Transcript
Series 8118 18-Meter Earth Station Antenna
Installation and Operation Guide
Manual Part No.1017415 Rev 001 February 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: 1017415 Copyright ® 2004 ViaSat, Inc. All rights reserved. No part of this book may be reproduced in any form or by any means without permission in writing from ViaSat, Inc.
TABLE OF CONTENTS
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TABLE OF CONTENTS
SECTION 1 1-1 1-1 1-5 1-6 SECTION 2 2-1 2-1 2-1 2-2 2-2 2-3 2-4 2-4 2-5 2-5 2-9 2-9 2-10 2-10 2-10 2-12 2-21 2-22 2-23 2-24 2-26 2-27 2-27 2-28
GENERAL INFORMATION Introduction to Manual Description Wind Load Options Specifications LOWER MOUNT INSTALLATION PROCEDURES General What to do About Visible Loss or Damage What to do About Concealed Damage How to Inventory Equipment Received How to Return Equipment General Mechanical Safety Summary Emergency Plan General Electrical Safety Summary Resuscitation Recommended Tools and Equipment Recommended Installation Sequency Recommended Torque Values Site Preparation Assembly of Lower Mount Azimuth Bearing Ring Assembly Leg Installation Bottom Skin Plate Installation Middle and Top Skin Plate Installation Torquing Lower Mount Fasteners Door Assembly and Installation Grouting Baseplate and Skin Plate to Foundation Hot Weather Grouting Cold Weather Grouting Grouting Procedures
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SECTION 3 3-1 3-1 3-10 3-15 3-20 3-20 3-21 3-28 3-28 3-28 3-29 SECTION 4
4-1 4-1 4-1 4-4 4-14 4-18 4-21 4-25 4-25 4-25 SECTION 5 5-1 5-1 5-1 5-2 5-5
UPPER MOUNT INSTALLATION PROCEDURES General Rotating Frame Installation Azimuth Drive Installation Elevation Drive Installation Hub Assembly and Installation Hub Assembly Hub Installation Installing Guardrails and Ladders Ladder Installation Guardrails Installation Miscellaneous Platform Hardware INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, MOTORIZED POLARIZATION DRIVE, AND FEED General Installation of Reflector Installation of Panel Mounting Ring and Optional LNA Enclosure Installation of 18M Truss Assemblies Installation of Panels Final Alignment of Panels Installation of Spars and Subreflector Installation of Motorized Polarization Drive Installation of Model 8118 Feed Installation of Feed OPERATION General Satellite Pointing Procedure Feed Polarization Subreflector Adjustment Azimuth and Elevation Resolver and Limit Switch Installation
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SECTION 6 6-1 6-1 6-1 6-1 6-2 6-5 6-5 SECTION 7 7-1 7-1 7-1 7-1
MAINTENANCE General Periodic Maintenance Weekly Maintenance Monthly Maintenance Bi-Monthly Maintenance Yearly Maintenance Corrosion Protection OPTIONS General Feed Options Lightning Protection Elevation Auxiliary Drive Option
APPENDIX A
INSTALLATION CHECKLIST WITH MANUAL PAGE REFERENCES
APPENDIX B
MECHNCIAL ALIGNMENT SPECIFICATION AND REPORT FOR 16/18-METER LIMITED MOTION ANTENNA (1017431)
APPENDIX C
CONTOUR ALIGNMENT SPECIFICATION AND RECORD FOR 16/18-METER ANTENNA (479821A)
APPENDIX D
B-SIZE COPY OF DRAWINGS
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SECTION 1
1017415 Rev 001
GENERAL INFORMATION
1-1
Introduction to Manual
1-1
Description
1-4
Specifications
SERIES 8118 18-METER EARTH STATION ANTENNA
GENERAL INFORMATION ____________________________________________________________________________________________
SECTION 1 INTRODUCTION TO MANUAL
GENERAL INFORMATION This manual contains information needed to properly install, operate, and maintain the 18-Meter (18M) Earth Station Antenna. This section contains general information on the 18M antenna. Sections 2 through 4 contain information pertaining to 18M antenna installation. Sections 5 and 6 contain information pertaining to operation and maintenance. Section 7 describes the different configurations available for the 18M antenna. Appendix A contains a complete antenna installation checklist with page references for the detailed procedures. Appendix B and Appendix C contain mechanical and contour alignment specifications and report information for the antenna, respectively. All warnings and cautions should be reviewed before any procedures are performed. Failure to do so may result in personal injury or equipment damage. Periodic maintenance and corrosion protection procedures are contained in Section 5. For replacing components of the antenna, refer to the installation and assembly drawings contained in Sections 2, 3, and 4.
DESCRIPTION
The 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 18M antenna. The following list identifies the main features of the antenna: • 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 180° azimuth travel • Internal access for a clean, elegant look.
The 18M antenna is a Cassegrain design with a reflector and subreflector that are shaped for maximum efficiency and low sidelobes. Feed options include circularly polarized, 4-port, frequency reuse feed consisting of a corrugated horn, orthomode transducer, diplexers, and connecting waveguide. All the performance specifications are in full compliance with INTELSAT-A specifications. ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 1-1
GENERAL INFORMATION ____________________________________________________________________________________________
Figure 1-1. 18-Meter Motorized Antenna (Sheet 1 of 3)
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Figure 1-1. 18-Meter Motorized Antenna (Sheet 2 of 3)
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Figure 1-1. 18-Meter Motorized Antenna (Sheet 3 of 3) The mount for the 18-meter antenna is a elevation-over-azimuth pedestal. The elevation travel limits can be set at any points between 0 and 90 degrees. The azimuth travel range is minus 90 degrees to plus 90 degrees reference to the zero azimuth foundation heading. Size 20 resolvers are supplied for position readout. The elevation axes is are equipped with 75 ton (667 kN) jack screw drive. 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 DC servo motors to provide high motor speeds for rapid stowing or slewing and slow speed required for satellite tracking. ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 1-4
GENERAL INFORMATION ____________________________________________________________________________________________
CAUTION __________________________________________ No buildings, walls, fences, or other permanent fixtures should be planned for installation any closer than two meters from the antenna and foundation envelope without consultation with the factory. __________________________________________ Wind Load Options
The 18-meter antenna will operate or drive to stow in winds up to 100 km/h) with the standard 75 ton (667 kN) actuators. Above 100 km/h the antenna must be stowed to prevent damage to the azimuth drive gears. 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 8 minutes to stow the antenna using servo 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.
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SPECIFICATIONS
Function/Item
Specification
General Antenna Type
Cassegrain, dual-reflector
Antenna Diameter
18 Meters
Reflector Construction 18-Meter Antenna Mount Configuration
168 precision aluminum panels Elevation-over-azimuth
Antenna Pointing Range Azimuth
180° continuous
Elevation
0 to 90° continuous
Antenna System Weight (Approximate) 18 Meter
127,000 lbs (57,594 kg)
Reflector Weight 18 Meter
42,000 lbs (19,047 kg)
Elevation Balance Angles 18 Meter Drive Rates
69° Variable up to:
Azimuth
0.2 deg/sec
Elevation
0.2 deg/sec
For a complete set of specifications please refer to the System manual.
