance Monthly Maintenance Bi-Monthly Maintenance Yearly Maintenance Corrosion Protection

SECTION 7 OPTIONS

7-1 7-1 7-1

General Feed Options Lightning Protection

APPENDIX A INSTALLATION CHECKLIST WITH MANUAL PAGE REFERENCES

APPENDIX B MECHNCIAL ALIGNMENT SPECIFICATION AND REPORT FOR 16/18-METER LIMITED MOTION ANTENNA (479820A)

APPENDIX C CONTOUR ALIGNMENT SPECIFICATION AND RECORD FOR 16/18-METER ANTENNA (479821B)

SECTION 1 GENERAL INFORMATION 1-1 Introduction to Manual 1-1 Description 1-3 Wind Load Options 1-4 Specifications

42S183D Series 8116/8118 16-/18-Meter Earth Station Antenna

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____________________________________________________________________________________________ 42S183D SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 1-1

SECTION 1 GENERAL INFORMATION 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.

INTRODUCTION TO MANUAL

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:

DESCRIPTION

• Cassegrain feed for high-efficiency performance

• 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


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. __________________________________________

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.

Wind Load Options

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).



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)



Continued SPECIFICATIONS 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 Temperature (K) 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)




Continued SPECIFICATIONS 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) ________________________________________________________________

SECTION 2 LOWER MOUNT INSTALLATION

PROCEDURES 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



SECTION 2 LOWER MOUNT INSTALLATION PROCEDURES 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.

GENERAL

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.

WHAT TO DO ABOUT VISIBLE LOSS OR

DAMAGE

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.

WHAT TO DO ABOUT CONCEALED

DAMAGE

LOWER MOUNT INSTALLATION PROCEDURES


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.

HOW TO INVENTORY EQUIPMENT

RECEIVED

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.

HOW TO RETURN EQUIPMENT

a) Notify ViaSat of the problem and request a Return Material

Authorization (RMA) number and shipping instructions. b) Tag or identify the defective equipment and note defect and

circumstances, if any. If known, reference sales order, purchase order and date equipment was received.

c) Reship equipment in original shipping container or use a strong

shipping container to protect equipment during shipment. d) Package equipment using shock-absorbing material around all sides

of equipment. e) Seal container securely and mark outside of container FRAGILE.

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.

http://www.viasat.com/


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.

GENERAL MECHANICAL

SAFETY SUMMARY

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. __________________________________________



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. __________________________________________

Have an emergency plan. Know the procedures for obtaining first-aid and fire-fighting assistance. Plan your work and maintain good housekeeping; the safety and quality of the product are at stake.

Emergency Plan

These are general electrical safety precautions that are not related to any specific procedure. These are recommended precautions that personnel must understand and apply.

GENERAL ELECTRICAL SAFETY

SUMMARY



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.

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.

RECOMMENDED TOOLS AND EQUIPMENT



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

inch size 1 Set* 1/2 inch drive ratchet, extensions, and sockets from 7/16 to 1

1/4 inch size 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

inch size 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



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. ______________________________________________________



Table 2-2. On-Site Machinery and Equipment Required for Installation

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

with mount] 1 Each 50 foot high platform lift or bucket truck [Optional, but very

useful] 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] ______________________________________________________

Table 2-4. Installation Aids, Rigging, and Expendable Items Required

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



Table 2-4. Installation Aids, Rigging, and Expendable Items Required - continued

Quantity Description 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. ______________________________________________________ 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.

RECOMMENDED INSTALLATION

SEQUENCY



The following list contains the recommended torque values for all antenna fasteners.

RECOMMENDED TORQUE VALUES

CAUTION

__________________________________________ 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)

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.

SITE PREPARATION

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 18-meter antenna. (The crane is required during the entire installation process except for the site preparation and electrical installation.)

ASSEMBLY OF LOWER MOUNT



Figure 2-1. Completed Mount Assembly With Hub



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.

Azimuth Bearing Ring Assembly

WARNING

__________________________________________ The following assemblies weigh from 870 lbs (395 kg) to 9300 lbs (4218 kg). Use extreme care when hoisting these assemblies into position. __________________________________________

CAUTION __________________________________________ 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 2-

2 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.

NOTE

The azimuth bearing ring assembly is now ready to be set on top of the columns in accordance with the next procedure.




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.

Leg Installation

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.


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.

Bottom Skin Plate Installation

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.



The optional mezzanine is installed at this time to aid in attaching the top skin plates and aligning the azimuth bearing ring assembly. Install the mezzanine in accordance with the following procedure and Figure 2-4.

Mezzanine Installation (Optional)

NOTE Leave all fasteners hand tight until directed to torque fasteners.

CAUTION

__________________________________________ The mezzanine is designed for a live load (personnel and tools) of 200 lbs per square foot (976 kg per square meter) or a concentrated load of 300 lbs (136 kg). __________________________________________

1. Attach hoist to floor support beam A (item 1, Figure 2-4). 2. Lift support beam into position between legs directly opposite from

door opening. 3. Align two slotted holes with leg bracket holes and secure with two

bolts, four flat washers, two oversized flat washers, and two nuts (items 100, 102, 103, and 101) at each end of support beam. Hand tighten.

4. Remove hoist from mezzanine support beam.

5. Install floor support beam F (item 5) in next clockwise position, (viewing from top of mount assembly) using steps 1 through 4.

6. Install floor support beam C (item 2).

7. Install floor support beam D (item 6).

8. Install floor support beam E (item 3).

9. Install floor support beam B (item 4).

10. Lift stairway header beam (item 8) into position between support beam (item 1) and stairway opening beam (item 7) which will be installed next.

11. Secure stairway header beam with two bolts, four flat washers, and two nuts (item 104,102, and 101) at beam A. Hand tighten.

12. Attach hoist to stairway opening beam (item 7). ____________________________________________________________________________________________ 42S183D SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-15


13. Lift stairway opening beam into position between beams B and F.

14. Align four holes in end plates with holes in beams B and F and secure

with screw, two flat washers, and nut (item 104, 102, and 101). Hand tighten. Install remaining two sets of bolts, flat washers, and nuts between stationary header beam and stairway opening beam.

15. Attach hoist to right floor support beam (item 9).

16. Lift right floor support beam into position between stairway opening beam and support beam C on right side of mount (viewing inward from door opening).

17. Align two end plate holes with holes in stairway opening beam and secure with two screws, four flat washers, and two nuts (item 104, 102, and 101).

18. Align end clip plate (item 11) with four holes each in right floor support beam and support beam C. a. Secure end clip plate in place using screw, two flat washers and nut (item 104, 102, and 101) eight places. b. Torque four bolts securing end clip plate to right floor support to 260 ft lbs (353 Nm). c. Hand tighten the bolts securing the end clip plate to support beam C.

19. Remove hoist from right floor support beam. 20. Install left floor support beam (item 10) to stairway opening beam and

support beam E on left side of mount (viewing inward from door opening) using steps 15 through 18.

21. Attach hoist to center floor beam (item 12).

22. Lift center floor beam into position between stairway opening beam and support beam D. Slide end plate holes on center support beam over studs at each end. (The center support beam is a removable beam to allow for equipment installation and removal.)

23. Remove hoist from center support beam.



The optional ships ladder is first assembled on ground, then hoisted into position and installed in the mount. Perform the following procedures to assemble and install the ships ladder (refer to Figure 2-5). ASSEMBLY OF SHIPS LADDER

Ships Ladder Assembly and

Installation (Optional)

1. Position stringers side by side with left hand stringer (item 1, Figure 2-5) on left side and right hand stringer (item 2) on the right side. Lay stringers flat with flanges upward.

2. Turn left hand stringer on edge with flanges toward right hand stringer.

3. Position one tread (item 11) inside stringer flanges and align hole in tread with hole in stringer at nearest end of stringer. a. Secure tread to stringer with screw, two flat washers, and nut (item 100, 101, and 102). b. Align slot in tread with hole in left hand stringer. c. Secure tread with screw, two flat washers, and nut (item 100, 101, and 102). d. Align slot in tread with hole in right hand stringer. e. Secure tread with screw, two flat washers, and nut (item 100, 101, and 102). f. Hand tighten fasteners.

NOTE

Assure that rough surface of tread will be up when the top end of stringer is raised to mezzanine floor.

4. Turn right hand stringer (item 2) on edge with flanges toward left hand

stringer.

5. Align hole in tread with hole in right hand stringer.

a. Secure tread to stringer with screw, two flat washers, and nut (item 100, 101, and 102). b. Align slot in tread with hole in left hand stringer. c. Secure tread with screw, two flat washers, and nut (item 100, 101, and 102). d. Hand tighten fasteners.

6. Repeat steps 3 and 5 for all fourteen tread locations. ____________________________________________________________________________________________ 42S183D SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-17


7. Install top mount (item 3) between right hand and left hand stringer at

end of stringers which will be raised to join with the mezzanine floor.

a. Secure with screw, two flat washers, and nut (item 103, 104, and 105) at both ends of top mount. b. Hand tighten fastener.

8. Attach bottom mount (item 4) to bottom end of both stringers using bolt, two flat washers, and nut (item 103, 104, and 105) through slotted hole in bottom mount. Hand tighten.

9. Position right hand stanchion (item 10) on outside of the right hand stringer just above the top tread.

10. Align holes in right hand stanchion with right stringer. Secure two places using screw, two flat washers, and nut (item 100, 101, and 102). Hand tighten.

11. Repeat step 9 and 10 just above the tenth tread, and the first tread.

12. Position left hand stanchion (item 9) on outside of left hand stringer just above the tenth tread.

13. Repeat step 10.

14. Repeat step 12 and 13 just above the fifth tread and the first tread.

15. Position left handrail (item 5) inside of and on top of the three left hand stanchion.

16. Align holes in handrail with stanchion and secure three places with

screw, two flat washers, and nut (item 100, 101, and 102). Hand tighten.

17. Position left hand kneerail (item 7) on inside of left hand stanchion and secure three places with screw, two flat washers, and nut (item 100, 101 and 102). Hand tighten.

18. Repeat step 15 on right side using right handrail (item 6) inside the four right hand stanchions.

19. Repeat step 16 four places.

20. Repeat step 17 on right side using right hand kneerail (item 8) secure four places.

21. Torque all 3/8-inch fasteners in treads, stanchions, handrails, and kneerails to 31 ft-lbs. (42 Nm).



SHIPS LADDER INSTALLATION 1. Attach hoist to ships ladder (see Figure 2-5).

2. Lift ships ladder into position in the stair opening (across the mount

from door opening).

3. Align three top mount holes at top of ladder with stairway header beam holes.

4. Secure three places with screw, two flat washers, and nut (item 103, 104, and 105). Hand tighten.

5. Mark position on concrete where two holes on stair bottom mount meet concrete floor.

6. Remove three bolts, washers, and nuts that secure ships ladder to stairway header beam and lift ships ladder away from marked concrete area.

7. Drill two 3/4-inch by 4-inch deep holes into concrete at marked locations.

8. Insert expansion bolt (item 106) into expansion bolt holes and remove nut and washer. (Retain these for use in step 10.)

9. Place ships ladder back in position and repeat step 4.

10. Secure bottom mount angles to concrete using the two nuts and washers

removed in step 8.

11. Level tread plate and torque bolts in slotted hole of bottom mount angle to 260 ft-lbs (353 Nm).

12. Torque bolts in top of ships ladder to 260 ft-lbs (353 Nm).

13. Remove hoist from ships ladder.

14. Attach hoist to mezzanine guard rail (item 21, Figure 2-4).

15. Lift guard rail into position on mezzanine stairway opening beam.

16. Align guard rail bottom plate holes with holes in stairway opening beam four places on each guard rail bottom plate.

17. Secure guard rail bottom plate to stairway opening beam with screw, two flat washers, and nut (item 104, 102, and 101) 16 places.

18. Remove hoist from mezzanine guard rail.



NOTE

The grating may be lifted into place by hand or with the crane. The stair landing grating and corner gratings weigh 20 lbs (9 kg) each and the center gratings weigh 100 lbs (45 kg) each.

MEZZANINE GRATING 1. Attach hoist to stair landing grating (item 13, Figure 2-4).

2. Lift grating into position on mezzanine at head of stairs.

NOTE

The grating hold-down will be installed after the top skins are installed and all fasteners in mount have been torqued.

3. Remove hoist from grating.

4. Attach hoist to corner grating C (item 15).

5. Lift grating to position on mezzanine at right side (facing inward from

door).


