Transcript
iNetVu® Drive-Away Platform Installation Manual Ka-75V/981/Ka-98(H/G/V), 987, 1201/1201-J, 1202, Ka-1202V and 1501
The iNetVu® brand and logo are registered trademarks of C-COM Satellite Systems, Inc. © Copyright 2006 C-COM Satellite Systems, Inc.
1-877-iNetVu6 www.c-comsat.com Revision 36.0 September 11, 2015
New Generation Installation Manual
Page 1 of 100
This page is intentionally left blank.
New Generation Installation Manual
Page 2 of 100
Table of Contents Chapter 1: Introduction .................................................................................................... 7 1.1 About This Manual ........................................................................................... 7 1.2 Important Safety Information ............................................................................ 7 1.3 System Overview ............................................................................................. 8 1.4 iNetVu® Antenna ............................................................................................ 10 1.5 Power Consumption....................................................................................... 14 1.5.1 7000 Series Controller ............................................................................... 14 1.5.2 7710 Controller Compatible with 7720 (RDM) ............................................ 14 1.6 iNetVu® Controllers ........................................................................................ 15 Chapter 2: iNetVu® Drive-Away General Specifications ................................................. 16 2.1 Mounting Surface ........................................................................................... 16 2.2 Roof Clearance .............................................................................................. 16 2.3 Weight Support .............................................................................................. 16 2.4 Additional Considerations .............................................................................. 16 Chapter 3: iNetVu® Drive-Away System Installation ...................................................... 17 3.1 General .......................................................................................................... 17 3.2 Recommended Tools ..................................................................................... 18 Installation Overview .................................................................................................. 19 3.3 Platform (All Drive-Away) Front / Back Orientation ......................................... 20 3.4 Direct Installation onto Vehicle ....................................................................... 21 3.4.1 Platform Clearance Requirements ............................................................. 22 3.5 Alternative Installation to Vehicle Using Thule® Racking System................... 38 3.6 iNetVu® Drive-Away System Wiring ............................................................... 39 Chapter 4: Additional Assemblies & Adjustments .......................................................... 41 4.1 Installing iNetVu® Reflector to 1201/1201-J/1202 & Ka-1202V ...................... 41 4.2 Ka-75V Surfbeam TRIA Installation ............................................................... 44 4.3 Ka-75V Feed Location Adjustment ................................................................. 46 4.4 Ka-75V ETRIA Installation ............................................................................. 48 4.5 Adjusting 981/Ka-98(H/G/V) Feed Horn ABCD Dimensions ........................... 53 4.6 Ka-1202V ETRIA Installation & ABCD Adjustment ......................................... 56 4.7 Stow Adjustment on iNetVu® Ka-75V/981/Ka-98(H/G/V) ................................ 59 4.8 A0985A-1 (Ka-98H Transceiver) RHCP and LHCP Configuration .................. 64 4.9 A0985A-2 (Ka-98G Transceiver) RHCP and LHCP Configuration.................. 67 4.10 EL Stow Switch Adjustment on Ka-75/Ka-98(H/G) Beta Only ........................ 69 4.11 Installing BUC to iNetVu® 1201 Drive-Away using Universal Bracket Kit ........ 71 4.12 Installing BUC Using Universal Mounting Clamp Kit....................................... 73 4.13 Installing/Routing Flexible Waveguide on iNetVu® 981 Drive-Away Platform . 80 4.13.1 Version 2.1 or older .................................................................................... 80 4.13.2 Version 3.0 or Newer ................................................................................. 82 Appendix 1: Default Limits and Configuration Data Tables ............................................ 83 Appendix 2: Platform ABCD Dimensions ....................................................................... 84 Appendix 3: Manual/Emergency Movement .................................................................. 87 Appendix 4: Pod Installation on 120 cm and 98 cm platforms ........................................ 90 Installation of POD on 1201&1202 Platforms ............................................................. 90 Installation of POD on 981 Series Platform ................................................................ 96 Appendix 5: Declaration of Conformity ........................................................................ 100
New Generation Installation Manual
Page 3 of 100
Proprietary Notice: This document contains information that is proprietary and confidential to C-COM Satellite Systems, Inc., and is intended for internal and or C-COM Satellite Systems Inc. partners use only. No part of this document may be copied or reproduced in any way, without prior written permission of C-COM Satellite Systems, Inc.