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SECTION 2
1017415 Rev 001
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
2-9
Recommended Torque Values
2-10
Site Preparation
2-10
Assembly of Lower Mount
2-26
Grouting Baseplate and Skin Plate to Foundation
SERIES 8118 18-METER EARTH STATION ANTENNA
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
SECTION 2 GENERAL
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 18-Meter Earth Station Antenna. The installation of the upper mount (including rotating frame, azimuth/elevation drives, hub, and optional work platform) is contained in Section 3. The installation of the reflector, spars, subreflector, and feed is contained in Section 4. General safety precautions and procedures for the entire installation are also described at the beginning of this section. ViaSat Inc 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 Inc 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).
WHAT TO DO ABOUT VISIBLE LOSS OR DAMAGE
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 CONCEALED 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 Inc guarantees its full support of your claims to protect you against loss from concealed damage.
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HOW TO INVENTORY EQUIPMENT RECEIVED
Check off each item received against that list on the packing slip included with the shipment, and verify that this list matches the purchase order. If any items are missing, please notify ViaSat immediately and return a copy of the packing slip with the missing item(s) circled. For a current list of telephone and email contract information please refer to the Contact Information section of the ViaSat internet site (http://www.viasat.com). Select Products, Satellite Ground Systems and Contact Us.
HOW TO RETURN EQUIPMENT
ViaSat’s Satellite Ground Systems division makes every reasonable effort to ensure that all items arrive safely and in working order. When equipment is received, which is not in working order, return the equipment to the factory for repair or replacement. Return the equipment according to the following procedure. This procedure will apply whenever equipment is returned for warranty or other services. a)
Notify ViaSat of the problem and request a Return Material 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.
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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. __________________________________________ GENERAL MECHANICAL SAFETY SUMMARY
These are general mechanical safety precautions that are not related to any specific procedure. They are recommended precautions that personnel must understand and apply. WARNING __________________________________________ Installation or maintenance of antennas may require persons to work at elevated work stations. Whenever persons are working at eight or more feet above ground and not on a guarded platform, they should wear safety belts with at least one, and preferably two, lanyards, with the exception that trained and qualified persons may work up to 25 feet (7.6m) if on an approved ladder. In the sentence above, approved usually means that the ladder is tied off once the person has climbed but before work begins. __________________________________________
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WARNING __________________________________________ Overhead hazards, either because items may fall or because a person may strike them unintentionally, are typical around construction sites or during installation of large antennas. It is prudent to adopt the following rules: 1. Never stand underneath anything while it is being hoisted. 2. Always wear a hard hat, especially if someone is above you. __________________________________________ WARNING __________________________________________ Ensure that all electrical tools and equipment are properly grounded. __________________________________________ Emergency Plan
Have an emergency plan. Know the procedures for obtaining firstaid and fire-fighting assistance. Plan your work and maintain good housekeeping; the safety and quality of the product are at stake.
GENERAL ELECTRICAL SAFETY SUMMARY
These are general electrical safety precautions that are not related to any specific procedure. These are recommended precautions that personnel must understand and apply. 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
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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. __________________________________________ Resuscitation
Personnel working with or near hazardous chemicals or voltages should be familiar with modern methods of resuscitation.
RECOMMENDED TOOLS AND EQUIPMENT
Tables 2-1 through 2-4 list the tools and equipment needed for installing ViaSat Inc 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. Table 2-1. Hand Tools Required for Installation Quantity 1 Set* 1 Each* 1 Each* 1 Each* 1 Each 1 Each* 1 Each* 1 Each* 1 Each* 1 Each 1 Each 1 Each 1 Each* 1 Each* 1 Each*
Description Combination wrenches up to 1 inch size 3/4 inch combination wrench 7/8 inch combination wrench 1 1/16 inch combination wrench 1 1/8 inch combination wrench 1 1/4 inch combination wrench 1 5/8 inch combination wrench 1 7/8 inch combination wrench 2 inch combination wrench 18 inch adjustable (Crescent) wrench 24 inch adjustable (Crescent) wrench 24 inch pipe wrench 1 1/16 inch spud wrench 1 1/4 inch spud wrench 1 5/8 inch spud wrench
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Table 2-1. Hand Tools Required for Installation - continued Quantity 1 Set 1 Set* 1 Each* 1 Each* 1 Each* 1 Each* 1 Each 1 Set* 1 Each* 1 Each* 1 Each* 1 Each* 1 Each 1 Each 1 Each 2 Sets 1 Set 1 Set* 2 Pairs 1 Each 2 Pairs 2 Pairs 1 Pair 2 Pair 1 Each 1 Each 1 Each 1 Each* 2 Each 2 Each 2 Each 1 Each 2 Each 2 Each 1 Each 1 Each 1 Each 6 Each 1 Each 1 Each 6 Each 1 Each 1 Each 1 Each 3 Each 1 Each 1 Each 2 Rolls
Description 3/8 inch drive ratchet, extensions, and sockets from 3/8 to 7/8 inch size 1/2 inch drive ratchet, extensions, and sockets from 7/16 to 1 1/4 inch size 3/4 inch x 1/2 inch drive socket 7/8 inch x 1/2 inch drive socket 1 1/16 inch x 1/2 inch drive socket 1 1/4 inch x 1/2 inch drive socket Socket adapter, 1/2 inch female to 3/4 inch male 3/4 inch drive ratchet, extensions, and sockets from 7/8 to 2 inch size 1 1/4 inch x 3/4 inch drive socket 1 5/8 inch x 3/4 inch drive socket 1 7/8 inch x 3/4 inch drive socket 2 inch x 3/4 inch drive socket Socket adapter, 3/4 inch female to 1/2 inch male 3/4 inch drive torque wrench, 250-300 ft-lbs capacity 3/4 inch drive torque wrench, 600 ~-lbs capacity Screwdrivers, flat blade and Phillips Hex keys (Allen wrenches) up to 1/2 inch size Nut drivers Mechanic's pliers Wire crimping tool Lineman's pliers Needle-nose pliers 12 inch channel lock pliers 10 inch vise grips 4 pound sledge hammer 8 pound sledge hammer 24 ounce ball peen hammer Rawhide hammer Claw hammer 1 inch bull pin 2 inch bull pin Small slaver bar Large slaver bar Crow (wrecking) bar Pry bar Band cutter Hacksaw Hacksaw blade Automatic center punch Drill index, 1/16 through 1/2 inch 3/16 inch drill bits (for panel targets) Tap and die set up through 3/8-16 size 12 inch machinist's flat file 12 inch round file 6 inch C-clamp Wire brush, stainless steel Grease gun with cartridges Electrical tape
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Table 2-1. Hand Tools Required for Installation - continued Quantity 1 Each 1 Each 1 Each 1 Each 1 Each 1 Each 1 Each 1 Each 1 Each 1 Each 1 Each 4 Each
Description Angle finder or magnetic base inclinometer 24 inch carpenter's level 12 inch machinist's scale with square head, 1/100 graduation Feeler gage set 12 foot tape 25 foot tape Chalk line reel (full of chalk) 1 inch putty knife 3 inch putty knife 4 x 12 inch finishing trowel 6 inch pointing trowel 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 1 Each* 4 Each 2 Each 4 Each 1 Each 1 Each 1 Each 1 Each 1 Each
Description 45 ton crane with a 100 foot boom 15 foot steel choker, 3/4 inch wire diameter 20 foot steel choker, 1 inch wire diameter Small, medium, and large shackles Electric generator [or power hook-up point] Air compressor with hoses and fittings, 600 cfm capacity 20 foot scaffold [Not needed if mezzanine option is included with mount] 50 foot high platform lift or bucket truck [Optional, but very useful] 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.]