7. Attach hoist to corner grating D (item 19).

8. Lift grating into position on mezzanine at right side (facing inward from door).


10. Attach hoist to corner grating A (item 17).

11. Lift grating into position on mezzanine at left side (facing inward from door).


13. Attach hoist to corner grating B (item 18).

14. Lift grating into position on mezzanine at left side (facing inward from door).


16. Attach hoist to center grating A (item 14).

17. Lift grating into position on mezzanine at center (by stairway).




19. Attach hoist to center grating C (item 20).

20. Lift grating into position on mezzanine at center (near doorway).


22. Attach hoist to center grating B (item 16).

23. Lift grating into position on mezzanine at center (mezzanine center).


After the optional mezzanine, stairway, and grating installation is complete, install the middle and top skins as follows.

Middle and Top Skin Plate Installation

WARNING __________________________________________ The following assemblies weigh approximately 1525 lbs (692 kg) each. Use extreme care when hoisting these assemblies into position. __________________________________________

1. Attach upper skin tee (item 6, Figure 2-3) to top surface of middle mount skin (item 10) at seven places with bolt, two flat washers, and nut (item 105, 103, and 104). Hand tighten.

2. Lift middle mount skin into position on outside of two legs which do not have the door opening between them.

3. Align plate side holes with holes in leg (eight holes in each leg) and secure with bolt, two flat washers, and nut (item 105, 103, and 104).

4. Secure middle mount skin to lower skin tee at nine places using bolt, two flat washers, and nut (item 105, 103, and 104). Hand tighten.

5. Repeat steps 1 through 4 on four more middle mount skins.

6. Attach upper skin tee (item 6) to inside top surface of middle door mount skin (item 12) at seven places with bolt, two flat washers, and nut (item 105, 103, and 104). Hand tighten.

7. Lift middle door mount skin into position using hoist. Locate between two legs where door will be located.

8. Repeat step 3.



9. Secure the middle door mount skin to the lower door tee, two places each side of door opening, using bolt, two flat washers, and nut (item 105, 103, and 104). Hand tighten.

10. Lift upper mount skin into position using hoist. Locate between two

legs.

11. Align plate side holes with holes in leg (thirteen holes in each leg) and secure with bolt, two flat washers, and nut (item 105, 103, and 104). Hand tighten.

12. Secure the upper mount skin to the upper skin tee at seven places with

bolt, two flat washers, and nut (item 105. 103 and 104). Hand tighten.

13. Secure the upper mount skin to the top skin mount angles, four places, with bolt two flat washers, and nut (item 105, 103 and 104). Hand tighten.

14. Repeat steps 10 through 13 for remaining five upper mount skin panels.

The mount is torqued from the top down in order to secure everything together prior to grouting the base. Perform the following procedures to properly torque all mount fasteners.

Torquing Lower Mount Fasteners

1. Loosen all nuts securing bottom skin mount angles to foundation by a couple turns (this will allow the skin to be pulled tight from the top down).

NOTE

Do not loosen nuts securing legs to foundation.

2. Tighten fasteners holding bearing ring assembly plate together to 600

ft-lbs (813 Nm).

3. Tighten fasteners securing bearing ring assembly to top mounting plate of legs to 600 ft-lbs (813 Nm).

4. Tighten bearing ring assembly plate to top skin mount angle fasteners to 600 ft-lbs (813 Nm).

5. Tighten upper mount skin to leg fasteners to 600 ft-lbs (813 Nm). Tighten from top down.

6. Tighten upper mount skin plate to upper skin tee fasteners to 600 ft-lbs (813 Nm).

7. Tighten middle mount skin panels to upper mount skin tee fasteners to

600 ft-lbs (813 Nm).



8. Tighten middle mount skin panels to leg fasteners to 600 ft-lbs (813 Nm). Tighten from top down.

9. Tighten middle mount skin panels to lower skin tee fasteners to 600 ft-lbs (813 Nm).

10. Tighten lower mount skin panels to lower skin tee fasteners to 600 ft-lbs (813 Nm).

11. Tighten lower mount skin panel to leg fasteners to 600 ft-lbs (813 Nm). Tighten from top down.

12. Tighten lower mount skin panel to bottom skin angle fasteners to 600 ft-lbs (813 Nm).

13. Ensure bottom nuts on leg base are snug against plate.

14. Tighten top nuts on leg base to 1100 ft-lbs (1491 Nm).

15. Ensure bottom nuts on bottom skin angle are snug against angle.

16. Tighten top nuts on bottom skin angle to 150 ft-lbs (200 Nm).

17. Tighten mezzanine guard rail to stair opening beam fasteners to 260 ft-lbs (353 Nm).

18. Tighten ships ladder to stair stringer support beam fasteners to 260 ft-lbs (353 Nm).

19. Tighten stair stringer to stair to right mount fasteners to 260 ft-lbs (353 Nm).

20. Tighten bottom mount to floor fasteners to 150 ft-lbs (203 Nm).

21. Tighten bottom mount to stringer fasteners to 260 ft-lbs (353 Nm).

22. Tighten all mezzanine edge beam to leg fasteners to 260 ft-lbs (353 Nm).

23. Install mezzanine grating hold downs (item 105 Figure 2-4) in accordance with the following procedure.

a. Space hold down approximately two feet (61 cm) apart (in each direction) with a minimum of two per grating. b. Transfer holes to mezzanine beams using a tap for 1/4-20 screws.

c. Install each hold down with one socket head cap screw (item 106).



After the mount is torqued the mount door and frame should be assembled and then installed from the inside of the mount in accordance with the following procedures.

Door Assembly and Installation

1. From inside mount, place right door skin (item 14, Figure 2-3) with small end pointing toward door opening and short flange on floor and turned toward outside of door.

2. From inside mount, locate left door skin (item 15) on floor with small end pointing toward door opening and short flange on floor and turned opposite from the flange in step 1 above.

3. Locate top door skin (item 16) across the narrow end of left and right door skins. The long flange should be placed on the floor and end flanges overlapping on outside of door skins.

4. Secure top door skin to left and right door skins in two places each side using screw, two flat washers, and nut (item 108, 109, and 110).

5. Install one door side channel (item 18) on right door skin.

6. Secure door side channel in six places using screw, two flat washers, and nut (item 108, 109, and 110). Torque to 31 ft-lbs (42 Nm).

7. Install one door side channel (item 18) on left door skin.

8. Repeat step 6.

9. Locate door top channel (item 17) on upper door skin.

10. Secure door top channel four places using screw, two flat washers, and nut (item 108, 109, and 110). Torque to 31 ft-lbs (42 Nm).

11. With one person on each side of door assembly (item 111), lift assembly and slide it onto the door side channels until door frame top covers door top channel.

NOTE

Make sure that the door will open inward when erected in the door opening.

12. Check that door frame rails are touching right and left door skins and completely hitting door side channels.

13. Check that top door frame rail is touching top door skin and hitting door top channel.

14. With door frame and side skin panels still laying on the ground, drill two holes in top of door frame and door top channel and secure door frame in place using self tapping screw (item 106).

15. With door frame and skin panel still laying on the floor, drill two pilot holes equally spaced through top door frame and top door channel using drill bit (item 107, Figure 2-3) and secure with self tapping screws (item 106).



16. Drill one pilot hole near bottom of each side door frame and install self

tapping screws (item 106).

NOTE

These two screws will be removed at a later procedure.

17. Set door assembly and side skins up in a vertical position.

18. Position bottom of right and left floor skins on doorway anchor bolts.

19. Secure with nut and flat washer (item 100 and 101, Figure 2-3), one on each side. Hand tighten.

20. Align holes in right and left door skins with holes in lower and middle door skin panels.

21. Secure in place, ten places on each side of door frame assembly, using bolt, two flat washers, and nut (item 105, 103, and 104).

22. Secure top door skin, four places, using bolt, two flat washers, and nut (item 105, 103, and 104).

23. Remove two self tapping screws installed at step 16.

24. Adjust door side skins to provide an equal gap between door and door frame along sides and across the top.

25. Torque door side skin to lower door skin and middle door skin fasteners to 260 ft-lbs (353 Nm).

26. Torque door top skin to middle door skin fasteners to 260 ft-lbs (353 Nm).

27. Torque door side skin to doorway anchor bolts to 1100 ft-lbs (1491 Nm).

28. Drill five pilot holes equally spaced through inside right door frame and door side channel using drill bit (item 107).

29. Secure door frame to side channel using self tapping screw (item 106).

30. Repeat step 28 and 29 along inside left door frame.

31. From outside door, drill two pilot holes, equally spaced, through top door frame and top door channel using drill bit (item 107).

32. Secure door frame to top door channel with self tapping screw (item 106).

33. From outside door, repeat step 28, 29, and 30.



Figure 2-2. Azimuth Bearing Ring Assembly, 483183



Figure 2-3. 16/18-Meter Mount Assembly (Sheet 1 of 3), 483184A



Figure 2-4. 16/18-Meter Mezzanine Installation, 512020



Figure 2-5. 16/18-Meter Stairway Installation, 483185




Grout is used between the concrete foundation surface and the six base plates to ensure a rigid, load-bearing connection between the mount and the foundation. Grout may also be placed between the concrete foundation and the bottom bracket on the bottom skin plates to ensure rigidity but is not required structurally. Standard shipments include enough grout for the six base plates only. It is important that the grout manufacturer's instructions be followed. These instructions are packaged with the grout. For convenience, the essentials of the procedure are repeated as follows: The grout must completely fill all locations (see Figure 2-6). Verify that each anchor bolt nut will have no less than two threads above the nut. The normal ambient temperature range for good "early-strength" grouting is 55°F to 80°F (13°C to 27°C). When temperatures at the job site are outside this range, the procedures given here must be modified to compensate for the high or low temperature. If the temperature is outside the range, perform one of the following procedures before proceeding to the grouting procedure.

GROUTING BASEPLATE AND

SKIN PLATE TO FOUNDATION

Temperatures above 80°F (27°C) accelerate hardening of the grout, reducing the time that the grout remains workable after mixing; therefore, it is necessary that either procedures be used which permit placing of the grout more quickly, or the available working time increased by cooling the mixture and the mount base plates. If the first approach is taken, it is suggested that grout be mixed for each base plate separately and poured immediately. Mixing time could be reduced to one minute by use of an electric drill and mixing blade made of steel rod. If the second approach is taken, grout working time may be increased by use of cold materials, cool foundation, and base plates. This approach involves the use of cold or iced water in the mix to keep the as-mixed temperature of the grout under 70°F (21°C), preferably between 50°F (10°C) and 55°F (13°C). In either case, the following practices are recommended:

Hot Weather Grouting

1. Store bags of grout in as cool a place as practicable, but at least in the shade. Avoid exposing the bags to dampness or rain.

2. Give extra attention to saturating the concrete foundation for 24 hours

before grouting. Heat and wind cause rapid evaporation; therefore, the concrete should be wet liberally and frequently to prevent drying. Consider the use of windbreaks and sunshades to maintain saturation.

3. Cool the base plates while saturating the foundation by covering the

plates with wet cloths and allowing evaporation to cool them.


Temperatures below 55°F (13°C) slow the hardening process and keep the grout in a flowable state long enough to permit settlement and bleeding. Although grouting may be successfully accomplished at ambient temperatures as low as 45°F (7°C), the rate of strength gain (hardening) is slow and the required time on-site may be excessive. To minimize the curing time, it is recommended that the grout, mixing water, and mount base plates be warmed to accelerate the curing process. The following procedure is suggested:

Cold Weather Grouting

1. Store bags of grout in a sheltered place so that the material will be at least above freezing, but preferably above 45°F (7°C).

2. Measure the temperature of the base plate and foundation by placing a

thermometer on the surface and covering it with a piece of dry insulation or dry rags. If the temperature is above 55°F (13°C) minimum, proceed with grouting following the grouting procedures. If the temperature is below 55°F (13°C), warm the base plate and foundation to bring the temperature above the minimum, using the following methods: a. Base plates may be warmed by use of infrared heat lamps or by building a small enclosure around the base plate and introducing heat from a convenient source. Warm the mixing water as necessary to provide mixed grout at a temperature of 60°F (15°C) or above, but avoid use of water hotter than 90°F (32°C). b. After installing grout, maintain the temperature of the in-place grout at 50°F (10°C) or above for a minimum of three hours to ensure adequate grout hardness for final tightening of the anchor bolt nuts.

NOTE

Grout will not harden unless the temperature is maintained above freezing. The minimum temperature is 40°F (4°C).

Perform the following procedure to grout base plates to foundation first. Then, grout bottom skin plates to foundation using the following procedure.

Grouting Procedures

1. Wash work surface with water. Keep surface saturated with water for at least 24 hours prior to grouting.

NOTE

Grouting must be completed within 10 minutes after mixing.



2. Pour grout into a five gallon bucket (0.019 cubic meter) or equivalent

mixing container and slowly add water. Stir the mix and add grout or water as required to obtain a good paste.

NOTE

Be sure to mix enough grout to complete each pad (or bottom plate) at one time. Once the grout begins to set, new grout will not bond to the old grout.