Copyright © 2006. All rights reserved. C-COM Satellite Systems Inc. This document contains information, which is protected by copyright. All rights reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as followed under the copyright laws. Both the iNetVu® and C-COM names and logos are registered trademarks of C-COM Satellite Systems Inc. Intel® Pentium is a registered trademark of Intel Corporation. Microsoft, Windows, Windows NT and MapPoint are registered trademarks of Microsoft Corporation. All other product names mentioned in this manual may be trademarks or registered trademarks of their respective companies and are the sole property of their respective manufacturers.
New Generation Installation Manual
Page 4 of 100
FCC and INDUSTRY CANADA INFORMATION TO THE USER: The FCC and Industry Canada have imposed the following conditions when operating, installing and deploying iNetVu® Drive-Away Earth Stations and is mandatory for all installations made within the Continental United States and Canada as well as Hawaii, Alaska, Puerto Rico, the U.S. Virgin Islands and other U.S. Territories. The FCC requires that a certified installer perform the installation. It is also strongly recommended that a qualified professional RV dealer/installer mount the system on your vehicle. These conditions are also required by C-COM for all other installed locations. All iNetVu® Drive-Away earth station installers must be C-COM Certified, and must have specifically acknowledged the requirements for iNetVu® Drive-Away installations, which are as follows: 1. “Installation” is the physical mounting and wiring of the Satellite provider’s earth station on a vehicle or other stationary site in order to prepare for correct operation. Only Certified C-COM iNetVu installers may perform the installation and removal of an iNetVu® Drive-Away system. 2. “Deployment” means the raising, pointing and orienting of the earth station to the communicating satellite, every time it is raised from a stowed position for use. The deployment of an iNetVu® Drive-Away system must only be done by a trained installer or by a consumer using the deployment software. 3. Installers shall install the iNetVu® systems only in locations that are not readily accessible to children and in a manner that prevents human exposure to potential radiation hazards. 4. For large vehicles with roof mounts, the height of the bottom lip of the earth station when fully deployed must be at least six feet above the ground at all times, or six feet above a surrounding surface which a person may easily access. 5. If a roof access ladder or any other means of access to the roof is installed on the vehicle, then the ladder or access must be blocked by a suitable rope or other barrier while the earth station is deployed or in operation. The installer must provide this rope or barrier directly to the end user at the time of installation and advise the user to use it at all times when the earth station is deployed or in operation. Warning signs shall also be provided by the installer to the end user to be posted on the rope or other barrier warning all persons not to attempt to access the roof of the vehicle while the earth station is deployed or in operation. 6. Warning signs shall be posted at prominent locations on the earth station informing all persons of the danger of harmful radiation from the earth station while it is deployed or while in operation. 7. The iNetVu® Drive-Away system may only be operated when the vehicle is stationary. 8. The installer must inform the end user that the vehicle must be stabilized during the transmission, to prevent movement of the vehicle for any reason, including movement of persons on or off the vehicle, or high winds. The installer shall advise the end user how to appropriately stabilize their vehicle. 9. Installers shall be liable for all damages if they fail to comply with the above mandatory conditions. This includes, but is not limited to damages caused by improper installation or due to the failure to provide required information to the end user. 10. Installers and end users will be deemed directly liable for any damages resulting from either of their failure to comply with the above rules. These rules are meant to ensure that extraordinary precautions and measures are used to prevent New Generation Installation Manual
Page 5 of 100
satellite interference or exposure to harmful radiation. C-COM reserves the rights to immediately suspend without liability or previous notice the operation of the earth station upon detection of a deviation from its installation or operational requirements until the deviation is corrected. In addition, C-COM reserves the right to suspend or cancel the Installer Certificate of any installer that has not fully complied with these installation requirements. 11. Further, the installer and end user may be directly liable for any damages resulting from any change undertaken by either of them. Including but not limited to, any modification of any part of the hardware, software, specific operational frequencies, the authorized satellite, or the size or other characteristics of the earth station supplied to them by C-COM or C-COM’s authorized representatives. Note 1: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with this instruction manual, may cause harmful interference with radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio / TV technician for help. Note 2: This Class B digital apparatus complies with Canadian ICES-003.