______________________________________________________
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Table 2-3. Precision Tools Required for Installation Quantity 1 Each 1 Each 1 Each 1 Each 1 Each 1 Each 1 Each 1 Each
Description Machinist's level, 0.005 inch/foot graduation Wild Heerburg T2 theodolite with tribrach GV01 short focus lens for T2 theodolite GV02 short focus lens for T2 theodolite GV03 short focus lens for T2 theodolite Battery pack and light kit for T2 theodolite 90 degree eyepiece set for T2 theodolite 18 meter reflector alignment kit [Part number 479609]
______________________________________________________ Table 2-4. Installation Aids, Rigging, and Expendable Items Required Quantity 1 Each 1 Each 2 Each 2 Each 1 Each* 1 Each 1 Each 2 Each 6 Each 1 Each* 1 Each* 1 Each* 1 Each* 1 Each 1 Each 3 Each 4 Each 4 Each 4 Each 1 Each 4 Each 4 Each 4 Each 3 Each 3 Each 4 Each 2 Pair 6 Pair 12 Pair 6 Pair 1 Each 1 Box 1 Can
Description 6 foot step ladder 12 foot step ladder 50 foot extension cord Trouble light with 25 foot cord Transformer with duplex receptacle, 220 Volt to 110 Volt Q-beam spotlight, 200,000 candle-power, 120 volt 12 volt power supply for Q-beam spotlight Flashlight, 2 D cell battery type Flashlight battery, D cell 1/2 inch drive electric impact wrench 3/4 inch drive electric impact wrench 1/2 inch drive air impact wrench (if a compressor is available) 3/4 inch drive air impact wrench (if a compressor is available) Cordless 3/8 inch drive drill motor with charger 7 1/4 inch circular saw Plywood blade for circular saw 20 foot nylon sling 15 foot nylon sling 10 foot nylon sling 50 foot nylon rope (1/2 inch) Moving quilts Safety belt with 2 D-rings Safety lanyard Tool belt Bolt bag with tool holder Hard hat Safety glasses Ear plugs Cloth gloves Leather palm gloves First aid kit Garbage bags Hand Cleaner
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Table 2-4. Installation Aids, Rigging, and Expendable Items Required - continued Quantity 6 Rolls 1 Each 1 Each 1 Each
Description Toilet paper Ice Chest Water Cooler Umbrella
* Doubling the quantity of this item will enable a larger crew to install the antenna more quickly.
______________________________________________________ RECOMMENDED INSTALLATION SEQUENCY
In order to ensure proper and trouble-free installation, the following installation sequence is recommended: 1. 2. 3. 4. 5. 6. 7.
Site Preparation (contained in manual #42S182) Assembly of Lower Mount (contained in this section) Assembly of Upper Mount (contained in Section 3) Installation of Reflector (contained in Section 4) Assembly of Spars and Subreflector (contained in Section 4) Installation of Feed, Spars, and Subreflector (contained in Section 4) Electrical Installation
Appendix A provides a checklist with manual page number references. The checklist follows the recommended sequence listed above. RECOMMENDED TORQUE VALUES
The following list contains the recommended torque values for all antenna fasteners. 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 1-inch Fasteners 3/4-inch Fasteners 5/8-inch Fasteners 1/2-inch Fasteners 3/8-inch Fasteners 5/16-inch Fasteners 1/4-inch Fasteners
1100 ft-lbs (1491 Nm) 600 ft-lbs (813 Nm) 260 ft-lbs (353 Nm) 150 ft-lbs (203 Nm) 76 ft-lbs (103 Nm) 31 ft-lbs (42 Nm) 24 ft-lbs (33 Nm) 9 ft-lbs (12 Nm)
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SITE PREPARATION
Refer to 18-Meter Earth Station Antenna Site Preparation Technical Manual #42S182 for information needed to properly locate and install the foundation for the 18-Meter Earth Station Antenna.
ASSEMBLY OF LOWER MOUNT
The following procedure describes the complete assembly of the lower mount for the 18-meter antenna. The completed lower and upper mount assembly is identified in drawing 1010038. A crane will be required during the entire assembly of the 18-meter antenna. (The crane is required during the entire installation process except for the site preparation and electrical installation.)
Azimuth Bearing Ring Assembly
The platform plate is assembled on the ground and then installed on the top of the mount after the columns are erected during the frame installation procedure. Assemble the azimuth bearing ring assembly in accordance with the following procedure. 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. __________________________________________
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1.
Block up 2 piece tapped plate (item 23, P/N 483180) in 1008944) with ends 0.125 inches apart forming a hexagon (1008944 Sheet 2).
2.
Using hoist set 2 piece top plate (item 25, P/N 483182 in 1008944) in place rotating ends 60° from ends of item 23.
3.
Using hoist set 2 piece mounting plate (item 22, P/N 483181 in 1008944) in place rotating ends 60° from ends of item 25 and item 23.
4.
Secure all three layers together through bolt holes indicated in 1008944 using screws and washers (items 103 and 113). 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 1008944) to underside of azimuth bearing ring assembly using screw, two flat washers, and nut (items 102, 103 and 104 in 1008944). 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.
Leg Installation
The leg assembly must be properly aligned and installed for all assemblies to properly fit together. Install the legs and associated frame assemblies in accordance with the following procedure. WARNING __________________________________________ The following assemblies weigh from 135 lbs (61 kg) to 15355 lbs (16965 kg). Use extreme care when hoisting these assemblies into position. __________________________________________ 1.
Install one hex nut (item 100, 483184) 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, 483184) 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.
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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 22 in 1008944) should be leveled now by adjusting leg anchor nuts up or down as required.
Bottom Skin Plate Installation
The bottom skin angles, door skin angles, lower skin tees, lower door tees, lower skins, and lower door skins (items 3, 4, 5, 7, 11, and 13 in 483184) are installed prior to installation of the optional mezzanine and stairway. 1.
Attach lower skin tee (item 5, 483184) 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.
5.
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.
Remove hoist from bottom skin plate.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-21
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
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.
Middle and Top Skin Plate Installation
Installation of the middle and top skins as follows. 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, 483184) 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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-22
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
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.
Torquing Lower Mount Fasteners
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. 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).
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-23
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
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 ftlbs (813 Nm).
10. Tighten lower mount skin panels to lower skin tee fasteners to 600 ftlbs (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).
Door Assembly and Installation
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. 1.
From inside mount, place right door skin (item 14, 483184) 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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-24
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
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, 1008944) 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, 1008944), 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). ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-25
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
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.
GROUTING BASEPLATE AND SKIN PLATE TO FOUNDATION
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 2-1). 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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-26
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Hot Weather Grouting
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:
Cold 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 onsite 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: 1.
2.
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).
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: ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-27
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
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). .