3. Starting on one side of each base plate, use a small strip of wood to work the grout between base plate and foundation. It is important that the grout be worked from one side to the other to prevent air from being trapped under each plate. Once the area under the plate is full of grout, smooth the edges around each plate for best appearance.

4. Immediately after the grout is installed, cover all exposed grout with

clean wet rags (do not use burlap). Keep the rags moist for at least two hours.



Figure 2-6. Location of Grouting


SECTION 3 UPPER MOUNT INSTALLATION

PROCEDURES 3-1 General 3-1 Azimuth Drive Anchor Installation 3-1 Rotating Frame Installation 3-14 Azimuth Drive Installation 3-19 Elevation Drive Installation 3-22 Hub Assembly and Installation 3-29 Installation Guardrails and Ladders


____________________________________________________________________________________________


SECTION 3 UPPER MOUNT INSTALLATION PROCEDURES This section contains procedures for installing the upper mount hardware. This hardware includes the rotating frame, azimuth/elevation drives, hub, and work platform of the 16-/18-Meter Earth Station Antenna. The installation of the lower mount is contained in Section 2 and the installation of the reflector, spars, subreflector, and feed is contained in Section 4. General safety precautions and procedures for the entire installation are described in Section 2 and should be reviewed before proceeding with these procedures.

GENERAL

Perform the following procedure to install the azimuth drive anchor. This should be accomplished prior to installing the rotating frame (azimuth frame and alignment assembly).

AZIMUTH DRIVE ANCHOR

INSTALLATION 1. Determine center of optimum azimuth sector to locate azimuth drive

anchor (item 2 in Figure 3-1). See Figure 3-1, Sheet 2. 2. Install azimuth drive anchor to azimuth frame and alignment

assembly (item 4) using 2 azimuth anchor spacer plates (item 25), 2 azimuth anchor pins (item 3), 12 hex head bolts (item 102), and 12 flat washers (item 107).

Perform the following procedure to install the rotating frame. ROTATING FRAME

INSTALLATION 1. Determine center of optimum azimuth sector to locate azimuth frame

and alignment assembly. See Figure 3-1, Sheet 2. The center of azimuth travel in the sector should be as closely aligned to the test satellite position as possible.

2. Remove necessary bolts for installing azimuth frame and alignment

assembly. (See Figure 3-2 and 3-3 for the assembly drawings for azimuth frame and alignment assembly.)

WARNING __________________________________________ The azimuth frame and alignment assembly weighs 18,000 lbs (8,165 kg). Use extreme care when hoisting the assembly into position. __________________________________________

UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________

3. Using hoist, lift azimuth frame and alignment assembly onto selected location and attach azimuth frame and alignment assembly using 34 hex head bolts (item 113), 2 hex head bolts (item 102), and 36 flat washers (item 103).

NOTE

Two bolts (item 102) will be used later to install LSR beam assembly.

4. Remove hoist from rotating frame. 5. Install azimuth frame stow pin block (item 12) at appropriate position

using four bolts (item 110), eight washers (item 111), and four nuts (item 112). It should be attached so that the slotted holes provide a fore/aft adjustment, not side to side. These fasteners need not be torqued.

6. Torque fasteners to the following values: 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)




Figure 3-1. Installing Upper Mount (Sheet 1 of 5), 512560B



Figure 3-2. Azimuth Frame and Alignment Assembly (Sheet 1 of 4), 511960C



Figure 3-2. Azimuth Frame and Alignment Assembly (Sheet 4 of 4), 511960E



Figure 3-3. Elevation Axis Clevis Alignment (Sheet 1 of 2), 477689B



Figure 3-3. Elevation Axis Clevis Alignment (Sheet 2 of 2), 477689B




Perform the following procedure to install the azimuth drive assembly. (Figure 3-1 contains installation information and Figure 3-4 provides the azimuth drive/clevis assembly information.) The azimuth drive can be installed later, if desired, so that the reflector installation can proceed. It can also be installed during the reflector installation.

AZIMUTH DRIVE INSTALLATION

1. Attach azimuth drive mount (item 5, Figure 3-1) using: a. Eight bolts (item 104), two washer plates (item 15), and two nut

plates (item 14) as identified in left view on sheet 5. b. 10 bolts (item 113), 20 washers (item 103), and 10 nuts (item

109) as identified in right view on sheet 5. c. 2 bolts (item 104), washer plate (item 17), and nut plate (item

16) as identified in view A-A on sheet 5. 2. Attach knee brace plate (item 21) using 10 bolts (item 105), 20

washers (item 107), and 10 nuts (item 108). 3. Using hoist, lift azimuth drive assembly (item 8 or 23) and attach

assembly to azimuth drive mount as illustrated in Figure 3-1 using the following procedure.

a. Grease and insert azimuth clevis pin (item 11) so that azimuth

drive anchor (item 2) is attached to azimuth drive assembly (see Sheet 2 of Figure 3-1). Secure pin with two retaining rings (item 101).

b. Rig azimuth drive assembly by eye-bolts on bracket and motor

and by choking the protection tube with a nylon sling so that it can be picked up level.

c. Insert protection tube through azimuth drive mount and move

choker past azimuth drive mount once choker reaches it. d. Secure azimuth drive to mount as illustrated in Figure 3-1 using

26 bolts (item 106), 56 washers (item 107), 28 nuts (item 108). e. Remove 12 bolts from top of mount for location of azimuth drive

anchor (item 2). Save bolts for securing anchor. f. Grease and insert two anchor pins (item 3) to secure azimuth

drive anchor. Secure anchor using 12 bolts previously removed. g. Remove eye-bolt from drive bracket and install a 3/4-10 x 1 1/2

inch hex head bolt. h. Install elbow and breather vent on highest reducer plug. 4. Remove hoist from azimuth assembly.


5. Torque azimuth assembly fasteners to the following values: 1 1/4-inch fasteners 1100 ft-lbs (1491 Nm)

3/8-inch fasteners 31 ft-lbs (42 Nm)

5/16-inch fasteners 24 ft-lbs (33 Nm)



Figure 3-4. Azimuth Drive/Clevis Assembly (Sheet 1 of 3), 512010



Perform the following procedure to install the elevation drive assembly. (Figure 3-1 contains installation information and Figure 3-5 provides the elevation actuator assembly information.)

ELEVATION DRIVE INSTALLATION

1. Attach hoist to elevation drive assembly (item 9 or 24).

WARNING __________________________________________ The elevation drive assembly weighs 4500 lbs (2040 kg). Use extreme care when hoisting the elevation drive assembly into position. __________________________________________

2. Carefully, lift elevation actuator assembly until it is standing straight

up and extend actuator protection tube through slot in rotating frame as indicated in Figure 3-1.

3. Secure elevation assembly to rotating frame mounting bracket with

two elevation drive pivot pins (item 10) and four retaining rings (item 100).

4. Remove hoist from elevation assembly.



Figure 3-5. Elevation Drive Assembly (Sheet 1 of 2), 482655D



Figure 3-5. Elevation Drive Assembly (Sheet 2 of 2), 482655E




Prior to installing the hub, it must be assembled on the ground. The hub can be assembled at any convenient time prior to installation. Perform the following procedures to assemble and install the hub.

HUB ASSEMBLY AND INSTALLATION

Assembly of the hub requires a large (at least 14 square feet (1.3 square meter)) area, flat, clean, and capable of handling at least 8000 lbs (3629 kg). The hub is shipped in three large segments. Each segment weighs approximately 2500 lbs (1134 kg). These three segments are bolted together using braces supplied in the kit. Perform the following procedures to assemble the hub.

Hub Assembly

1. Place 4 x 4s on assembly area to set the hub segments onto during

hub assembly process.

WARNING __________________________________________ The hub segments weigh approximately 2500 lbs (1134 kg) each. Use extreme care when hoisting the hub segments into position. __________________________________________

2. Place hub segment (item 2 in Figure 3-6) with two pivots upright

(pivots facing up) on 4 x 4s. 3. Place hub segment splice (item 5) onto left side of hub segment using

three bolts (item 105) without washers and nuts.

NOTE The bolts without washers and nuts hold the splice plate in place during installation of the next segment.

4. Align and secure next hub segment (item 1) to left side of first hub

using 15 bolts (item 105), 30 washers (item 107), and 15 nuts (item 108).

5. Place hub segment splice (item 5) onto left side of second hub

segment using three bolts (item 105) without washers and nuts. 6. Attach elevation jack plate (item 3) onto remaining hub segment

(pivot facing up) using three bolts (item 105) without washers and nuts.

7. Align and secure last hub segment (item 1) to other two segments



8. Attach three hub segment braces (item 6) on each corner of hub segments using 10 bolts (item 100), 20 washers (item 101), and 10 nuts (item 102) on each brace.

9. Attach rear left brace (item 7) and rear right brace (item 8) using 13

bolts (item 103), 26 washers (item 107), and 13 nuts (item 108) on each brace as shown in Figure 3-6.

10. Secure elevation jack plate (item 3) braces to hub using 5 bolts (item

100), 10 washers (item 101), and 5 nuts (item 102). 11. Secure top and bottom of hub segments using 8 bolts (item 106) on

top, 8 bolts (item 104) on bottom, 32 washers (item 107), and 16 nuts (item 108) as indicated in Section B-B, Figure 3-6.

12. Secure middle of hub segments using 40 bolts (item 104), 80 washers

(item 107), and 40 nuts (item 108) as indicated in Section B-B, Figure 3-6.

13. Ensure upper and outside seams are even then torque all hub

assembly fasteners as follows:

1-inch Fasteners 600 ft-lbs (813 Nm)


1/2-inch Fasteners 76 ft-lbs (103 Nm) Perform the following procedure after installing the rotating frame and the elevation actuator.

Hub Installation

WARNING

__________________________________________ The hub assembly weighs 8000 lbs (3629 kg). Use extreme care when hoisting the hub assembly into position. __________________________________________

1. Using hoist, lift hub assembly (item 6 in Figure 3-1) to top of mount

and attach hub elevation pivot brackets to rotating frame clevises using two pivot pins (item 7 in Figure 3-1) and four retaining rings (item 101).

2. Use a come-along or some other means to pull elevation actuator

clevis over to meet blade on hub. 3. Attach hub elevation drive bracket to elevation actuator plate (item 3

in Figure 3-6) using clevis pin (item 11 in Figure 3-1) and two retaining rings (item 101).

4. Pivot hub about elevation axis using drive assembly so that top of

hub is horizontal.



Figure 3-6. Assembling Hub (Sheet 1 of 5), 512015B




This procedure includes mounting the ladders from the mount mezzanine to the rotating frame and from the rotating frame to the hub. The procedures also include the jib installation. The ladders will be installed first, followed by the guardrails for the rotating frame, and then the jib installation. The optional equipment installation is illustrated in Figure 3-7 and described in the following procedures.

INSTALLING GUARDRAILS AND

LADDERS

Perform the following procedure to install the ladders for access to the rotating frame and hub.

Ladders Installation

1. Attach two ladder hanger brackets (item 14 in Figure 3-7) to bearing

assembly using two bolts (item 106), four flat washers (item 107), and two nuts (item 108) on each bracket.

2. Install ladder (item 12 or 13) to brackets. 3. Attach hub access tread plate using four bolts (item 100), four

washers (item 101), and two nuts (item 102). 4. Install hub access ladder (item 11) using two bolts (item 109), four

washers (item 110), and two nuts (item 111). 5. Torque all ladder fasteners to values listed below: 3/4-inch Fasteners 260 ft-lbs (353 Nm)


3/8-inch Fasteners 31 ft-lbs (42 Nm) Perform the following procedure to install the guardrails on the work platform.

Guardrails Installation

1. Install left side guardrail (item 1 in Figure 3-7) to rotating frame


2. Install right side guardrail (item 2) to rotating frame using 22 bolts

(item 100), 44 washers (item 101), and 22 nuts (item 102). 3. Install rear guardrail (item 3) to rotating frame using 6 bolts (item

100), 12 washers (item 101), and 6 nuts (item 102). 4. Install rear guardrail (item 4) to rotating frame using 11 bolts (item

100), 22 washers (item 101), and 11 nuts (item 102). 5. Attach azimuth drive platform (item 5) and platform plate (item 18)



6. Install azimuth drive left side guardrail (item 6) to rotating frame using 14 bolts (item 100), 28 washers (item 101), and 14 nuts (item 102).

7. Install azimuth drive rear guardrail (item 7) to rotating frame using 12

bolts (item 100), 24 washers (item 101), and 12 nuts (item 102). 8. Install azimuth drive front guardrail (item 8), corner angle (item 19)

and front toe rail (item 20) to rotating frame using 14 bolts (item 100), 28 washers (item 101), 14 nuts (item 102), corner angle (item 19), and front toe rail (item 20).