New Generation Installation Manual
Page 6 of 100
Chapter 1: Introduction 1.1 About This Manual This manual explains the iNetVu® Drive-Away System Installation and General Assembly. An electronic version of this manual is included on the iNetVu® USB flash drive that came with your system.
1.2 Important Safety Information For your safety and protection, read this entire manual before attempting to install or use the iNetVu® Drive-Away System. Keep this manual where you can refer to it if necessary. Types of Warnings Used in This Manual This section introduces the various types of warnings used in this manual to alert you to possible safety hazards.
Indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury.
Indicates a situation or practice that might result in property or equipment damage.
New Generation Installation Manual
Page 7 of 100
1.3 System Overview
The iNetVu® Drive-Away Satellite Internet system is an automatic scanner, polarizer and beam positioning system for a foldable two-way satellite antenna. It has been designed to automatically find and acquire the satellite beam and the position based on both a GPS position reading as well as other positioning parameters. It is targeted for mobile users worldwide who require broadband Internet access in large continuous coverage areas, including remote locations where DSL and Cable and other Internet services do not exist. It provides two-way, high-speed data communications over satellite. iNetVu® empowers mobile users with the ability to stop anywhere there is Satellite coverage and access Internet at broadband speeds. This Manual covers and includes the following mount types:
A0755A-3 (Ka-75V) ----------Viasat SurfBeam, Transceiver, 2 Axis A0755A-5 (Ka-75V) ----------Viasat ETRIA Transceiver, 2 Axis **A0985A-1 (Ka-98H) ----------HNS Transceiver, 2 Axis (Spaceway Radio) **A0985A-2 (Ka-98G) ----------Skyware Global Transceiver, 2 Axis **A0985A-3 (Ka-98V) ----------Viasat SurfBeam Transceiver, 2 Axis **A0985A-4 (Ka-98H) ----------HNS Transceiver, 2 Axis (Jupiter Radio) **A0985A-5 (Ka-98V) ----------Viasat Etria Transceiver, 2 Axis **A0985B-1 (Ka-98H) ----------HNS Transceiver, 3 Axis (Spaceway Radio) **A0985B-2 (Ka-98G) ----------Skyware Global Transceiver, 3 Axis A0981A (981) ---------------Ku Band **A0987A-1 (Ka ) ---------------HNS Transceiver, SMC Refl, 2 Axis (Spaceway Radio) A1201A (1201) --------------Ku Band
** The dash and number after the letter is dropped when selecting the mount type in the iNetVu software, i.e. A0985A-1 becomes A0985A and so on. Refer to iNetVu Controller User Manual. Systems that are equipped with 7710/7720 Controller and Remote Drive Module (7720):
A0985B-2 Ver.10.0 (Ka-98G) ----------Skyware Global Transceiver, 3 Axis A0987A-1 Ver.10.0 (Ka-98H) ----HNS Transceiver, SMC Refl, 2 Axis (Spaceway Radio) A0987B-4 Ver.10.0 (Ka-98H) ----HNS Transceiver, SMC Refl, 3 Axis (Jupiter Radio) A1201A Ver.10.0 (1201-J) --------Ku Band, 3 Axis, X-Pol (Not convertible) A1205A-5 (Ka-1202V) ---------Viasat Etria Transceiver, 2 Axis ***A1205C (1202) ----------------Ku Band, 3 Axis, X-Pol A1505C (1501) ----------------Ku Band, 3 Axis, X-Pol A1805C (1801) ----------------Ku Band, 3 Axis, X-Pol A1805D (1801) ----------------2 Axis, C Band, Circular A1805E (1801) ----------------2 Axis, C Band, Linear
***Convertible to Ka Band
New Generation Installation Manual
Page 8 of 100
The Drive-Away system offers the following additional capabilities and features:
Some Drive-Away platforms are integrated to work with the 7710 Controller. These systems have a very low backlash and refined sensors to ensure a high level of pointing accuracy and optimized speed control
The 7000 series controller continues to provide reliability and high precision antenna pointing with its integration
The New Generation Drive-Away Platform feature both a 2&3-axis DC motor drive system