Grouting Procedures
Perform the following procedure to grout base plates to foundation first. Then, grout bottom skin plates to foundation using the following procedure. 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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-28
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Figure 2-1. Location of Grouting
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-29
LOWER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 2-30
SECTION 3
1017415 Rev 001
UPPER MOUNT INSTALLATION PROCEDURES
3-1
General
3-1
Rotating Frame Installation
3-10
Azimuth Drive Installation
3-15
Elevation Drive Installation
3-20
Hub Assembly and Installation
SERIES 8118 18-METER EARTH STATION ANTENNA
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
SECTION 3 GENERAL
ROTATING FRAME INSTALLATION
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 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. Perform the following procedure to install the rotating frame. 1.
The center of the azimuth travel is 180° from the door assembled on Section 2. See 1005311, Sheet 1 and 1010038, Sheet 1. Lift the lower azimuth drive bearing spacer, Item 27, and position on top of azimuth bearing plate (Part # 483181).
2.
Secure the rotating frame assembly to the crane with (4) hoisting cables. Attach (2) equal length cables to the elevation pivot pins and (2) equal length cables to the elevation jack anchor pivot pins.
NOTE The two cables attached to the elevation jack anchor pivot pins should be approximately 4 feet (1.2 meters) longer than the two cables attached to the elevation pivot pins.
WARNING The azimuth frame assembly weight is 25,000 lbs (11,340 kg). Use extreme care when hoisting the assembly into position. 3.
Using a hoist, lift azimuth frame and position on top of the bearing spacer, item 27. Alignment and assembly rotating frame with 36 hex head bolts (item 131) and 36 flat washers (item 132). NOTE Two bolts (item 131) will be used later to install the azimuth LSR beam assembly in Section 5.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-1
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
4.
Remove hoist from rotating frame.
5.
Torque fasteners to the following values: 1 1/4-inch Fasteners
1045 ft-lbs (1416 Nm)
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-2
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Mount Assembly (Sheet 1 of 2), 1005311
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-3
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Mount Assembly (Sheet 2 of 2), 1005311
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-4
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Mount Assembly (Sheet 1 of 5), 1010038 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-5
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Mount Assembly (Sheet 2 of 5), 1010038
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-6
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Mount Assembly (Sheet 3 of 5), 1010038 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-7
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Mount Assembly (Sheet 4 of 5), 1010038
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-8
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Mount Assembly (Sheet 5 of 5), 1010038 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-9
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
AZIMUTH DRIVE INSTALLATION
The azimuth gearbox assembly 1007221 and 1007222 was preassembled to the rotating frame prior to factory shipment. The azimuth drive motors were removed for shipment and must be installed during the field installation. See 1010038, Note 6 for information on manually driving the azimuth axis with an adapter shaft and drill motor. Attach one azimuth drive motor to each gearbox with 1 key (item 13), 4 screws (item 22), 4 flat washers (item 23), 4 lock washers (item 24) and 4 nuts (item 25). Once the motors are installed, apply a bead of RTV Silicone Rubber Sealant (item 35) to the motor flange and motor mounting plate. The purpose of the RTV is to allow water to drain away from the mounting surface.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-10
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Azimuth Gearbox Assembly (Sheet 1 of 2), 1007221 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-11
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Azimuth Gearbox Assembly (Sheet 2 of 2), 1007221
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-12
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Azimuth Gearbox Assembly (Sheet 1 of 2), 1007222 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-13
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Azimuth Gearbox Assembly (Sheet 2 of 2), 1007222 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-14
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
ELEVATION DRIVE INSTALLATION
Perform the following procedure to install the elevation drive assembly. (1005311 and 1010038 contains installation information and 1007228 and 1007229 provides the elevation actuator assembly information.) 1.
Attach hoist to elevation drive assembly.
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 1010038.
3.
Secure elevation assembly to rotating frame mounting bracket with two elevation drive pivot pins (item 16) and four retaining rings (item 17).
4.
Remove hoist from elevation assembly.
NOTE Elevation jack length (Pin to Pin) @ 0° Elevation Angle = 219.5 inches. [5.57 Meters] Elevation jack length (Pin to Pin) @ 90° Elevation Angle = 55.2 inches. [1.40 Meters]
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-15
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Elevation Jack Assembly (Sheet 1 of 2), 1007228
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-16
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Elevation Jack Assembly (Sheet 2 of 2), 1007228
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-17
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Elevation Jack Assembly (Sheet 1 of 2), 1007229 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-18
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Elevation Jack Assembly (Sheet 2 of 2), 1007229 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-19
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
HUB ASSEMBLY AND INSTALLATION
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
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. 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 512015) 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 using 30 bolts (item 105), 60 washers (item 107), and 30 nuts (item 108).
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-20
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
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 512015.
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, 512015. 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, 1007229. 13. Ensure upper and outside seams are even then torque all hub assembly fasteners as follows:
Hub Installation
1-inch Fasteners
600 ft-lbs (813 Nm)
3/4-inch Fasteners
260 ft-lbs (353 Nm)
1/2-inch Fasteners
76 ft-lbs (103 Nm)
Perform the following procedure after installing the rotating frame and the elevation actuator. 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 (512015) to top of mount and attach hub elevation pivot brackets to rotating frame clevises using two pivot pins (item 14 in 105311) and four retaining rings (item 16).
NOTE One end of the elevation pivot pin has a pilot hole used for aligning the elevation resolver. Install both elevation pivot pins with the pilot hole positioned toward the inside of each pivot ear. ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-21
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
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 512015) using clevis pin (item 15 in 1005311) and two retaining rings (item 16).
4.
Pivot hub about elevation axis using drive assembly so that top of hub is horizontal.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-22
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Assembling Hub (Sheet 1 of 5), 512015B ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-23
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Assembling Hub (Sheet 2 of 5), 512015B ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-24
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Assembling Hub (Sheet 3 of 5), 512015B ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-25
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Assembling Hub (Sheet 4 of 5), 512015B ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-26
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Assembling Hub (Sheet 5 of 5), 512015B ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-27
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Installing Guardrails and Ladders
This procedure includes mounting the ladders from the foundation to the rotating frame and from the rotating frame to the hub. The ladders will be installed first, followed by the guardrails for the rotating frame.
Ladder Installation
Perform the following procedure to install the ladders for access to the rotating frame and hub per 512569. 1.
Attach two ladder hanger brackets (item 14 in 512569) 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 13) to brackets.
NOTE The 20 foot ladder 9item 13) must be removed during rotation of the azimuth axis.
Guardrails Installation
3.
Attach hub access tread plate (item 10) using four bolts (item 100), eight washers (item 101), and four nuts (item 102).
4.
Install hub access ladder (item 11) using two bolts (item 109), four washers (item 110), and two nuts (item 111).
Perform the following procedure to install the guardrails on the work platform per 1007226 and 1007227. 1.
Install left side guardrail (items 1, 2, 3, 4, 5, 6 and 8, 1007227) to rotating frame using 12 bolts (item 21), 24 washers (item 23), and 12 nuts (item 24).
2.
Install right side guardrail (item 1,2, 3,4,5,7 and 8) to rotating frame using 12 bolts (item 21), 24 washers (item 23), and 12 nuts (item 24). Install stringer angles (item 9) and two stringer angles (item 10) to vertical stanchions (item 1-9) using 20 bolts (item 30), 40 washers (item 31) and 20 Nuts (item 32).
3.
4.
Install rear guardrail (item 11) to rotating frame using four bolts (item 22), eight washers (item 23) and four nuts (item 24).