9. Install azimuth drive right side guardrail (item 9) to rotating frame


10. Torque all guardrail fasteners to values listed below: 3/8-inch Fasteners 31 ft-lbs (42 Nm) 11. Install wire rope to guardrails as shown in Figure 3-7 using 6 eye

bolts (item 112), 6 washers (item 113), 6 nuts (item 114), 3 snap hooks (item 115), and 12 wire clips (item 116).

Install the miscellaneous platform hardware in accordance with the following instructions.

Miscellaneous Platform Hardware

1. Attach man-hole cover (item 15) at location shown in Figure 3-7. 2. Attach man-hole cover (item 16) at location shown in Figure 3-7. 3. Install azimuth frame standpipe (item 17) using 2 bolts (item 103), 4

washers (item 104), and 2 nuts (item 105) at location shown in Figure 3-7.

4. Attach hub access tread plate (item 10) using 4 hex head bolts (item

100) and 8 flat washers (item 101), and 4 nuts (item 102) at location shown in Figure 3-7.

5. Install azimuth frame standpipe (item 17) using 2 hex head bolts

(item 103), 4 flat washers (item 104), and 2 nuts (item 105) at location shown in Figure 3-7.



Figure 3-7. 16/18 Meter Optional Equipment Installation (Sheet 1 of 4), 512569C


SECTION 4 INSTALLATION OR REFLECTOR, SPARS,

SUBREFLECTOR, FEED, AND WAVEGUIDE 4-1 General 4-1 Installation of Reflector 4-32 Installation of Spars and Subreflector 4-38 Installation of Feed 4-41 Installation of Waveguide



SECTION 4 INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, AND FEED This section contains procedures for installing the reflector, spars, subreflector, and feed of the 16-/18-Meter Earth Station Antenna. The installation of the mount is contained in Section 2 and the installation of the azimuth/elevation drives and hub is contained in Section 3. General safety precautions and procedures for the entire installation are described in Section 2 and should be reviewed before proceeding with these procedures.

GENERAL

The reflector installation procedure includes installation of feed/panel mount, installation of trusses, alignment of trusses, installation of panels, and alignment of panels. The alignment of trusses and panels procedures will require the use of a theodolite to properly align the trusses and panels.

INSTALLATION OF REFLECTOR

The following procedure describes the installation of the feed mounting hardware to the hub.

Installation of Panel Mounting Ring and

Optional LNA Enclosure

1. Install 6 feed/panel mount brackets (item 3 in Figure 4-1) to hub

using 12 bolts (item 13), 24 washers (item 15), and 12 nuts (item 16) as indicated in Figure 4-1.

2. Attach LNA enclosure (item 2) to feed/panel mount (item 1) using 16

screws (item 8), 16 lock washers (item 10), and 16 washers (item 11). (This must be done prior to step 3 below.)

3. Install feed/panel mount to feed/panel mount brackets using 6 bolts

(item 17), 6 washers (item 18), and 6 nuts (item 19) as indicated in Figure 4-1.

4. There are two extra pairs of 1/4-20 tapped holes near the inside

diameter of the ring. Clock the ring such that these two pairs of holes will be oriented at 12 o'clock and approximately 8 o'clock in the finished reflector.

5. Accurately center and level the ring with respect to the 3 machined

bosses on the top of the hub. 6. Accurately align the 24 pairs of panel mounting holes with the truss

mounting holes in the outer skin of the hub. 7. Install LNA enclosure inner ladder (item 4) and LNA enclosure

ladder (item 5) to LNA enclosure using 12 screws (item 9), 12 washers (item 10), 12 washers (item 11), and 12 nuts (item 12).

INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, AND FEED

8. Secure LNA enclosure ladder to hub using two bolts (item 13), four washers (item 15) and two nuts (item 16).

9. Install LNA enclosure cover assembly (item 7) using seven screws

(item 8), seven washers (item 10), seven washers (item 11), and seven nuts (item 12).


INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, AND FEED ____________________________________________________________________________________________

Figure 4-1. Feed Mounting Hardware Installation, 512570C




The 18M trusses, nodes, and intercostals are assembled into a truss assembly using the following procedure. Refer to the next procedure for installation of 16M truss assemblies.

Installation of 18M Truss Assemblies

Two truss assemblies are assembled together first on the ground. Then the two truss assembly is lifted into position using the crane. Perform the following procedure to assemble and install the trusses to the hub. 1. Place and hold two main trusses (item 1 in Figure 4-2) resting on 4 x

4 close to hub end. 2. Angle main trusses out to approximate end result angle (hub end

about 18-inches (45.75 cm) apart and outer end about 4-feet (122 cm) apart).

3. Attach intercostal #1A (item 4) to inside of attaching tabs (first node

location from hub) at top of truss using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end.

4. Attach intercostal #1B (item 5) to inside of attaching tabs (underneath

1A) at bottom of truss using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end.

5. Attach two intercostals #1C (item 6) from center of item 1A toward

bolt location of item 1B using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end. (Items 5 and 6 share the same bolts.)

6. Attach two intercostals #1D (item 7) from center of item 1A to upper

hub end of truss using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end. (The assembly should now be self supporting.)

7. Align two truss extensions (item 2) to end of main trusses and attach

using two hex head bolts (item 106), four flat washers (item 107), and two hex nut (item 108) at inner location in each end pad.

8. Attach node 2 assembly (item 21) to outside of attaching tabs (second

pad location from hub) at top of truss using hex head bolt (item 103), flat washer (item 104), and hex nut (item 105) in each end, and items 106, 107, and 108 from step 7 above.

9. Attach intercostal #2B (item 8) to outside of attaching tabs at bottom

of truss using hex head bolt (item 106), flat washer (item 107), and hex nut (item 108) in each end.

10. Attach two intercostals #2C (item 9) from center of item 2A to bolt

location of item 2B using hex head bolt (item 103), flat washer (item 104), and hex nut (item 105) in each end.


11. Attach two intercostals #2D (item 10) from center of item 2A toward bolt location of item 1A using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) at truss end, and two bolts (100), four washers (101), and two nuts (102) at node end.

12. Attach intercostal #3A (item 11) to inside of attaching tabs (third

attachment location from hub) at top of truss using two hex head bolts (item 103), four flat washers (item 104), and two hex nuts (item 105) in each end.

13. Attach intercostal #3B (item 12) to inside of attaching tabs

(underneath 3A) at bottom of truss using two hex head bolts (item 103), four flat washers (item 104), and two hex nuts (item 105) in each end.


location of item 3B using one hex head bolt (item 103), two flat washers (item 104), and one hex nut (item 105) in each end.

15. Attach two intercostals #3D (item 14) from center of item 3A toward

bolt location of item 2A using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end.

16. Attach node 4 assembly (item 22) to inside of attaching tabs (fourth


17. Attach intercostal #4B (item 15) to inside of attaching tabs at bottom

of truss using two hex head bolts (item 103), four flat washers (item 104), and two hex nuts (item 105) in each end.




bolt location of item 3A using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) at truss end, and two bolts (100), four washers (101), and two nuts (102), at node end.

20. Attach node 5 assembly (item 18) to inside of attaching tabs (fifth





bolt location of item 4A using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) at truss end, and two bolts (100), four washers (101), and two nuts (102), at node 5A end.



23. Repeat steps 3 through 6 and 8 through 22 to attach the intercostal

and node assemblies on the outside left portion of the truss assembly assembled in steps 1 through 22. The outside of portion many of these intercostal #s will be unsecured; therefore, the loose intercostal should be tied down to prevent unnecessary movement and possible damage during installation. (This portion of the assembly will be used to secure the assemblies together once mounted on the hub.)

NOTE Every sixth truss must use a spar truss (item 3) instead of the truss extension (item 2), see Figure 4-2.

24. Install threaded rod (item 10 in Figure 4-5) in each hole on every pad

on top of truss assembly using two washers (item 12) and four nuts (item 11). Install another two nuts (item 11) 2-inches above pad on each rod. (These threaded rods will be used to mount the panels.)

WARNING __________________________________________ The completed truss assembly weighs 1600 lbs (726 kg). Use extreme care when hoisting the completed truss assembly into position. __________________________________________

25. Attach hoist to completed truss assembly and lift assembly to hub

(see Figure 4-3). 26. Align truss assembly to hub and secure with truss-shims (items 23

and 24 in Figure 4-2), four bolts (item 106), eight washers (item 107), and four nuts (item 108) at top and bottom of hub. (The truss-shims (T-shims) will be removed or more added to align the trusses.)

27. Assemble and install the remaining truss assemblies in accordance

with steps 1 through 26. When truss assembly is secured to hub, secure truss assembly to preceding truss assembly using the loose end of the intercostal and node assembly.

NOTE Every sixth truss must use a spar truss (item 3) instead of the truss extension (item 2), see Figure 4-2.

28. When all truss assemblies are installed, align truss assemblies using a

theodolite to within 3/8 inch (10 mm) laterally and vertically.



29. Align truss assembly to feed/panel mount ring by adding or removing

T-shims. 30. Torque all fasteners (except nuts on panel rods) to the following

values: 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)



Figure 4-2. Installation of 18M Trusses, Nodes, and Intercostals (Sheet 1 of 6), 513586



Figure 4-3. Installing 18M Trusses




The 16M trusses, nodes, and intercostals are assembled into a truss assembly using the following procedure. Refer to the previous procedure for installation of 18M truss assemblies.

Installation of 16M Truss Assemblies

Two truss assemblies are assembled together first on the ground. Then the two truss assembly is lifted into position using the crane. Perform the following procedure to assemble and install the trusses to the hub. 1. Place and hold two main trusses (item 1 in Figure 4-4) resting on 4 x

4 close to hub end. 2. Angle main trusses out to approximate end result angle (hub end

about 18-inches (45.75 cm) apart and outer end about 4-feet (122 cm) apart).

3. Attach intercostal #1A (item 4) to inside of attaching tabs (first node

location from hub) at top of truss using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end.

4. Attach intercostal #1B (item 5) to inside of attaching tabs (underneath

1A) at bottom of truss using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end.

5. Attach two intercostals #1C (item 6) from center of item 1A toward

bolt location of item 1B using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end. (Item 5 and 6 share the same bolts.)

6. Attach two intercostals #1D (item 7) from center of item 1A to upper

hub end of truss using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end. (The assembly should now be self supporting.)

7. Align two truss extensions (item 2) to end of main trusses and attach

using two hex head bolts (item 106), four flat washers (item 107), and two hex nut (item 108) at inner location in each end pad.

8. Attach node 2 assembly (item 17) to outside of attaching tabs (second

pad location from hub) at top of truss using hex head bolt (item 103), flat washer (item 104), and hex nut (item 105) in each end, and items 106, 107, and 108 from step 7 above.

9. Attach intercostal #2B (item 8) to outside of attaching tabs at bottom

of truss using hex head bolt (item 106), flat washer (item 107), and hex nut (item 108) in each end.




11. Attach two intercostals #2D (item 10) from center of item 2A toward bolt location of item 1A using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) at truss end, and two bolts (100), four washers (101), and two nuts (102) at node end.

12. Attach intercostal #3A (item 11) to inside of attaching tabs (third


13. Attach intercostal #3B (item 12) to inside of attaching tabs

(underneath 3A) at bottom of truss using two hex head bolts (item 103), four flat washers (item 104), and two hex nuts (item 105) in each end.




bolt location of item 2A using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end.

16. Attach node 4 assembly (item 18) to inside of attaching tabs (forth


17. Attach right intercostal #4C (item 15) from node 4 to bolt location of

item 3B (on right side, from hub end looking out) using one hex head bolt (item 100), two flat washers (item 101), and one hex nut (item 102) in each end.

NOTE The notched end of items 15 and 19 attach to the truss (item 2 or 3) while the straight cut end attaches to node 4 (item 18).

18. Attach left intercostal #4C (item 19) from node 4 to bolt location of

item 12 (on left side) using one hex head bolt (item 100), two flat washers (item 101), and one hex nut (item 102) in each end.

19. Attach two intercostals #4D (item 16) from node 4 toward bolt

location of item 11 using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) at truss end, and two bolts (100), four washers (101), and two nuts (102) at node end.

20. Repeat steps 3 through 6 and 8 through 19 to attach the intercostal

and node assemblies on the outside left portion of the truss assembly assembled in steps 1 through 22. The outside of portion many of these intercostal #s will be unsecured; therefore, the loose intercostal should be tied down to prevent unnecessary movement and possible



damage during installation. (This portion of the assembly will be used to secure the assemblies together once mounted on the hub.)

NOTE

Every sixth truss must use a spar truss (item 3) instead of the truss extension (item 2), see Figure 4-4.

21. Install threaded rod (item 10 in Figure 4-6) in each hole on every pad

on top of truss assembly using two washers (item 12) and four nuts (item 11). Install another two nuts (item 11) 2-inches (5.1 cm) above pad on each rod. (These threaded rods will be used to mount the panels.)