All power transmission components are high strength, low backlash gear motors and maintenance free. Housed and coupled with high strength, zero backlash timing belts, which result in a rigid, highly reliable system with the minimum weight and maximum accuracy
New A0987A (Ka-98H) platform is equipped with an SMC reflector that has an offset, prime focus, SMC high strength plastic illuminated by a corrugated horn
Satellite acquisition and lock in less than 5 minutes (under normal circumstances)
Satellite independent – compatible with any configured satellite
Dish pointing is automatic and fully software controlled
Optimized signal reception and transmission
Fast re-acquisition based on last good position
Interfaces with a full-function controller with features such as automatic stowing, GPS and flux-gate compass and automatic satellite pointing
Reliable acquiring, minimal maintenance
Self-calibrating and tuning after satellite acquisition
New Generation Installation Manual
Page 9 of 100
1.4 iNetVu® Antenna The iNetVu® Ka-75V Antenna is an elliptical 75 cm two-way Ka-Band satellite dish mounted over an arm that supports the antenna plus the Radio Transmitter (Tria). The remaining iNetVu® 981 (98 cm), Ka-98H/G/V (98 cm), 1201/1201-J and 1202 (120 cm), 1501 (150 cm) and 1801(180 cm) Antennas are a circular two-way Ka or Ku-Band satellite dish mounted over an arm that supports the antenna, Radio Transmitter and Low Noise Block (LNB). Some iNetVu antennas are compatible only with the 7710 controller and 7720 Remote Drive Module. Check supported mounts list.
Ka-75V Drive-Away
***Ka-98H Drive-Away
Fig. 1:
Ka-75V and Ka-98H (Ka Band) Antennas
Note1: Elevation Stow sensor is no longer on the elevation stow plate. *** The 98 cm Antennas will look the same for all of the different model types (Ka-98H/G/V) with the exception of the TRIA type and or the Feedboom.
New Generation Installation Manual
Page 10 of 100
981 Drive-Away
Fig. 2:
981 Drive-Away (with optional pod)
981 Ku Band Antenna
1201 Drive-Away (with optional pod)
Fig. 3:
1201 Ku Band Antenna
New Generation Installation Manual
Page 11 of 100
Ka-1202V Drive-Away
Ka-1202V Drive-Away Stowed with pod option
Fig. 4: Ka-1202V Band Antenna
New Generation Installation Manual
Page 12 of 100
1501 Drive-Away
Fig. 5: 1501 Ku Band Antenna equipped with redundant 100W BUCS
New Generation Installation Manual
Page 13 of 100
1.5 Power Consumption 1.5.1 7000 Series Controller Minimum Power Consumption: Maximum Power Consumption: Controller AC Universal Input:
10W (when system is idle. i.e. Controller with possible LNB powered). 24 @ 9A = 216W 90 ~ 264 VAC, 47 ~ 63 Hz
1.5.2 7710 Controller Compatible with 7720 (RDM) RDM = Remote Drive Module Power Consumption (Idle): Maximum Power Consumption: Universal AC Input:
New Generation Installation Manual
24 VDC @ 1A 24 VDC @ 15A (Max.) = 360W 100 – 240 VAC, 50/60 Hz, 4.0 – 2.0 A
Page 14 of 100
1.6 iNetVu® Controllers The iNetVu® Antenna Controllers have been designed to automate the operation of Drive-Away systems. Key Features: Movement on 2 or 3 axis simultaneously improving satellite acquisition speed with a high level of accuracy (7710 Controllers integrated with 7720 equipped platforms) Automatic azimuth, polarization, and elevation pointing calculation GPS receiver for determining antenna latitude and longitude coordinates 24 VDC input, allows powering of controller from an external power source (see Appendix in Controller User Manual for External Cable Connectivity). Fluxgate compass for determining orientation/direction of iNetVu® Drive-Away Platform Non-volatile, flash memory for storing satellite locations and configuration data Automatic dish repositioning to previously accessed satellites (if the vehicle or structures location is unchanged) Slim, 1U high rack or desktop mounted unit Continuous monitoring of antenna drive status RS-232 remote control serial interface USB interface Network interface L-Band RF detector to support Ku and Ka satellite operations
See the Controller User Manual for more details.