5.
Install two rear / side plates (item 12) using four bolts (item 20), eight washers (item 23) and 4 nuts (item 24).
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-28
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Miscellaneous Platform Hardware
Install the miscellaneous platform hardware in accordance with the following instructions per 512569. 1.
Attach man-hole cover (item 15) at location shown in 512569.
2.
Attach man-hole cover (item 16) at location shown in 512569.
3.
Install azimuth frame standpipe (item 17) using two bolts (item 103), four washers (item 104), and two nuts (item 105) at location shown in 512569, (2 places.).
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-29
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Optional Equipment Installation (Sheet 1 of 4), 512569C ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-30
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Optional Equipment Installation (Sheet 2 of 4), 512569C ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-31
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Optional Equipment Installation (Sheet 3 of 4), 512569C ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-32
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Optional Equipment Installation (Sheet 4 of 4), 512569C ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-33
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Hand Rail and Work Platform Installation, 1007226
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-34
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Hand Rail and Work Platform Installation (Sheet 1 of 2), 1007227 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-35
UPPER MOUNT INSTALLATION PROCEDURES ____________________________________________________________________________________________
Hand Rail and Work Platform Installation (Sheet 2 of 2), 1007227 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 3-36
SECTION 4
1017415 Rev 001
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, MOTORIZED POLARIZATION DRIVE AND FEED
4-1
General
4-1
Installation of Reflector
4-21
Installation of Spars and Subreflector
4-25
Installation of Motorized Polarization Drive
4-25
Installation of Model 8118 Feed
4-25
Installation of Feed
SERIES 8118 18-METER EARTH STATION ANTENNA
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
SECTION 4
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, MOTORIZED POLARIZATION DRIVE AND FEED
GENERAL
This section contains procedures for installing the reflector, spars, subreflector, motorized polarization drive and feed of the 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.
INSTALLATION OF REFLECTOR
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 Panel Mounting Ring and Optional LNA Enclosure
The following procedure describes the installation of the feed mounting hardware to the hub. 1.
Install 6 feed/panel mount brackets (item 3 in 512570) to hub using 12 bolts (item 13), 24 washers (item 15), and 12 nuts (item 16) as indicated in 512570.
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 512570.
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).
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-1
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE 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).
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-2
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Feed Mounting Hardware Installation, 512570C ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-3
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installation of 18M Truss Assemblies
The 18M trusses, nodes, and intercostals are assembled into a truss assembly using the following procedure. 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 513586) 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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-4
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
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. 14. Attach two intercostals #3C (item 13) from center of item 3A to bolt 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 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. 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. 18. Attach two intercostals #4C (item 16) from center of item 4A to bolt location of item 4B using one hex head bolt (item 103), two flat washers (item 104), and one hex nut (item 105) in each end. 19. Attach two intercostals #4D (item 17) from center of item 4A toward 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 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. 21. Attach two intercostals #5C (item 19) from center of item 5A to bolt location of item 4B using hex head bolt (item 100), flat washer (item 101), and hex nut (item 102) in each end.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-5
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
22. Attach two intercostals #5D (item 17) from center of item 5A toward 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 513586.
24. Install threaded rod (item 10 in 477757) 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 513586). 26. Align truss assembly to hub and secure with truss-shims (items 23 and 24 in 513586), 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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-6
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
NOTE Every sixth truss must use a spar truss (item 3) instead of the truss extension (item 2), see 513586.
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)
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-7
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installation of 18M Trusses, Nodes, and Intercostals (Sheet 1 of 6), 513586 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-8
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installation of 18M Trusses, Nodes, and Intercostals (Sheet 2 of 6), 513586 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-9
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installation of 18M Trusses, Nodes, and Intercostals (Sheet 3 of 6), 513586 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-10
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installation of 18M Trusses, Nodes, and Intercostals (Sheet 4 of 6), 513586 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-11
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installation of 18M Trusses, Nodes, and Intercostals (Sheet 5 of 6), 513586 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-12
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installation of 18M Trusses, Nodes, and Intercostals (Sheet 6 of 6), 513586 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-13
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installation of Panels
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). 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 477757 for the 18-meter antenna. 1.
Place A panel (item 1) on threaded rods at position closest to hub as shown in 477757. 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).
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-14
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
11. 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. 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 nuts (item 11). 17. 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. 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 nuts (item 11). 27. 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. 28. Repeat steps 25 through 27 for the remainder of the D panels on the fourth row. ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-15
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installing 18M Panels (Sheet 1 of 2), 477757B ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-16
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Installing 18M Panels (Sheet 2 of 2), 477757B ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-17
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Final Alignment of Panels
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. 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.) 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 480594). 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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-18
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Reflector Alignment, 479609
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-19
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Theodolite Adapter Installation Assembly, 480594 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-20
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
INSTALLATION OF SPARS AND SUBREFLECTOR
The spars and subreflector installation procedure includes assembly of spars and subreflector. 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 the 18-meter antenna (illustrated in 476807). 1.
Support subreflector (item 1 in 476807) 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. 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)
5.
Carefully, lay mounting frame (item 4) on top of subreflector back as indicated in 476807, 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 476807.
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 476807, Sheet 2.
8.
Secure mounting frame to support frame using three screws (110), six washers (item 104), and three nuts (item 106).
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-21
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
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 476807). 19. After aligning subreflector, remove alignment tool (item 9) and install domed screw (item 8). ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-22
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
18-Meter Antenna Subreflector Installation (Sheet 1 of 2), 476807C ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-23
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
18-Meter Antenna Subreflector Installation (Sheet 2 of 2), 476807C ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-24
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
INSTALLATION OF MOTORIZED POLARIZATION DRIVE
The following procedure describes the installation of the motorized polarization drive assembly to the hub. Refer to 516860 for details. 1.
Attach rotating feed mount assembly (item 2, 516860) to feed / panel mount (item 1, 512570) with 14 washers (item 101) and 14 screws (item 100) 516860.
2.
Attach drive assembly (item 1, 516860) to the LNA enclosure (item 2, 512570) with 4 washers (101), 2 screws (102) and 2 screws (103).
3.
Attach chain assembly (item 3, 516860) to drive assembly. Adjust chain tension and potentiometer sprocket per note 4, 516860.
INSTALLATION OF MODEL 8118 FEED
The following procedure describes the installation of the feed mounting hardware, the Model 8118 2-Port 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 FEED
The following procedure describes the installation of the Model 8118 2-Port Feed. 1.
Attach hoist to feed assembly and lift feed into center of hub area as indicated in 476807.
2.
Secure feed to mount using 16 screws (item 109 in 476807), 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 476807, Sheet 1.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-25
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Motorized Polarization Drive Installation (Sheet 1 of 2), 516860A ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-26
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Motorized Polarization Drive Installation (Sheet 2 of 2), 516860A ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-27
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Model 8118 Feed Installation (Sheet 1 of 2), 1010375 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-28
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
Model 8118 Feed Installation (Sheet 2 of 2), 1010375 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-29
INSTALLATION OF REFLECTOR, SPARS, SUBREFLECTOR, POLARIZATION DRIVE AND FEED ____________________________________________________________________________________________
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 4-30
SECTION 5
1017415 Rev 001
OPERATION
5-1
General
5-1
Satellite Pointing Procedure
5-1
Feed Polarization
5-2
Subreflector Adjustment
5-5
Azimuth and Elevation Resolver and Limit Switch Installation
SERIES 8118 18-METER EARTH STATION ANTENNA
OPERATION ____________________________________________________________________________________________
SECTION 5
OPERATION
GENERAL
With this elevation-over-azimuth mount, pointing the antenna is accomplished by jogging the antenna in elevation and jogging the antenna in azimuth. In normal operation, the antenna is jogged to track satellites using Model 3880 Antenna Controller or to new antenna locations using an Earth Station Controller.