WARNING __________________________________________ The completed truss assembly weighs 1350 lbs (612 kg). Use extreme care when hoisting the completed truss assembly into position. __________________________________________

22. Attach hoist to completed truss assembly and lift assembly to hub

(see Figure 4-3). 23. Align truss assembly to hub and secure with T-shims (items 23 and

24 in Figure 4-4), four bolts (item 106) eight washers (item 107), and four nuts (item 108) at top and bottom of hub. (The T-shims will be removed or more added to align the trusses.)

24. Assemble and install the remaining truss assemblies in accordance

with steps 1 through 23 and the following steps. When truss assembly is secured to hub, secure truss assembly to preceding truss assembly using the loose end of the intercostal and node assembly.

NOTE

Every sixth truss must use a spar truss (item 3) instead of the truss extension (item 2), see Figure 4-4.

25. When all truss assemblies are installed, align truss assemblies using a

theodolite to within 3/8 inch (10 mm) laterally and vertically. Align truss assembly to feed/panel mounting ring by adding or removing T-shims.

26. Torque all fasteners (except nuts on panel rods) to the following

values: 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)




When all of the trusses are assembled, installed, and aligned, the antenna structure is ready for the panel installation. There are four rows of panels for the 18-meter antenna (rows A, B, C, and D). There are three rows of panels for the 16-meter antenna (rows A, B, and C). The inner row of panels (row A) is installed first, then the next row, and so on until all rows of panels are installed. Perform the following procedure to install the panels on the trusses. (Refer to Figure 4-5 for the 18-meter antenna or Figure 4-6 for the 16-meter antenna.

Installation of Panels

1. Place A panel (item 1) on threaded rods at position closest to hub as

shown in Figure 4-5 or 4-6. a. Remove existing screw, nut, and washers supplied with panel

assembly and discard. b. Insert wedge (item 7) under narrow end of, and between, two A

panels. Then secure panel to hub using two screws (item 13), two washers (item 14).

2. Secure panel to rods using two flat washers (item 12) and two hex

nuts (item 11). (The set dimensions shown in the figure are for a crude setting.)

3. Roughly align panel by moving threaded rod up or down with nuts on

truss. Sight the outer corners of each panel using the theodolite and data provided in paragraph 3 of 479821. Set both corner’s height to the angles shown. Set the panel laterally by sighting one corner using the nominal azimuth angle less the offset for the gap.. (This will minimize the final adjustments.)

4. Repeat steps 1 through 3 for the remainder of the panels on the first

row spacing panels 1/8 inch (0.32 cm) apart. Align panels to panels on either side.

5. Place B panel (item 2) on threaded rods at next position spaced 1/8

inch (0.32 cm) out from A panel. 6. Secure panel to rods using two flat washers (item 12) and two hex

nuts (item 11). 7. Align panel flush to first row/adjacent panels by moving threaded rod

up or down with nuts on truss. Align outer corners using theodolite as in step 3.

8. Repeat steps 5 through 7 for the remainder of the panels on the

second row. Align panels to panels on either side. 9. Starting at a position 37.5° up from center line of antenna (see Sheet

1), place left-hand spar attachment C panel (item 5) on threaded rods at next position spaced 1/8 inch (0.32 cm) out from B panel.

10. Secure panel to rods using two flat washers (item 12) and two hex

nuts (item 11).


11. Align panel flush to adjacent panels by moving threaded rod up or down with nuts on truss. Align the outer corners using the theodolite as in step 3.

12. Place right-hand spar attachment C panel (item 6) on threaded rods at

next counterclockwise position. 13. Secure panel to rods using two flat washers (item 12) and two hex

nuts (item 11). 14. Align panel flush to adjacent panels by moving threaded rod up or

down with nuts on truss. Align outer corners using theodolite as in step 3.

15. Place C panel (item 3) on threaded rods at next counterclockwise

position. 16. Secure panel to rods using two flat washers (item 12) and two hex


down with nuts on truss. Align outer corners using the theodolite as in step 3.

18. Repeat steps 15 through 17 for the next nine panels on the C row. 19. Place left-hand spar attachment C panel (item 5) on threaded rods at

next counterclockwise position. 20. Repeat steps 10 through 18 for the next set of C row panels. 21. Place left-hand spar attachment C panel (item 5) on threaded rods at

next counterclockwise position. 22. Repeat steps 10 through 18 for the next set of C row panels. 23. Place left-hand spar attachment C panel (item 5) on threaded rods at

next counterclockwise position. 24. Repeat steps 10 through 18 for the final set of C row panels.

NOTE For an 18-meter antenna, follow the remainder of the steps below.

25. Place D panel (item 4) on threaded rods at next position spaced 1/8

inch (0.32 cm) out from C panel. 26. Secure panel to rods using two flat washers (item 12) and two hex


down with nuts on truss. Align outer corners using theodolite as in step 3.

28. Repeat steps 25 through 27 for the remainder of the D panels on the

fourth row.



Figure 4-5. Installing 18M Panels (Sheet 1 of 2), 477757B




The panels are aligned using a theodolite attached to the center of the hub. Care must be exercised to ensure the panels are in alignment after the fasteners are torqued. Perform the following procedure for final alignment of the panels using a theodolite and an alignment kit PN 479609.

Final Alignment of Panels

1. With reflector pointed at zenith, assemble drill template in reflector

and attach to theodolite spindle base. 2. Drill a 3/16 inch (0.48 cm) diameter hole in the panel surface above

each of the panel adjustment rods. (There are 720 adjustments for an 18-meter antenna and 528 adjustments for a 16-meter antenna.) Install a plastic target into each drilled hole.

3. Using elevation drive system, position reflector at 35° to 40°

elevation. 4. Using theodolite, adjust each panel screw to set the surface within

0.005 inch (0.13 mm) accuracy (see Figure 4-7). Tighten adjusting nuts on adjuster screw.

5. When all adjustments have been completed, use theodolite to verify

and record the setting of all targets (see Appendix C). Readjust any locations which are out of tolerance.

6. Tighten four locking nuts on each adjuster screw, so that each

connection is double-nutted.


Figure 4-7. Theodolite Adapter Installation Assembly, 480594




The spars and subreflector installation procedure includes assembly of spars and subreflector and installation of spars and subreflector assembly. The spars and subreflector are assembled together on the ground, then hoisted into position on the reflector. Perform the following procedure to install the spars and subreflector on either the 18-meter antenna (illustrated in Figure 4-8) or the 16-meter antenna (illustrated in Figure 4-9).

INSTALLATION OF SPARS AND

SUBREFLECTOR

1. Support subreflector (item 1 in Figure 4-8 or 4-9) face down on soft

packing material so that the spun surface is not dented or scarred. 2. Secure lifting straps to each of the spars (item 2).

NOTE The lifting straps must be able to support a 500 lb (227 kg) load. The straps should be attached to balance the subreflector to prevent damage.

3. Assemble four spars to spar fitting (item 3) using three screws (item

101), six washers (item 103), and three nuts (item 105).

NOTE The center lines of the four spars come together at a point in the center of the spar connector.

4. Torque fasteners to the following values and remove straps.



1/2-inch Fasteners 76 ft-lbs (103 Nm) 5. Carefully, lay mounting frame (item 4) on top of subreflector back as

indicated in Figure 4-8 or 4-9, Sheet 2. 6. Install 6 subreflector adjusters (item 7) on 6 threaded rods (item 10)

and secure two to support frame and four to mounting frame using 18 nuts (item 112) and 18 washers (item 103) as indicated in Figure 4-8 or 4-9.

7. Attach support frame (item 5) to subreflector using three studs (item

6), nine nuts (item 108), and nine washers (item 109). Make sure support frame is aligned with subreflector and mounting frame as indicated in Figure 4-8 or 4-9, Sheet 2.

8. Secure mounting frame to support frame using three screws (110), six

washers (item 104), and three nuts (item 106).


CAUTION

__________________________________________ When lifting and supporting subreflector, exercise care to prevent damage to subreflector formed surface. Any damage to this surface will affect the performance of the subreflector. __________________________________________

9. Lift subreflector and adjust straps as necessary to level assembly a

few feet (a meter or so) above the ground. 10. Lubricate threads and shaft and install alignment tool (item 9) into

center of subreflector.

NOTE

Alignment tool (item 9) is used for subreflector alignment. 11. Align four mounting frame holes with subreflector mounting holes on

spars. 12. Secure subreflector to spars using four screws (110), eight washers

(item 104), and four nuts (item 106). 13. Remove hoist from subreflector and attach hoist to spars/subreflector

assembly. 14. Lift assembly into place on antenna spar mounting brackets. 15. Secure spars to antenna spar mounting brackets using eight screws

(item 101), eight washers (item 103), and eight nuts (item 105). 16. Torque fasteners to the following values and remove hoist.

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) 17. Align subreflector for tilt and lateral adjustment using theodolite and

alignment tool (item 9) for reference. 18. Set subreflector distance as measured from feed/panel mounting

surface. The 18-meter distance is 194.69 inches or 4.95m (see Figure 4-8) and the 16-meter distance is 192.43 inches or 4.89m (see Figure 4-9).

19. After aligning subreflector, remove alignment tool (item 9) and install

domed screw (item 8).



Figure 4-8. 18-Meter Antenna Subreflector Installation (Sheet 1 of 2), 476807C



Figure 4-8. 18-Meter Antenna Subreflector Installation (Sheet 2 of 2), 476807C



Figure 4-9. 16-Meter Antenna Subreflector Installation (Sheet 1 of 2), 477753B



Figure 4-9. 16-Meter Antenna Subreflector Installation (Sheet 2 of 2), 477753B




The following procedure describes the installation of the feed mounting hardware, the Model 8118 4-Port Feed, and the installation of the waveguide for this feed. If other feeds are installed, they may require slightly different installation instructions. Refer to the appropriate installation drawings or instructions for installing other feeds and waveguides.

INSTALLATION OF MODEL 8118 FEED

The following procedure describes the installation of the Model 8118 4-Port Feed.

INSTALLATION OF FEED

1. Attach hoist to feed assembly and lift feed into center of hub area as

indicated in Figure 4-10. 2. Secure feed to mount using 16 screws (item 109 in Figure 4-10), 32

washers (item 111), and 16 nuts (item 110).

NOTE The hardware is provided to install the LNA and WR-137 waveguide. Four holes are provided for mounting the LNA package. Ports not used should be loaded.

3. Install the appropriate receive and transmit ports in accordance with

Figure 4-10, Sheet 1.


Figure 4-10. Model 8118 Feed Installation (Sheet 1 of 2), 513398



Figure 4-10. Model 8118 Feed Installation (Sheet 2 of 2), 513398




The following procedure describes the installation of the waveguide for the Model 8118 4-Port Feed.

INSTALLATION OF WAVEGUIDE

1. Install long feed can waveguide (item 2 in Figure 4-11) and short

feed can waveguide (item 3) to feed using crossguide coupler (item 1) on each flange.

2. Install waveguide tray (item 11) by removing appropriate 1/2-13

bolts, laying waveguide tray into place, and securing lower waveguide tray using 1/2-13 bolts previously removed. Secure upper waveguide tray using 2 bolts (item 107), 4 washers (item 108), and 2 nuts (item 109).

3. Install waveguides (item 3 to 9) using flange gaskets (item 104) with

8 screws (item 100), 16 flat washers (item 103), 8 lock washers (item 102), and 8 nuts (item 101) at each flange as illustrated in Figure 4-11. Use the following procedures to secure waveguide.

a. Secure waveguides to hub and in cable tray as illustrated in

Figure 4-11 view C and the following procedure: (1) Install top waveguide hanger (item 13) to hub using 2 screws

(item 114). (2) Install bottom waveguide hanger (item 14) to hub using 2

bolts (item 107), 4 washers (item 108), and 4 nuts (item 109).

(3) Install waveguide support spacer in waveguide using 2

adjusting rods (item 17), 6 washers (item 106), and 6 nuts (item 105).

b. Secure waveguides to upper rotating frame as illustrated in

Figure 4-11 view B and the following procedure: (1) Install top waveguide hanger (item 13) to frame using 2

screws (item 114). (2) Install bottom waveguide hanger (item 14) to frame. (3) Install waveguide frame spacer (item 16) in waveguide using

2 adjusting rods (item 18), 6 washers (item 111), and 6 nuts (item 110).

c. Secure waveguides to lower rotating frame as illustrated in

Figure 4-11 view D and the following procedure: (1) Install top waveguide hanger (item 13) to frame using 2

screws (item 114). (2) Install bottom waveguide hanger (item 14) to frame.