New Generation Installation Manual
Page 15 of 100
Chapter 2: iNetVu® Drive-Away General Specifications 2.1 Mounting Surface
The mounting surface must be flat within 1/16” (1.6mm) A 1½” (38mm) diameter hole is needed near the mounting surface for routing of the control and signal cables.
2.2 Roof Clearance All iNetVu® systems require a specific unobstructed clearance from any other roofmounted equipment such as air conditioners, air vents, etc. See section 3.5 for geometrical coordinates.
2.3 Weight Support All iNetVu® Drive-Away systems are capable of being mounted to a vehicle that can support the following constraints. See datasheets for more up to date specs.
iNetVu® iNetVu® iNetVu® iNetVu® iNetVu®
iNetVu® iNetVu® iNetVu® iNetVu® iNetVu®
A0755A (Ka-75V) – 115 lbs. (52.0 kg) A0981A (981) – with pod 139 lbs. (63 kg) /without pod 124 lbs. A0985A-1,/-2,/-3 (Ka-98H/G/V) – with pod 139 lbs. (63 kg) /without pod 124 lbs. A0985B-2 (Ka-98G) – with pod 139 lbs. (63 kg) /without pod 124 lbs. A0987B-4 (Ka-98H(Jupiter Radio))- with pod 139 lbs. (63 kg) /without pod 124 lbs. A1201A (1201/1201-J) with pod 342 lbs. (88 kg) /without pod 180 lbs. A1205A (Ka-1202V) with pod – 193 lbs. (88 kg) /without pod 180 lbs. A1205C (1202) with pod 193 lbs. (88 kg) /without pod 180 lbs. A1505C (1501) 185 lbs. (84 kg). A1805C (1801) 358 lbs. (162 kg).
2.4 Additional Considerations A clear unobstructed view of the southern sky is required for reliable satellite communication for users in the Northern Hemisphere. Vice versa (northern sky) for those in the Southern Hemisphere. Note: Always re-apply threadlocker on fasteners when reinstalling covers, components or accessories that were removed for maintenance, repairing and or troubleshooting. New Generation Installation Manual
Page 16 of 100
Chapter 3: iNetVu® Drive-Away System Installation
THE iNetVu® DRIVE-AWAY PLATFORM SHOULD NEVER BE OPERATED WITHOUT ITS CONTROLLER AND SHOULD NEVER BE CONNECTED DIRECTLY TO A BATTERY. DOING SO WILL VOID THE WARRANTY ON BOTH THE CONTROLLER AND THE PLATFORM AND THE CUSTOMER WILL BE CHARGED FOR REPAIR AND REPLACEMENT COSTS RELATING TO THE DAMAGE. THE POWER TO OPERATE THE DRIVE-AWAY PLATFORM SHOULD ALWAYS BE CONNECTED TO THE CONTROLLER VIA ITS APPROPRIATE POWER CABLE, WHICH IS FUSED. POWER SHOULD NEVER BE APPLIED DIRECTLY TO THE PLATFORM TO RAISE OR LOWER IT WITHOUT THE USE OF THE CONTROLLER. ALWAYS CONNECT THE CABLES (MOTOR, SENSOR AND COAXIAL) TO THE CONTROLLER PRIOR TO POWERING IT ON. NOT FOLLOWING THESE INSTRUCTIONS WILL SEVERELY DAMAGE THE PLATFORM AND WILL ALSO DAMAGE THE CONTROLLER ONCE IT IS ATTACHED TO THE PLATFORM THAT HAS BEEN SUBJECTED TO DIRECT BATTERY OPERATION WITHOUT THE USE OF THE CONTROLLER.
3.1 General All iNetVu® Drive-Away Systems have been fully tested with the iNetVu ® Controller prior to shipment. All position feedback; limit sensing, limit switches and motor speeds have been calibrated and preset prior to shipping. The wave-guide, the boom mounted Radio Transmitter cables and the Transmission/Receive coaxial cables have all been pre-wired. There is no need to re-calibrate the Drive-Away Platform unless directed by a C-COM Support Technician. It is critical that the iNetVu® Controller stay together with the Drive-Away Platform it shipped with. You may refer to the iNetVu® Shipping Checklist to confirm this. The iNetVu® Drive-Away System has been designed for either roof rack mounting or mounting directly to a vehicle. The iNetVu ® Drive-Away Platform should always be secured to the vehicle. Ensure that the inverter is grounded the same as the iNetVuTM controller chassis.