SATELLITE POINTING PROCEDURE
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 3880 Antenna Controller; however, if these are not available, the following procedure is used to point the antenna at a satellite.
FEED POLARIZATION
1.
Refer to the Site Preparation manual to determine the required elevation and azimuth angles.
2.
Move antenna to the required elevation angle. 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
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: 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.
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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-1
OPERATION ____________________________________________________________________________________________
SUBREFLECTOR ADJUSTMENT
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. 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. 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 Hplane null depth).
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-2
OPERATION ____________________________________________________________________________________________
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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-3
OPERATION ____________________________________________________________________________________________
Figure 5-1. Typical Antenna Patterns for Various Subreflector Positions
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-4
OPERATION ____________________________________________________________________________________________
AZIMUTH AND ELEVATION RESOLVER AND LIMIT SWITCH INSTALLATION
See 1007230, 1007231, 1007232, 1007233, 1009751, and 1009752 for installation instructions.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-5
OPERATION ____________________________________________________________________________________________
Resolver and Limit Switch Installation, (Sheet 1 of 3) 1007230
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-6
OPERATION ____________________________________________________________________________________________
Resolver and Limit Switch Installation (Sheet 2 of 3) 1007231
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-7
OPERATION ____________________________________________________________________________________________
Resolver and Limit Switch Installation (Sheet 3 of 3, 1007231 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-8
OPERATION ____________________________________________________________________________________________
Resolver and Limit Switch Mounting Assembly, (Sheet 1 of 2, 1007232
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-9
OPERATION ____________________________________________________________________________________________
Resolver and Limit Switch Mounting Assembly, (Sheet 2 of 2) 1007233 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-10
OPERATION ____________________________________________________________________________________________
Elevation Limit Switch Assembly, (Sheet 1 of 4) 1009751
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-11
OPERATION ____________________________________________________________________________________________
Elevation Limit Switch Assembly, (Sheet 2 of 4) 1009751
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-12
OPERATION ____________________________________________________________________________________________
Elevation Limit Switch Assembly, (Sheet 3 of 4) 1009752 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-13
OPERATION ____________________________________________________________________________________________
Elevation Limit Switch Assembly, (Sheet 4 of 4) 1009752 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 5-14
SECTION 6
1017415 Rev 001
MAINTENANCE
6-1
General
6-1
Periodic Maintenance
6-5
Corrosion Protection
SERIES 8118 18-METER EARTH STATION ANTENNA
MAINTENANCE ____________________________________________________________________________________________
SECTION 6 GENERAL
MAINTENANCE The Series 18-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. CAUTION __________________________________________ The backlash and bearing preload on elevation 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. __________________________________________
PERIODIC MAINTENANCE
The suggested service intervals apply to a typical antenna installation and may vary due to environmental conditions.
Weekly 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.
Monthly Maintenance
Apply electrical power, as necessary, to azimuth axis, 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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 6-1
MAINTENANCE ____________________________________________________________________________________________
Bi-Monthly Maintenance
Perform the following procedures at least once every two months. In extreme environments (ice, snow, etc.), perform these procedures monthly. 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 spraytype 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 reducers and add Mobil SHC 634 oil, as required, to maintain a level of approximately half full.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 6-2
MAINTENANCE ____________________________________________________________________________________________
6.
Inspect elevation actuators for sufficient lubrication. 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 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 lowtemperature greases: • Shell Aeroshell #7 (ViaSat # 79054 or ViaSat # 1017767)
7.
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.
Apply Aeroshell #7 grease to all of the following grease fittings shown in Figure 6-1: Elevation Hub Blade Elevation Jack Hub Blade
8.
2 places 1 place
Apply Mobilux EP2 grease to the following grease fittings shown in Figure 6-1: Azimuth Bearing Assembly
2 places
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 6-3
MAINTENANCE ____________________________________________________________________________________________
Figure 6-1. Grease Fitting Maintenance Locations
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 6-4
MAINTENANCE ____________________________________________________________________________________________
Yearly Maintenance
CORROSION PROTECTION
Perform the following procedures at least once every year. 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 Fastner
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. 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.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 6-5
MAINTENANCE ____________________________________________________________________________________________
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 6-6
SECTION 7
1017415 Rev 001
OPTIONS
7-1
General
7-1
Feed Options
7-1
Lightning Protection
7-1
Elevation Auxiliary Drive Option
SERIES 8118 18-METER EARTH STATION ANTENNA
OPTIONS ____________________________________________________________________________________________
SECTION 7 GENERAL
OPTIONS For even greater versatility, there are several optional features for the 18-Meter Earth Station Antenna. Any or all of the following de-ice options are available: • 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.
FEED OPTIONS
The feed option available for the 18-meter antenna is a 2-port Cband feed. The assembly drawing is shown in 1007182 and 1008549. NOTE The feed specifications are subject to change without notice due to product improvements. Consult with ViaSat Inc. sales department for current specifications.
LIGHTNING PROTECTION
The optional Model 8118-LP Lightning Protection kit can be purchased from ViaSat Inc. Install the lightning protection kit in accordance with the procedures contained in 478096, 1009212 and 1009468 .
ELEVATION AUXILIARY DRIVE OPTION
Under normal antenna operation, the auxiliary drive coupling shall be separated to prevent back driving of the gear-motor. The auxiliary drive shall only be used when the antenna operating system is turned off. To engage the auxiliary drive, slide the coupling together and apply electrical power to the gear-motor. See Figure 7-1 for installation.
Notice:
Exercise care when using the auxiliary drive system. To prevent damage to the antenna, use an inclinometer or pointer device to control the position of the antenna. Do not drive the antenna into a mechanical stop or limit switches. The auxiliary drive operator must limit the elevation travel to greater than 5° and less than 85°.