(3) Install waveguide frame spacer (item 16) in waveguide using 2 threaded waveguide hangers (item 12), 6 washers (item 111), and 6 nuts (item 110).

d. Secure waveguides to lower mount waveguide support (item 10),

as illustrated in Figure 4-11, Sheet 1, using waveguide hanger kit (item 113), 2 screws (item 112), 4 washers (item 111), and 2 nuts (item 110).



Figure 4-11. Model 8116/8118 Waveguide Installation (Sheet 1 of 2), 513360



Figure 4-11. Model 8116/8118 Waveguide Installation (Sheet 2 of 2), 513360


SECTION 5 OPERATION 5-1 General 5-1 Satellite Pointing Procedure 5-1 Feed Polarization 5-2 Subreflector Adjustment 5-5 Azimuth Sector Change Procedure


____________________________________________________________________________________________


SECTION 5 OPERATION With this elevation-over-azimuth mount, pointing the antenna is accomplished by jogging the antenna in elevation and jogging the antenna in azimuth. The antenna can be jogged locally using the jog switches on the lower mount or remotely using the jog switches on Model 8864 Antenna Position Controller. In normal operation, the antenna is jogged to track satellites using Model 8860 Antenna Tracking Controller or to new antenna locations using the Earth Station Controller.

GENERAL

With the feed installed and the electronics operational, the following procedure can be used for pointing at the desired satellite and peaking on the signal. Typically, the antenna will be driven to the satellite location using an Earth Station Controller, Personnel Computer, or Model 8860 Antenna Tracking Controller; however, if these are not available, the following procedure is used to point the antenna at a satellite.

SATELLITE POINTING

PROCEDURE

1. Refer to the Site Preparation manual to determine the required

elevation and azimuth angles. 2. Move antenna to the required elevation angle by turning the elevation

actuator on using jog switches on Model 8864 or the local jog switches on the lower mount. The elevation angle is measured from the horizon to the reflector boresight. A good reference surface for the reflector boresight is between the two elevation pivot brackets.

3. Rotate the antenna in azimuth by turning azimuth actuator on using

jog switches on Model 8864 or the local jog switches on the lower mount.

4. Peak up the signal by jogging the elevation and azimuth actuators as

necessary until the signal strength is at a maximum. For circular polarization, no polarization alignment is required. For linear polarization, peak the feed polarization on the signal as follows:

FEED POLARIZATION

1. Rotate feed until the signal peaks. 2. Monitor receiver C/N meter or a power meter. 3. Rotate the feed counterclockwise until the signal decreases by 1 dB.

Record the signal level. Mark a line on the feed mounting plate and a matching line on the hub.

OPERATION ____________________________________________________________________________________________

4. Rotate the feed clockwise until the meter has passed through the peak and has decreased to the level recorded in step 3. Make a mark on the hub in line with the mark of the feed mounting plate.

5. Measure the distance between the marks on the hub. Calculate the

mid-point between these marks. Rotate the feed until the mark on the feed mounting plate is aligned with the mid-point.

The following procedure should be used in the event that the antenna performance demonstrates that a subreflector adjustment is necessary. (Subreflector alignment using the theodolite should be performed prior to this final adjustment.) The purpose of the physical measurement is to position the subreflector to its optimum optical location along the adjustment axis.

SUBREFLECTOR ADJUSTMENT

1. Ensure all antenna hardware including mount parts are installed and

tightened properly prior to making any subreflector adjustment.

NOTE

A straight edge may be placed across the feed bezel and measurement may then be made from the inside of the straight edge to the subreflector. The subreflector adjustment screws should not stress the subreflector in any way.

2. Take a reference measurement from back of subreflector mounting

frame at each adjustment rod prior to subreflector adjustment. 3. The subreflector should be adjusted toward or away from the main

dish with the subreflector adjustment mechanism. By adjusting the support studs equally, the subreflector alignment is maintained. Signal level monitoring equipment is necessary to accurately set the subreflector for the highest gain and the deepest radiation pattern nulls. The following equipment or its equivalent is necessary:

• Spectrum Analyzer • Power Meter • X-Y Recorder • Time Base The radiation pattern (relative power versus off-axis angle) should be

recorded and evaluated for each adjustment of the subreflector. Typical patterns at various subreflector positions which are identified in Figure 5-1 show the changes which take place as the subreflector is moved closer to the optimum focal position.


OPERATION ____________________________________________________________________________________________

a. The first nulls to each side of the main beam will become deeper and eventually bottom out at some level (see Figure 5-1). This level varies depending on the antenna, but should be equal to or greater than 10 dB below the level of the first sidelobe. The deepest null in the H-plane sometimes occurs at a different subreflector position than in the E-plane. In this case, the subreflector should be set at a compromise position between the two planes (i.e., E-plane null depth approximately equals the H-plane null depth).

b. The signal level of the main beam will also increase as the

subreflector is moved closer to the focal position. The power meter can be used to monitor this change. The main signal level will peak at the antenna focus; however, this change will not be as sensitive as the change in the null depths. Peak main beam signal level and minimum first null depths should coincide for the best subreflector position.

c. As the subreflector is adjusted toward the optimum focal

position, the first sidelobe levels should decrease and remain symmetrical within 2 dB. The minimum sidelobe level will occur approximately at the same subreflector position as the highest signal level and lowest nulls. Should the sidelobes become asymmetrical (greater than 2 dB), a small tilt and/or lateral adjustment may be required. It is recommended that after each adjustment of the subreflector, the antenna azimuth and elevation adjustments be re-peaked to compensate for any beam steering due to axial misalignment.


OPERATION ____________________________________________________________________________________________

Figure 5-1. Typical Antenna Patterns for Various Subreflector Positions


OPERATION ____________________________________________________________________________________________


Under normal operation, the antenna will remain pointed at one satellite, but it may be necessary at some time to point the antenna at a different one. If that will require a movement in azimuth beyond the limits set for the current sector, it will be necessary to change sectors. Following is the procedure for changing azimuth sectors.

AZIMUTH SECTOR CHANGE

PROCEDURE

1. Move antenna in azimuth toward desired position. Note whether the

azimuth drive pivot frame (attached to the fixed portion of the mount) will be beside the rotating frame at the end of travel (outboard position) or under the frame (inboard position). It will need to be moved to the other of these two positions.

2. Lift out removable deck plate and set it aside on rotating frame. 3. Locate stow pin and set it on rotating frame under hub. Do not insert

stow pin in the stow block yet. 4. Notice positions of 12 bolts used to secure pivot frame to mount and

remove corresponding ones from the top of mount in the next sector (next face of hexagon as seen from top of mount). Only the center row of bolts, except for the one closest to each 3-inch hole, needs to be removed. See Figure 3-1, Sheet 2 and Figure 5-2. Save the bolts to use in the current sector.

5. If sector change will be from inboard to outboard position, remove all

pivot frame attachment bolts except two (per end) that remain beside two alignment pins either before the rotating frame is moved over pivot frame or while movement is taking place. After pivot frame is in the inboard position, access can be gained to four remaining bolts but the others will be under the rotating frame.

6. Move antenna in azimuth to the stow position closer to desired new

azimuth position. 7. Insert stow pin in stow block and into the 3-inch hole in top of mount

structure. It may be necessary to jog antenna and to loosen bolts holding the stow block to rotating frame in order for stow pin to drop into place.

8. Tighten stow block attachment bolts if they were loosened. 9. Record azimuth position shown on antenna position controller. 10. Disconnect coupling from azimuth LSR drive shaft. Leave coupling

attached to LSR shaft.

11. Note that LSR drive channel is close to one side of access hatch. When it is put back up after sector change, it will need to be in the position closer to the other side of access hatch.

OPERATION ____________________________________________________________________________________________

CAUTION __________________________________________ In the following step, do not remove or loosen any other bracket screws or the LSR will have to be completely realigned. __________________________________________

12. Remove two screws securing azimuth LSR drive channel to azimuth

bearing. Set drive channel aside being careful not to lose coupling clamp.

13. Using a come-along, a crane, or other means, hook onto the azimuth

drive pivot frame assembly and take the weight off the attachment bolts.

CAUTION __________________________________________ Do not allow the weight of the pivot frame to be completely taken by the free end of the azimuth actuator or damage to the actuator may occur. __________________________________________

14. Keep tension on lift cable while removing four remaining bolts and

two alignment pins. The weight of the pivot frame will now be taken by the lift cable and the azimuth actuator.

15. Manually run azimuth actuator to move the pivot frame to new sector

position. It will be necessary to guide it along with slaver bars or guide pins to get it into position. During this procedure, there will be no azimuth readout information available at the antenna position controller.

16. When pivot frame approaches new position, insert alignment pins and

all accessible bolts in the holes. Jog azimuth drive as necessary to bring pivot frame into position.

17. Tighten all accessible bolts securing pivot frame to mount. 18. Unhook lift cable from pivot frame. 19. From underneath at azimuth LSR location, remove two bolts from

azimuth bearing at new location for LSR channel and install these two bolts in holes where channel was previously attached.


OPERATION ____________________________________________________________________________________________

20. Carefully install LSR drive channel in position at other side of access hatch by aligning coupling onto LSR shaft while installing previously removed screws between channel and azimuth bearing. Be sure coupling clamp is on coupling.

21. Rotate LSR shaft until antenna controller shows a reading that is 60°

(±0.1°) off from recorded reading and tighten coupling clamp.

NOTE The limit switch strikers inside the LSR package will only permit rotation in one direction from the initial position.

22. Open cover to LSR package. 23. Loosen servo clamps securing resolver to mounting plate and rotate

resolver (only) back 60° until antenna position controller reads the value that was recorded before LSR was disabled. This procedure will require some back and forth rotation to get resolver into the proper position (within about ±0.005°).

24. Tighten servo clamps on resolver and reinstall cover on the LSR

package. 25. Remove stow pin by slightly jogging the drive, if necessary. 26. Take out any remaining azimuth realignment error by recalibrating

antenna position controller using recorded value of azimuth position. The azimuth drive should now be operational again.

27. Move antenna back and forth in azimuth, as required, to install all

remaining bolts. 28. Check azimuth drive by moving to new extremes of travel and make

sure limit switches are properly set.

29. If it is necessary to move still further in azimuth to reach the desired position, go back to step 4 to complete another sector change.


OPERATION ____________________________________________________________________________________________

Figure 5-2. Azimuth LSR Installation (Sheet 1 of 2), 482569


OPERATION ____________________________________________________________________________________________

Figure 5-2. Azimuth LSR Installation (Sheet 2 of 2), 482569


SECTION 6 MAINTENANCE 6-1 General 6-1 Periodic Maintenance 6-5 Corrosion Protection


____________________________________________________________________________________________


SECTION 6 MAINTENANCE The Series 16M/18M-Meter Earth Station Antenna is designed for use in many different environmental conditions with minimum maintenance requirements. Several areas on the antenna require service at various intervals to ensure the proper use and operation. Modification to the suggested service intervals is expected pending customer operation and environmental conditions. The azimuth and elevation actuators contain a gearbox or reducer and a machine screw or ball screw mechanism which require inspection and application of lubricant as required. Structural fasteners used on the mount, actuators, reflector, and feed may require additional corrosion protection.

GENERAL

CAUTION __________________________________________ The backlash and bearing preload on azimuth and elevation machine screw assemblies are factory set on a test fixture to exact standards. To maintain proper adjustment, the assemblies have been keyed in place to prevent rotation. Do not attempt to adjust these parameters. Any questions concerning this should be directed to ViaSat Inc. __________________________________________

The suggested service intervals apply to a typical antenna installation and may vary due to environmental conditions.

PERIODIC MAINTENANCE

Ensure antennas are driven in azimuth and elevation on a weekly basis. In areas of heavy snow and ice, mounts should be inspected before movement for excessive accumulation of ice, or damage may result.

Weekly Maintenance

Apply electrical power, as necessary, to azimuth actuator, elevation actuator, and polarization drive assembly (if applicable). Run each axis for two or three minutes in the normal operating sector. If a pressurization system is installed, check pressure of feed and transmit waveguide. Service as required.

Monthly Maintenance

MAINTENANCE ____________________________________________________________________________________________


Perform the following procedures at least once every two months. In extreme environments (ice, snow, etc.), perform these procedures monthly.

Bi-Monthly Maintenance

WARNING __________________________________________ Remove electrical power from antenna system prior to performing these maintenance procedures. __________________________________________

CAUTION __________________________________________ The mezzanine, if provided, is designed for a live load (personnel and tools) of 200 lbs per square foot (976 kg per square meter) or a concentrated load of 300 lbs (136 kg). __________________________________________

1. Remove resolver covers, inspect mechanical operation, and check for

condensation accumulation. If moisture exists, open all drain holes. Apply a spray-type lubricant (WD-40 or equivalent) to all moving parts. Secure covers.