New Generation Installation Manual
Page 17 of 100
3.2 Recommended Tools The following tools are recommended to have handy during the installation and operation of the iNetVuTM Drive-Away System.
RG6 (coax) Cable Stripper and Crimping tool Wrenches – 3/4, 5/8, 9/16, 1/2, 7/16, 3/8, 5/16 (all Qty 1 except 2 for 1/2) 1/2 Ratchet with 3/4, 5/8, 9/16, 1/2, 7/16, 3/8, 5/16 sockets Allen Key Set. Both Standard and Metric. Phillips Screwdrivers. Assorted set Flat Screwdrivers. Assorted set Ball peen hammer Plastic hammer Pin drift punches. Assorted sizes Grease gun WD 40 7024B/C iNetVu Controller iNetVu 7710 & 7720 Controllers on supported mount types Satellite Recognition Device (i.e. Spectrum Analyzer, etc.) Emery cloth (Sandpaper for metal) Utility Knife Pliers Side cutters Vice grips Hacksaw
New Generation Installation Manual
Page 18 of 100
Installation Overview 1. Unpack the Drive-Away Platform and reflector (Ka-75V/Ka-98(H/G/V) and 981 arrive with the reflector already installed) 2. Attach reflector to iNetVu® 1201/1201-J, 1202, Ka-1202V, 1501 or 1801 Drive-Away Platform(s). (See section 4.1 for more details). 3. Locate a suitable mounting site with adequate clearance. The correct installation must use the three (3) mounting points on the base that are specified in the CAD drawings in Section 3.5.1. Note: If using Roof Racks, ensure correct rack structure is used with platform installation to accommodate for the three mounting points on the base structure. 4. Installation Using Structural Mounting Surface: (See section 3.5 for complete and detailed steps) a. Mark the position of the Drive-Away Platform ensuring the front / back orientation is correct. Note mounting points of base. b. Pre-seal the roof or mounting surface. c. Place the Drive-Away Platform in position. d. Drill pilot holes if necessary and secure with screws. Note that the dish may obscure some of the mounting holes. e. Install the corner screws. f. Raise the dish either via Handheld Controller or iNetVu® Mobile software. g. Attach Drive-Away Platform to roof structural mounting surface. h. Run Power, Motor Control, Coaxial, Sensor cables. 5. For Thule Rack Installation: (See section 3.6 for complete and detailed steps) a. Attach Drive-Away Platform to Thule Rack. b. Ensure the three (3) mounting points are used with the rack installation. It is recommended to use minimum 3 railing bars or alternative method that will ensure the three mounting points on the base are utilized. c. Run Power, Motor Control, Coaxial, Sensor cables. d. Connect iNetVu® Controller, Satellite Modem, PC and Drive-Away Platform. e. Install iNetVu® Mobile Software. f. Configure to correct service and operate (see Service User Manual for more detail)
New Generation Installation Manual
Page 19 of 100
3.3
Platform (All Drive-Away) Front / Back Orientation The iNetVu® Drive-Away Platform should be mounted so that the Reflector faces the rear of the vehicle on which it is mounted when antenna is deployed. Failure to adhere to these requirements could cause the Drive-Away Platform to detach from the vehicle at high speed.