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-1
OPTIONS ____________________________________________________________________________________________
2-Port C-Band Feed Assembly (Sheet 1 of 7), 1007182
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-2
OPTIONS ____________________________________________________________________________________________
2-Port C-Band Feed Assembly (Sheet 2 of 7), 1007182
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-3
OPTIONS ____________________________________________________________________________________________
2-Port C-Band Feed Assembly (Sheet 3 of 7), 1007182
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-4
OPTIONS ____________________________________________________________________________________________
2-Port C-Band Feed Assembly (Sheet 4 of 7), 1008549 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-5
OPTIONS ____________________________________________________________________________________________
2-Port C-Band Feed Assembly (Sheet 5 of 7), 1008549 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-6
OPTIONS ____________________________________________________________________________________________
2-Port C-Band Feed Assembly (Sheet 6 of 7), 1008549 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-7
OPTIONS ____________________________________________________________________________________________
2-Port C-Band Feed Assembly (Sheet 7 of 7), 1008549 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-8
OPTIONS ____________________________________________________________________________________________
Lightning Protection Kit Installation (Sheet 1 of 2), 478096 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-9
OPTIONS ____________________________________________________________________________________________
Lightning Protection Kit Installation (Sheet 2 of 2), 478096 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-10
OPTIONS ____________________________________________________________________________________________
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-11
OPTIONS ____________________________________________________________________________________________
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-12
OPTIONS ____________________________________________________________________________________________
Figure 7-1. Elevation Auxiliary Drive Installation (Sheet 1 of 3), 1016124
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-13
OPTIONS ____________________________________________________________________________________________
Figure 7-1. Elevation Auxiliary Drive Installation (Sheet 2 of 3), 1016126 ____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-14
OPTIONS ____________________________________________________________________________________________
Figure 7-1. Elevation Auxiliary Drive Installation (Sheet 3 of 3), 1016126
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-15
OPTIONS ____________________________________________________________________________________________
____________________________________________________________________________________________ 1017415 Rev 001 SERIES 8118 18-METER EARTH STATION ANTENNA 7-16
APPENDIX A
1017415 Rev 001
INSTALLATION CHECKLIST WITH MANUAL PAGE REFERENCES
SERIES 8118 18-METER EARTH STATION ANTENNA
INSTALLATION CHECKLIST WITH MANUAL PAGE REFERENCES LOWER MOUNT NOTE As fasteners are installed, tighten finger tight only, until specifically directed to torque a fastener. PAGE
CHECK _____
Set bottom tapped onto a sturdy platform which will allow access to four corner bolt holes.
2-12
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. ________________________________________________________________________ _____
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.
2-13
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. _____
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 middle and top skin plates.
2-15
_____
Loosen all nuts securing bottom skin plates to foundation. (This will allow skin plates to be pulled tight from the top down.)
2-16
_____
Torque mount fasteners in the following sequence: • 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
2-16
_____
Assemble, Transfer-drill, and install door and frame assembly.
2-17
_____
Grout baseplate and skin plates to foundation.
2-27
A-1
UPPER MOUNT 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
CHECK _____
Determine center of azimuth travel sector.
3-1
_____
Remove necessary bolts. Install pivot frame brace and drive pivot frame.
3-1
_____
Install rotating frame.
3-1
_____
Torque rotating frame fasteners.
3-1
_____
Install azimuth drive assembly.
3-9
_____
Install elevation drive assembly.
3-14
_____
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.
3-19
_____
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.
3-19
_____
Align and secure next hub segment to left side of first hub segment.
3-19
_____
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.
3-19
_____
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.
3-19
_____
Align and secure last hub segment to other two segments.
3-19
_____
Attach two elevation angle plates on each side of hub segment with elevation jack plate.
3-20
_____
Ensure upper and outside seams are even then torque all hub assembly fasteners.
3-20
_____
Lift hub assembly and attach hub elevation pivot brackets to rotating frame pivot brackets.
3-20
_____
Attach hub elevation drive bracket to elevation drive assembly.
3-20
_____
Install ladders for access to rotating frame and hub.
3-26
_____
Install guard rails on work platform.
3-26
_____
Attach covers, standpipes, and tread plate.
3-27
A-2
REFLECTOR, SPARS, SUBREFLECTOR, AND FEED INSTALLATION PAGE
CHECK _____
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
_____
Lift truss assembly and secure to hub.
4-6
_____
Assemble and install remaining truss assemblies.
4-6
_____
Align truss assemblies using theodolite.
4-7
_____
Torque fasteners to values given in manual.
4-7
_____
Install and align panels in row A.
4-15
_____
Install and align panels in row B.
4-15
_____
Install and align panels in row C making sure spare panels are in right location.
4-15
_____
Install and align panels in row D (18-meter reflector only).
4-16
_____
Perform final alignment of panels.
4-19
_____
Assemble four spars to spar fitting.
4-21
_____
Attach adjusters, support frame, and mounting frame to subreflector.
4-21
_____
Attach subreflector to spars.
4-22
_____
Lift and secure spar and subreflector assembly to reflector.
4-22
_____
Using theodolite and alignment tool, align subreflector for tilt and lateral adjustment.
4-22
_____
Install domed screw.
4-22
_____
Install motorized polarization drive.
4-25
_____
Install feed.
4-25
A-3
A-4
APPENDIX B
1017415 Rev 001
MECHNICAL ALIGNMENT SPECIFICATION AND REPORT FOR 18-METER LIMITED MOTION ANTENNA
SERIES 8118 18-METER EARTH STATION ANTENNA
REVISION REV
DATE
APPROVED
001
INITIAL RELEASE PER ECO C0-009836
1/16/04
K.EDENFIELD
002
CO-014040: Changed para. 3. leveling to +/-1 div as a goal
5/25/04
K. Edenfield
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED
CONTRACT NO.
TOLERANCES 3 PLACE DECIMAL ±.005 2 PLACE DECIMAL ±.02 1 PLACE DECIMAL ±.1 FRACTIONS ±1/16 ANGLES ±0° 30’
DWN
MAX SURFACE ROUGHNESS ALL MACHINES SURFACES 125 EXCEPT AS NOTED BREAK SHARP EDGES AND CORNERS .010 MAX
DESCRIPTION
EARL BRAGG KEITH EDENFIELD
4356 Communications Drive Norcross, Georgia 30093
1/16/04
ENGR
1/16/04
®
MECHANICAL ALIGNMENT SPECIFICATION AND REPORT FOR 13 AND 18 METER LIMITED MOTION ANTENNA
CHK
SIZE
CAGE CODE
A
1Q601
PROD
SCALE
DWG NO.
REV
1017431
002 SHEET
NONE
1 of 5
MECHANICAL ALIGNMENT SPECIFICATION AND REPORT FOR 13 AND 18 METER LIMITED MOTION ANTENNA Antenna size _________ meters.ViaSat program manager __________________________________ Customer _________________________________ 1.0
Installation location _______________________
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 (Coarse)
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._________________________________________
3.0
Date:____________________
AZIMUTH/ELEVATION AXIS ALIGNMENT (Fine)
The Elevation to Azimuth Orthogonality was set at the factory (ref. 1010038). Thus the fine setting of the azimuth and elevation axes are done in one step by leveling the Elevation axis while rotating the azimuth bearing ±90°. The level of the elevation axis should be no greater than ±1 division on Starret no. L199 level (0.0005 inch per foot) as a goal. Higher deviations may be allowed depending upon the allocation in the pointing budget. Actual Deviation___________________ The elevation drive mount has been aligned and centered with respect to the elevation clevises. ViaSat Rep._________________________________________
4.0
Date:____________________
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:____________________
ViaSat Inc. 4356 Communications Drive Norcross, GA 30093
SIZE
CAGE NO.
DWG. NO.
REV
SHEET
A
1Q601
1017431
002
2 of 5
MECHANICAL ALIGNMENT SPECIFICATION AND REPORT FOR 13 AND 18 METER LIMITED MOTION ANTENNA Antenna size _________ meters.ViaSat program manager __________________________________ Customer _________________________________ 5.0
Installation location _______________________
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._________________________________________
6.0
Date:____________________
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: 18 Meter Antenna:
69°13'12"
Peak truss tip elevation error ___________ minutes-seconds/inches. (Circle one). ViaSat Rep._________________________________________
ViaSat Inc. 4356 Communications Drive Norcross, GA 30093
Date:____________________
SIZE
CAGE NO.