2. Inspect polarization drive assembly, if applicable, and apply a spray-

type lubricant (WD-40 or equivalent) to chain and drive sprocket. Inspect the drive chain for correct tension and lubricate if necessary with the spray-type lubricant. Ensure that feed rollers are all functional. Inspect flexible transmit waveguide, if applicable, for fatigue. Check limit switch operation. Inspect feed window for damage and replace window as required.

3. Inspect all cotter pins and other devices used as pin retainers.

Replace if damaged or corroded; tighten if loose. 4. Inspect mount, reflector, and feed, for loose or missing fasteners and

replace as required. 5. Check the oil level in both the azimuth and elevation actuator gear

boxes and add Mobil SHC 634 oil, as required, to maintain a level of approximately half full.

MAINTENANCE ____________________________________________________________________________________________

6. Inspect azimuth and elevation actuators for sufficient lubrication. For either actuator, the following steps should be performed:

a. Run the actuator out 12 inches from the normal operating

position. b. Disconnect the boot from the actuator housing and slide the boot

back. c. Examine the last 12 inches of the screw for the condition of the

grease. d. If the grease is dry, contaminated, or lacking, it must be replaced

(as follows). e. Using a clean cloth and solvent, remove any dry or contaminated

grease.

CAUTION __________________________________________ If one of the following low-temperature greases is not used on the actuator screw, damage to the screw or motor could occur. __________________________________________

f. Apply a thin, uniform coating of one of the following low-

temperature greases: • Texaco Low Temperature #2346 • Shell Aeroshell #17 (SA# 488563), (14 oz) Moly Grease

Cartridges • Mobil Low Temperature #28 g. Connect the boot back to the actuator housing. h. Run the actuator in and out 12 inches each way two times. i. Move the reflector back to the satellite position. 7. Apply Aeroshell #17 grease to all of the following grease fittings

shown in Figure 6-1:

NOTE Six tubes of Aeroshell #17 grease cartridges supplied with each antenna.

Azimuth Bearing Assembly 2 places Azimuth Anchor 1 place Elevation Hub Blade 2 places Elevation Jack Hub Blade 1 place


MAINTENANCE ____________________________________________________________________________________________

Figure 6-1. Grease Fitting Maintenance Locations


MAINTENANCE ____________________________________________________________________________________________


Perform the following procedures at least once every year. Yearly Maintenance 1. Inspect the foundation pad for structural cracks and repair as

required. 2. Inspect feed and feed radome. 3. Check torque values on all fasteners as follows:

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 Fastener 24 ft-lbs (33 Nm) 1/4-inch Fasteners 9 ft-lbs (12 Nm) Perform the following procedures after completing the installation and every 12 months thereafter.

CORROSION PROTECTION

NOTE

Pressurization of transmit waveguide runs and feed components should be maintained to prevent moisture from entering the system.

1. Evaluate the corrosion protection on the mount, actuators, and related

hardware. If the protective finish is damaged, clean with a wire brush, remove all rust, and apply a coat of Rust-Oleum (or equivalent) spray-on cold galvanizing compound.

2. Evaluate the corrosion protection on the reflector surface, spars, feed,

resolver brackets and related hardware. If the paint is scratched, chipped, beginning to flake, or just wearing thin, lightly sand with 320 grit (or finer) sandpaper and apply a coat of Rust-Oleum (or equivalent) primer and semi-gloss white paint.

SECTION 7 OPTIONS 7-1 General 7-1 Feed Options 7-1 Lightning Protection


____________________________________________________________________________________________


SECTION 7 OPTIONS For even greater versatility, there are several optional features for the 16-Meter or 18-Meter Earth Station Antenna. Any or all of the following de-ice options are available:

GENERAL

• Full Main Reflector De-Icing • Half Main Reflector De-Icing • Feed and Subreflector De-Icing Lightning protection that includes rod air terminals and cabling to a single ground rod is also available. The antenna can use a wide variety of feed options for both domestic and international applications. The feed option available for the 16-meter or 18-meter antenna is currently only a 4-port circular C-band feed. The assembly drawing is shown in Figure 7-1.

FEED OPTIONS

NOTE The feed specifications are subject to change without notice due to product improvements. Consult with ViaSat’s sales department for current specifications.

The optional Model 8118-LP Lightning Protection kit can be purchased from ViaSat. Install the lightning protection kit in accordance with the procedures contained in Figure 7-2.

LIGHTNING PROTECTION

OPTIONS ____________________________________________________________________________________________

Figure 7-1. 4-Port Circular C-Band Feed Assembly (Sheet 1 of 5), 477259A


OPTIONS ____________________________________________________________________________________________



OPTIONS ____________________________________________________________________________________________

Figure 7-2. Lightning Protection Kit Installation (Sheet 1 of 2), 478096


OPTIONS ____________________________________________________________________________________________

Figure 7-2. Lightning Protection Kit Installation (Sheet 2 of 2), 478096


APPENDIX A INSTALLATION CHECKLIST WITH

MANUAL PAGE REFERENCES


INSTALLATION CHECKLIST WITH MANUAL PAGE REFERENCES

LOWER MOUNT CHECK

NOTE

As fasteners are installed, tighten finger tight only, until specifically directed to torque a fastener.

PAGE

_____ Set bottom tapped onto a sturdy platform which will allow access to four corner bolt holes.

CAUTION _____________________________________________________________________________ Mount damage can occur if the platform plates are not properly aligned. Ensure proper plate alignment is maintained as described in the following steps. _____________________________________________________________________________

2-12

_____ Set and align mounting plates onto two tapped plates.

2-12

_____ Set and align top plates onto two lower plates.

2-12

_____ Secure plates together.

2-12

_____ Attach six top skin mount angles.

2-12

_____ Install flat washers and hex nuts on anchor bolts, 1-inch above pad.

2-13

_____ Lift column into position and secure to pad with four flat washers and hex nuts.

2-13

_____ Install remaining five columns as described above.

2-13

_____ Align and attach bearing ring assembly to top of six columns.

NOTE

It may be necessary to raise or lower some of the column legs using the nuts on the column base in order to properly align the platform plate assembly to the tops of each column.

2-13

_____ Attach bottom skin plates using hex bolts, flat washers, and hex nuts.

2-14

_____ Install right and left door hardware and skin assemblies.

2-14

_____ Install floor edge beam A (see Figure 2-8).

2-15

_____ Install floor edge beams in order of F, C, D, E, and B.

2-15

_____ Attach stair opening beam.

2-15

_____ Attach right and left floor support beams.

2-15

_____ Place center support beam into position (center support beam is removable).

2-15

_____ Assemble ships ladder.

2-17

_____ Attach ships ladder to stair stringer support beam and mark stair bottom plate holes in concrete.

2-19

A-1

LOWER MOUNT - continued CHECK

PAGE

_____ Remove ships ladder and drill four 3/4- by 4-inch deep holes in concrete.

2-19

_____ Attach ships ladder to stringer support beam and secure to concrete using expansion bolts.

2-19

_____ Install mezzanine guardrail.

2-19

_____ Install mezzanine grating on mezzanine support beams.

2-20

_____ Install middle and top skin plates.

2-21

_____ Secure platform plate assembly to top skin plates.

2-22

_____ Loosen all nuts securing bottom skin plates to foundation. (This will allow skin plates to be pulled tight from the top down.)

2-22

_____ Torque mount fasteners in the following sequence: • Fasteners holding platform plate assembly together • Platform plate assembly to column • Platform plate assembly to top skin plate • Top skin plate to column • Top skin plate to bottom plate and door head • Right and left door skin plate to door jamb • Door head to door jamb • Bottom skin plate to column • Ensure bottom nuts on column feet are snug against plate, then torque top nuts on column feet • Tighten nuts on bottom bracket of bottom skin plates • Mezzanine guard rail-to-stair opening fasteners to 260 ft-lbs • Ships ladder to stair stringer support beam fasteners to 260 ft-lbs • Mezzanine stair opening and all support beam fasteners to 260 ft-lbs • Mezzanine edge beam to column fasteners to 260 ft-lbs

2-22

_____ Transfer-drill and install mezzanine hold downs.

2-23

_____ Assemble, Transfer-drill, and install door and frame assembly.

2-23

_____ Grout baseplate and skin plates to foundation.

2-32

A-2

UPPER MOUNT CHECK

NOTE

The hub assembly process requires a large (14 feet diameter) area which is flat, clean, and capable of handling at least 18,000 lbs (8,165 kg).

PAGE

_____ Determine center of azimuth sector.

3-1

_____ Remove necessary bolts. Install pivot frame brace and drive pivot frame.

3-1

_____ Install rotating frame.

3-2

_____ Install stow pins.

3-2

_____ Torque rotating frame fasteners.

3-2

_____ Install azimuth drive assembly.

3-14

_____ Torque azimuth assembly fasteners.

3-15

_____ Install elevation drive assembly.

3-19

_____ Place hub segment with two elevation pivots upright (elevation pivots facing up) on one side of assembly area. Assembly area should be flat and 4 X 4s should be used to set the hub segments onto during the hub assembly process.

3-22

_____ Place segment splice onto left side of hub segment using three bolts without washers and nuts. Bolts hold spacer plate in place during installation of the next segment.

3-22

_____ Align and secure next hub segment to left side of first hub segment.

3-22

_____ Place segment splice onto left side of second hub segment using three bolts without washers and nuts. Bolts hold spacer plate in place during installation of the third segment.

3-22

_____ Attach elevation jack plate onto remaining hub segment (pivot facing up) using three bolts without washers and nuts. Bolts hold spacer plate in place during installation of the third segment.

3-22

_____ Align and secure last hub segment to other two segments.

3-22

_____ Attach two elevation angle plates on each side of hub segment with elevation jack plate.

3-23

_____ Ensure upper and outside seams are even then torque all hub assembly fasteners.

3-23

_____ Lift hub assembly and attach hub elevation pivot brackets to rotating frame pivot brackets.

3-23

_____ Attach hub elevation drive bracket to elevation drive assembly.

3-23

_____ Install ladders for access to rotating frame and hub.

3-29

_____ Install guard rails on work platform.

3-29

_____ Attach covers, standpipes, and tread plate.

3-30

A-3

REFLECTOR, SPARS, SUBREFLECTOR, AND FEED INSTALLATION CHECK

PAGE

_____ Install feed/panel mount brackets, LNA enclosure, and feed/panel mount.

4-1

_____ Clock ring to proper orientation.

4-1

_____ Center and level ring.

4-1

_____ Align 24 pairs of panel mounting holes with truss mounting holes.

4-1

_____ Install LNA enclosure inner ladder and LNA enclosure ladder.

4-1

_____ Install LNA enclosure cover assembly.

4-2

_____ Assemble truss assembly on ground level.

4-4/15

_____ Lift truss assembly and secure to hub.

4-4/17

_____ Assemble and install remaining truss assemblies.

4-6/17

_____ Align truss assemblies using theodolite.

4-6/17

_____ Torque fasteners to values given in manual.

4-7/18

_____ Install and align panels in row A.

4-23

_____ Install and align panels in row B.

4-23

_____ Install and align panels in row C making sure spare panels are in right location.

4-24

_____ Install and align panels in row D (18-meter reflector only).

4-24

_____ Perform final alignment of panels.

4-29

_____ Assemble four spars to spar fitting.

4-31

_____ Attach adjusters, support frame, and mounting frame to subreflector.

4-31

_____ Attach subreflector to spars.

4-32

_____ Lift and secure spar and subreflector assembly to reflector.

4-32

_____ Using theodolite and alignment tool, align subreflector for tilt and lateral adjustment.

4-32

_____ Install domed screw.

4-32

_____ Install feed.

4-37

_____ Install waveguide.

4-40

A-4

APPENDIX B MECHNICAL ALIGNMENT SPECIFICATION

AND REPORT FOR 16-/18-METER LIMITED MOTION ANTENNA (479820A)


cgulledge

MECHANICAL ALIGNMENT SPECIFICATION AND REPORT FOR 16 AND 18 METER LIMITED MOTION ANTENNA

Antenna size _________ meters. ViaSat program manager __________________________________ Customer _________________________________ Installation location __________________________________ 1.0 SCOPE This specification serves as a consolidated final report of field mechanical alignment and test data. Each successive item depends on proper completion of previous items. Each item should be performed and verified in the order listed as the earth station is erected, so that the completed antenna will meet specifications. Copies of this completed report are to be delivered to the customer and to the ViaSat program manager for the job. 2.0 AZIMUTH AXIS ALIGNMENT Starret no. 98 level deviation should be 1 division (.005 inch per foot) or less across azimuth bearing while rotating through range of azimuth travel.

Deviation on level_______________ divisions The azimuth bearing is properly greased.

ViaSat Rep._________________________________________ Date:____________________ 3.0 ELEVATION AXIS ALIGNMENT The height deviation of the elevation axis clevis pins should be no greater than 1/32 inch, or 1 division on Starret no. 98 level.