This end faces the FRONT of the Vehicle
This end faces the REAR of the Vehicle
Fig. 6: Front / Back orientation of iNetVu® 1201 Platform with Optional Pod
This end faces the FRONT of the Vehicle This end faces the REAR of the Vehicle
Fig. 7: Front / Back orientation of iNetVu® Ka-75V/Ka-98(H/G/V)/Ku-981 Platform
New Generation Installation Manual
Page 20 of 100
3.4 Direct Installation onto Vehicle 1. Remove the top and sides of shipping crate. 2. Remove any internal bracing and all packaged parts. 3. Remove the screws attaching the iNetVu Drive-Away System to the bottom of crate and remove the iNetVu® Drive-Away System from its shipping base. Note that iNetVu® system is shipped pre-assembled. The iNetVu system is an extremely heavy load and must therefore be handled correctly and with care. If it is NOT handled correctly, a potentially hazardous situation can arise that could result in death or serious injury. The Roofing must be assessed and capable of handling the load prior to installation. 4. With the aid of at least four people or a lifting mechanism, raise and position the system on the roof. The system must be handled and supported at both ends. Under no circumstances should one person attempt this alone. 5. The 981,1201, and 1202 systems come in two (2) different base configurations: a. Pod with steel base b. No Pod with steel base Note: Ensure that the front/back orientation of the Drive-Away Platform is correct. 6. Maneuver the Drive-Away Platform over the mounting position on the vehicle and verify that the proper clearance space is available. Visually check that the dish arm will not hit any other mounted equipment or other devices such as air conditioner during movement rotation. 7. Mount the Drive-Away platform in position using the three (3 on each side) mounting points on the base frame. See the following figures for Roof Clearance Requirements and Platform Mounting points:
New Generation Installation Manual
Page 21 of 100
3.4.1 Platform Clearance Requirements Ka-75V – 75 cm Ka Band – Circular Platform
Fig. 8: Clearance requirements for the iNetVu® Ka-75V Drive-Away Platform
New Generation Installation Manual
Page 22 of 100
981 – 98 cm Ku Band Platform
Fig. 9: Clearance requirements for the iNetVu® 981 Drive-Away Platform
New Generation Installation Manual
Page 23 of 100
981 Version 3.0+ – 98 cm Ku Band Platform (High Capacity Feed)
With Pod
________________________________________ Without Pod
Fig. 10: Clearance requirements for the iNetVu® 981 Version 3.0+ Drive-Away Platform with Pod option
New Generation Installation Manual
Page 24 of 100
Ka-98G (SKYWARE) & Ka-98V (Viasat) – 98cm Ka Band - Circular (98G shown)
Fig. 11: Clearance requirements for the iNetVu® Ka-98G Drive-Away Platform
New Generation Installation Manual
Page 25 of 100
Fig. 12:
Radius Clearance requirement for the iNetVu® Ka-98G Drive-Away Platform
Fig. 13:
Radius Clearance requirement for the iNetVu® Ka-98V Drive-Away Platform
New Generation Installation Manual
Page 26 of 100
Ka-98H (HNS) – 98 cm Ka Band - Circular
Fig. 14: Clearance requirements for the iNetVu® Ka-98H Drive-Away Platform
New Generation Installation Manual
Page 27 of 100
1201/1202 – 120 cm Ku Band
Without Pod
With Pod
Fig. 15: Clearance requirements for the iNetVu® 1201/1202 Drive-Away Platform
New Generation Installation Manual
Page 28 of 100
Ka-1202V – 120 cm Ka Band
Fig. 16: Clearance requirements for the iNetVu® Ka-1202V Drive-Away Platform
New Generation Installation Manual
Page 29 of 100
1501 – 150 cm Ku Band
New Generation Installation Manual
Page 30 of 100
8. Slide the Drive-Away Platform over to the center of the roof/roof mounting structure; using a tape measure locate center. 9. Mark a “foot print” or outline of the Drive-Away Platform’s base onto the vehicle’s roof using chalk or non-permanent marker. Metal base may look different than the one in Fig 3, Fig 4 or Fig 5:
Fig. 17: Marked outline of an iNetVu® Drive-Away Platform
10. Verify that the roof is flat within 1/16” (1.6mm). Note: If the roof surface is not flat within 1/16” (1.6mm), apply a thin layer of structural epoxy grout between the base and vehicle surface. Snug the bolts finger tight and allow epoxy to cure before the final torque-down. 11. Drill the appropriate sized pilot holes for the roof type (if required) Fiberglass: Required. Regular (non-self-tapping) stainless steel screws. Rubber-covered metal: Not required. Self-tapping, stainless steel screws Aluminum: Not required. Self-tapping, stainless steel screws. If pilot holes are required, the dimensions on the following CAD drawing can be utilized. The hole sizes shown are the Drive-Away Platform (clearance) holes. The holes to be drilled for self-tapping screws will require a smaller diameter. Ensure the roof top is capable of handling the iNetVu System load, prior to installation. CCOM Satellite Systems Inc. does not hold responsibility to any damage caused by direct roof installations.