DWG. NO.
REV
SHEET
A
1Q601
1017431
002
3 of 5
MECHANICAL ALIGNMENT SPECIFICATION AND REPORT FOR 13 AND 18 METER LIMITED MOTION ANTENNA Antenna size _________ meters.ViaSat program manager __________________________________ Customer _________________________________ 7.0
Installation location _______________________
PANEL CONTOUR ALIGNMENT
For the 18m: 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. For the 13.5m: Panel contour alignment has been performed according to procedure 724754-5050 (on the ground ie. 90° elevation). Reflector panel target deviation should be no greater than 0.006 inch RMS. Reflector alignment elevation angle _________ degrees. Reflector alignment deviation ________ inch RMS. ViaSat Rep._________________________________________
8.0
Date:____________________
SUBREFLECTOR ALIGNMENT
18m: 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: 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. 13m: Subreflector aligned per 724754-5050 section 4.9 ViaSat Rep._________________________________________
ViaSat Inc. 4356 Communications Drive Norcross, GA 30093
Date:____________________
SIZE
CAGE NO.
DWG. NO.
REV
SHEET
A
1Q601
1017431
002
4 of 5
MECHANICAL ALIGNMENT SPECIFICATION AND REPORT FOR 13 AND 18 METER LIMITED MOTION ANTENNA Antenna size _________ meters.ViaSat program manager __________________________________ Customer _________________________________ 9.0
Installation location _______________________
FEED HORN ALIGNMENT (18m Only)
The perpendicular distance between the top of the feed horn radome bezel and the subreflector vertex should be: 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._________________________________________
10.0
Date:____________________
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. 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. The motor to reducer interface was sealed with RTV. ViaSat Rep._________________________________________
11.0
Date:____________________
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._________________________________________
12.0
Date:____________________
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 or 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._________________________________________
ViaSat Inc. 4356 Communications Drive Norcross, GA 30093
Date:____________________
SIZE
CAGE NO.
DWG. NO.
REV
SHEET
A
1Q601
1017431
002
5 of 5
APPENDIX C
1017415 Rev 001
CONTOUR ALIGNMENT SPECIFICATION AND RECORD FOR 16 / 18 -METER ANTENNA
SERIES 8118 18-METER EARTH STATION ANTENNA
QTY
APPLICATION NEXT ASSY
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 FINISH
Form 722179 Rev B
USED ON
REV A B
REVISION DESCRIPTION REVISED AND REDRAWN PER ECR 11637 REVISED PER CO-013197
CONTRACT NO.
APPROVED D.G. FULLER K. EDENFIELD
ViaSat Inc. 4356 Communications Drive Norcross, GA 30093
DWN
H.L. HOWARD
DATE 10/12/94 4/23/2004
6/16/93
ENGR
D.G. FULLER
6/17/93
CHK
D.G. FULLER PROD
6/17/93
CONTOUR ALIGNMENT SPEC FOR 16/18-METER ANTENNAS SIZE
A APVD
SCALE
CAGE NO. DWG NO.
1Q601 NONE
479821
REV
B
SHEET
1
®
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 16 Meter Antenna
Dimension from Theodolite elevation axis to: Radius
18 Meter Antenna
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
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
355.00
143.656
67-58-07
First Tier Inside
Fourth Tier Outside Corner 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
CONTOUR ALIGNMENT SPECIFICATION AND RECORD FOR 16 AND 18 METER ANTENNA Antenna size _________ meters.
ViaSat program manager ____________________________
Customer _________________________________ Installation location _________________________________
Figure 1. Panel Contour Alignment Target Map (looking into reflector)
April 23, 2004
ViaSat
479821B, page 3
CONTOUR ALIGNMENT SPECIFICATION AND RECORD FOR 16 AND 18 METER ANTENNA Antenna size _________ meters.
ViaSat program manager ____________________________
Customer _________________________________ Installation location _________________________________ 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.
Row
6.
Panel Target Location
Equivalent arc seconds
Drill Template Arc Length
16 Meter Target Angle
18 Meter Target Angle
+0.01 inch Theodolite Ht
0.005
0.010
0.015
Target Error (inch)
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
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.
∑( ni x ε i ) RMS = N 2
Error Value
Number of Occurrences
Error Value Squared
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 =
Multiply column 2 x column 3
The total target RMS is __________ inch.
April 23, 2004
ViaSat
479821B, page 4
CONTOUR ALIGNMENT SPECIFICATION AND RECORD FOR 16 AND 18 METER ANTENNA Antenna size _________ meters.
ViaSat program manager ____________________________
Customer _________________________________ Installation location _________________________________
Target No.
16 and 18 Meter Target Final Readings Row 1
Row 2
Row 3
Row 4
Row 5
18 Meter Only Row 6
Row 7
Row 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
April 23, 2004
ViaSat
479821B, page 5
CONTOUR ALIGNMENT SPECIFICATION AND RECORD FOR 16 AND 18 METER ANTENNA Antenna size _________ meters.
ViaSat program manager ____________________________
Customer _________________________________ Installation location _________________________________ 16 and 18 Meter Target Final Readings
Target No.
Row 1
Row 2
Row 3
Row 4
Row 5
18 Meter Only Row 6
Row 7
Row 8
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
▒▒▒
50
▒▒▒
51
▒▒▒
52
▒▒▒
53
▒▒▒
54
▒▒▒
55
▒▒▒
56
▒▒▒
57
▒▒▒
58
▒▒▒
59
▒▒▒
60
▒▒▒
61
▒▒▒
62
▒▒▒
63
▒▒▒
64
▒▒▒
April 23, 2004
ViaSat
479821B, page 6
CONTOUR ALIGNMENT SPECIFICATION AND RECORD FOR 16 AND 18 METER ANTENNA Antenna size _________ meters.
ViaSat program manager ____________________________
Customer _________________________________ Installation location _________________________________ 16 and 18 Meter Target Final Readings
Target No.
Row 1
65
▒▒▒
66
▒▒▒
67
▒▒▒
68
▒▒▒
69
▒▒▒
70
▒▒▒
71
▒▒▒
72
▒▒▒
73
▒▒▒
74
▒▒▒
75
▒▒▒
76
▒▒▒
77
▒▒▒
78
▒▒▒
79
▒▒▒
80
▒▒▒
81
▒▒▒
82
▒▒▒
83
▒▒▒
84
▒▒▒
85
▒▒▒
86
▒▒▒
87
▒▒▒
88
▒▒▒
89
▒▒▒
90
▒▒▒
91
▒▒▒
92
▒▒▒
93
▒▒▒
94
▒▒▒
95
▒▒▒
96
▒▒▒
April 23, 2004
Row 2
Row 3
Row 4
ViaSat
Row 5
18 Meter Only Row 6
Row 7
Row 8
479821B, page 7
APPENDIX D
B-SIZE COPY OF DRAWINGS 1008944 483180 482182 483181 483184 1010038 1007222 1007229 512015 512569 1007227 512570 513586 477757 480594 476807 516860 1010375 1007231 1007233 1009752 1008549 478096 1009468 1016126
1017415 Rev 001
SERIES 8118 18-METER EARTH STATION ANTENNA