Actual Deviation___________________ The elevation drive mount has been aligned and centered with respect to the elevation clevises.

ViaSat Rep._________________________________________ Date:____________________ 4.0 HUB AND ELEVATION DRIVE ALIGNMENT The hub and elevation drive have been installed, and elevation travel 0 through 90 degrees has been demonstrated with no elevation drive binding. All bearing seals are in place and not torn.

ViaSat Rep._________________________________________ Date:____________________

May 15, 1996 ViaSat 479820A

2 of 5


Antenna size _________ meters. ViaSat program manager __________________________________ Customer _________________________________ Installation location __________________________________ 5.0 PANEL/FEED MOUNTING RING AND THEODOLITE ALIGNMENT The azimuth bearing and elevation axis have been aligned according to steps 2 and 3 above, and the hub positioned to 90 degrees elevation. The theodolite mount and theodolite have been installed to the panel/feed mounting ring. The theodolite azimuth axis should be perpendicular to the panel/feed mounting ring, by sighting a machine scale, to within 30 arc seconds (0.005 inches), at three points on the ring 120 degrees apart.

Theodolite azimuth axis deviation from perpendicular to panel mounting ring __________ seconds/inches. Theodolite elevation axis average height from panel/feed mounting ring should be 10.75 ± 0.01 inches.

Theodolite elevation axis measured average height ____________ inches. Panel mounting hole pattern in panel/feed mounting ring should be aligned with truss mounting hole pattern in hub to within 0.01 inches (70 arc seconds).

Panel hole pattern alignment to truss hole pattern ___________ inches/arc seconds. (Circle one). Panel/feed mounting ring should be level in hub to within 1 division (.005 inches per foot) on a Starret no. 98 level.

Panel/feed mounting ring level deviation ____________ divisions Above measurements and alignments are verified with all hub and panel/feed mounting ring installation hardware torqued to specification.

ViaSat Rep._________________________________________ Date:____________________

6.0 TRUSS ALIGNMENT Trusses (radials) are spaced at 15 degree angular increments. Angular (lateral) truss alignment error should be less than 3'-30" of arc (0.38 inches) from the panel mounting holes in the panel/feed mounting ring, for all 24 trusses.

Peak radial error at inner-to-outer truss interface ___________ minutes-seconds/inches. (Circle one).

Peak radial error at truss tips ___________ minutes-seconds/inches. (Circle one). Truss tip elevation angle is measured at the upper edge of the outer panel adjuster slots of each truss. Truss tip elevation (vertical) error should be less than 04'-20" of arc (0.50 inches) for all 24 trusses. Truss tip elevations are:

16 Meter Antenna: 72°04'42" 18 Meter Antenna: 69°13'12"

Peak truss tip elevation error ___________ minutes-seconds/inches. (Circle one).

ViaSat Rep._________________________________________ Date:____________________

May 15, 1996 ViaSat 479820A

3 of 5


Antenna size _________ meters. ViaSat program manager __________________________________ Customer _________________________________ Installation location __________________________________ 7.0 PANEL CONTOUR ALIGNMENT Panel contour alignment has been performed according to procedure 479821, at the customer's average elevation look angle (or 35 to 40 degrees if look angle is not specified). Reflector panel target deviation should be no greater than 0.010 inch RMS.

Reflector alignment elevation angle _________ degrees.

Reflector alignment deviation ________ inch RMS.

ViaSat Rep._________________________________________ Date:____________________

8.0 SUBREFLECTOR ALIGNMENT Subreflector alignment should be performed at the same elevation angle as panel alignment.

Subreflector alignment elevation angle _________ degrees. The subreflector perpendicular distance to top of feed/panel mounting ring (vertex) should be:

192.43 inches (± 0.25) for 16 Meter Antenna 194.69 inches (± 0.25) for 18 Meter Antenna.

Actual measured distance ________ inches.

The subreflector mirror crosshair should be set to less than .060 inch (or 70 arc seconds) deviation from the reflector parabolic axis.

Actual Deviation________ inches/seconds. (Circle one). The subreflector mirror perpendicular (autoreflection) deviation should be less than sixty (60) arc seconds.

Actual Deviation _______ seconds.

ViaSat Rep._________________________________________ Date:____________________

May 15, 1996 ViaSat 479820A

4 of 5


Antenna size _________ meters. ViaSat program manager __________________________________ Customer _________________________________ Installation location __________________________________ 9.0 FEED HORN ALIGNMENT The perpendicular distance between the top of the feed horn radome bezel and the subreflector vertex should be:

59.82 inch (± 0.50) for 16 Meter Antenna, 62.08 inch (± 0.50) for 18 Meter Antenna

Measured perpendicular distance ____________ inches. The feed axis shall be concentric with the main reflector axis within 0.12 inch.

Maximum concentric deviation at top of feed horn measures ___________ inches.

ViaSat Rep._________________________________________ Date:____________________ 10.0 AZIMUTH ROTATION AND DRIVE The azimuth rotation has been demonstrated (possibly during the controller tests) and mechanical limits have been set. Electrical limit switches have been adjusted for the 90 degree sector. The boot has been properly installed. All lubrication points are visible and accessible. The reducer vent plug has been installed and the oil level verified. All bearing seals are in place and not torn.

ViaSat Rep._________________________________________ Date:____________________ 11.0 ELEVATION ROTATION AND DRIVE The elevation rotation has been demonstrated (possibly during the controller tests) and mechanical limits have been set. Electrical limit switches have been adjusted for 0 degrees through 90 degrees of travel. The boot has been properly installed. All lubrication points are visible and accessible. The reducer vent plug has been installed and the oil level verified.

ViaSat Rep._________________________________________ Date:____________________

12.0 FINAL VISUAL INSPECTION All components should be properly installed according to the installation manual and drawings. All fasteners (except any known special cases) should be hot-dipped galvanized or stainless steel and should be properly installed. All (non-stainless) steel components should be hot-dipped galvanized and painted. All aluminum components should be chemically treated and painted. The mount should be grouted to the foundation. Damage to paint or galvanizing during installation has been repaired.

ViaSat Rep._________________________________________ Date:____________________

May 15, 1996 ViaSat 479820A

5 of 5

APPENDIX C CONTOUR ALIGNMENT SPECIFICATION

AND RECORD FOR 16-/18-METER ANTENNA (479821B)


ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED

TOLERANCES 3 PLACE DECIMAL ±.005 2 PLACE DECIMAL ±.02 1 PLACE DECIMAL ±.1

FRACTIONS ± ANGLES ±0° 30’ MAX SURFACE ROUGHNESS ALL MACHINES SURFACES 125 EXCEPT AS NOTED

BREAK SHARP EDGES AND CORNERS .010 MAX

SHEET

REV DWG NO.

CONTRACT NO.

DWN

H.L. HOWARD 6/16/93

SCALE NONE

SIZE A

CAGE NO.1Q601

CONTOUR ALIGNMENT SPEC FOR 16/18-METER ANTENNAS

ENGR

D.G. FULLER 6/17/93 CHK

D.G. FULLER 6/17/93 PROD

APVD

FINISH

Form 722179 Rev B

1

ViaSat Inc. 4356 Communications Drive

Norcross, GA 30093

479821 B

APPLICATION REVISION QTY NEXT ASSY USED ON REV DESCRIPTION DATE APPROVED

A REVISED AND REDRAWN PER ECR 11637 10/12/94 D.G. FULLER B REVISED PER CO-013197 4/23/2004 K. EDENFIELD

CONTOUR ALIGNMENT SPECIFICATION AND RECORD FOR 16 AND 18 METER ANTENNA Antenna size _________ meters. ViaSat program manager ____________________________ Customer _________________________________ Installation location _________________________________

1. SCOPE This specification provides panel installation and final alignment data. When completed it will also serve as a record of the reflector alignment. Copies of this completed record are to be delivered to the customer and to the ViaSat program manager for the job. 2. PREPARATION FOR PANEL INSTALLATION All steps of specification 479820 leading up to Panel Contour Alignment must have been performed and verified. Measured height from top of panel/feed mounting ring to theodolite elevation axis ___________ inches. 3. REFLECTOR PANEL INSTALLATION REFERENCE First tier panels attach directly to the panel/feed mounting ring. All panels are spaced with a consistent 0.12 inch gap both laterally and radially. Offset for ½ of 0.12 inch gap (@ outside corner) First tier: 24 panels at 15.0 degrees azimuth spacing 00-01-47 (DMS) Second tier: 48 panels at 7.5 degrees azimuth spacing 00-01-02 Third tier: 48 panels at 7.5 degrees azimuth spacing 00-00-41 Fourth tier: 48 panels at 7.5 degrees azimuth spacing, 18 meter antenna only 00-00-36

Dimension from Theodolite elevation axis to:

16 Meter Antenna 18 Meter Antenna

Radius Height Angle Radius Height Angle

Main reflector vertex 0 -10.75 NA 0 -10.75 NA

Top of Panel/Feed Mounting Ring 0 -10.75 NA 0 -10.75 NA

Top of Theodolite Mounting Plate 0 -9.25 NA 0 -9.25 NA

First Tier Inside 30.0 Fixed Fixed 30.0 Fixed Fixed

First Tier Outside Corner 119.94 6.454 86-55-12 119.94 6.454 86-55-12

Second Tier Outside Corner 204.95 40.824 78-44-04 204.95 40.824 78-44-04

Third Tier Outside Corner 315.00 110.536 70-39-49 314.95 111.371 70-31-33

Fourth Tier Outside Corner ▒▒▒▒ 355.00 143.656 67-58-07

4. PREPARATION FOR FINAL ALIGNMENT Attach the drill template to the template arm, and install the arm to the spindle ring. The template must lie in the reflector with the screw heads down and the splice and drill blocks facing up. Drill 3/16 inch diameter holes 3 inches inside the edge of each panel using the 3rd, 4th, 7th, 8th, 10th, and 12th drill bushings, and also the 13th and 15th drill bushings for the 18 meter antenna. Install a plastic theodolite target into each drilled hole, with the white dots facing the theodolite.

April 23, 2004 ViaSat 479821B, page 2


Figure 1. Panel Contour Alignment Target Map (looking into reflector)



5. REFLECTOR PANEL FINAL ALIGNMENT REFERENCE Panel targets contain three 0.04 inch high white reference dots for theodolite sighting. The center of the middle dot is the nominal setting reference; it is 0.25 inches above the reflector surface. The other two dots are centered 0.06 inches above and below the main dot, for scaling the setting deviation. The error in inches for a target in any row can be determined from the table by measuring the error in arc seconds. Also, a compensation adjustment in arc seconds is listed for each row for a 0.01 inch error in theodolite elevation axis height.

Equivalent arc seconds

Target Error (inch)

Row Panel Target

Location

Drill Template

Arc Length

16 Meter Target Angle

18 Meter Target Angle

+0.01 inch Theodolite Ht 0.005 0.010 0.015

1 Tier 1 Outside 118.000 87-12-47 87-12-47 +17.7 9.6 19.3 28.9

2 Tier 2 Inside 125.000 86-26-06 86-26-06 +16.7 9.1 18.7 27.2

3 Tier 2 Outside 209.820 78-56-16 78-56-12 +9.8 5.2 10.5 15.7

4 Tier 3 Inside 216.820 78-24-37 78-25-07 +9.5 5.1 10.1 15.2

5 Tier 3 Midway 287.830 73-42-56 73-41-31 +7.1 3.8 7.5 11.3

6 Tier 3 Outside 340.650 70-46-58 70-40-41 +5.8 3.2 6.4 9.5

7 Tier 4 Inside 347.650 ▒▒▒▒ 70-18-22 +5.7 3.1 6.2 9.3

8 Tier 4 Outside 392.030 ▒▒▒▒ 68-06-04 +5.0 2.8 5.5 8.3

6. RMS ERROR CALCULATION

The RMS error of the target settings should be no greater than 0.010 inches. To calculate the RMS, fill in the table below. Count the number of occurrences of each error and multiply that count by the square of the error. Divide the sum of all these products by the total number of targets, and take the square root. This gives the RMS. The total number of targets is 528 for a 16 Meter Antenna, and 720 for an 18 Meter Antenna.

The total target RMS is __________ inch.

Error Value

Number of Occurrences

Error Value

Squared

Multiply column 2 x column 3

0.000 0.0 0.005 0.000025 0.010 0.0001 0.015 0.000225

0.020 0.0004 0.025 0.000625 0.030 0.0009

Total N = Summation =

N)xn(=RMS

2ii ε∑



16 and 18 Meter Target Final Readings 18 Meter Only Target No. Row 1 Row 2 Row 3 Row 4 Row 5 Row 6 Row 7 Row 8

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Series 8116/8118 16-/18-Meter Earth Station Antenna Installation ...

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