New Generation Installation Manual
Page 31 of 100
iNetVuTM Ka-75V Drive-Away Platform
Fig. 18: iNetVu® Ka-75V Drive-Away Platform CAD Drawing
iNetVuTM Ka-98G & Ka-98H Drive-Away Platform
Ka-98G Skyware Global
Ka-98H HNS
Fig. 19: iNetVu® 98G/H (SKYWARE & HNS) Drive-Away Platform CAD Drawing
New Generation Installation Manual
Page 32 of 100
iNetVuTM 1201/1201-J/1202 & Ka-1202V Drive-Away Platform
Note: The 1501 will use same mounting points as illustrated here.
Fig. 20: iNetVu® 1201/1201-J & Ka-1202V Drive-Away Platform CAD Drawing
New Generation Installation Manual
Page 33 of 100
12. Verify the location of the Drive-Away platform and drill the appropriate number of mounting holes for installation. The holes may be used for stabilizing the unit on the roof top.
Fig. 21: Drilling the pilot holes and caulking the mounting holes on the roof
13. Remove the Drive-Away platform from the roof and caulk the mounting holes. 14. Ensuring the proper front/back orientation of the Drive-Away platform, lower the iNetVu® system back over the pilot holes. 15. Insert the mounting bolts and torque them to 9-10 ft. lbs.
Fig. 22: Torque-down the mounting screws
16. Apply a small quantity of good quality caulk to the bolt heads.
New Generation Installation Manual
Page 34 of 100
17. There are two equivalent methods for running the cables and wiring into your vehicle:
Using the refrigerator ventilation opening (if large enough) If the refrigerator ventilation opening is used, take care not to block the vent and to keep the cables away from any hot surfaces.
Drilling an opening on the roof. Steps 17 – 21 describe this method.
18. Drill a 1½” (38.1mm) diameter opening and run the Motor Control Cable, Sensor Cable, GPS wire, TX and RX coaxial cables from the roof into the vehicle leaving AMP plugs on the outside. Running the cables from the roof in this manner will minimize the size of the hole that will need to be drilled.
Fig. 23: A plastic sleeve used to prevent the cables from chaffing
19. Use a plastic sleeve to prevent cables from chaffing in the event of the opening having rough edges. 20. Bundle the cables together neatly and use “P-clamps” to attach the cable assembly to the roof. The GPS antenna should be located in an open area with an unobstructed radius where it can “see" the GPS satellite constellation. To attach to the roof, the GPS antenna utilizes a magnetic fixing. If mounting on a fiberglass, wood or rubber coated roof, cut a 1/16” (1.6mm) thick mild steel sheet approximately 3” (76.2mm) x 3” (76.2mm) and drill four holes in the corners as shown in the figure below. To prevent rusting, this steel mounting plate must be first painted with a good quality rust proofing paint. It is highly recommended to use a bead of silicone around the complete circumference of the antenna.
New Generation Installation Manual
Page 35 of 100
Fig. 24: GPS antenna plate for the magnetic mounting
21. Apply caulking to prevent moisture from entering the opening.
Fig. 25: Completed roof wiring entry point
22. Install a standard 100A electrical service entry fitting (a clamshell fitting intended for residential 115 / 230VAC electrical hook-up to a city supply is recommended) over the cable entry point. Ensure that the clamshell fitting is positioned so that the cable entry point faces the rear of the vehicle. This will minimize the effects of wind driven rain. Apply a bead of caulk around the opening to seal the roof entry point.
New Generation Installation Manual
Page 36 of 100
Fig. 26: Weather proofing the cable entry point with a “clamshell” fitting
Note: Clamshell fitting is not sold with any C-COM iNetVu® products and is merely a recommended method of waterproofing the roof top cable entry point. 23. Run the cables neatly inside the vehicle to the iNetVu® Controller. System wiring is described later in a later section. 24. Congratulations! Direct installation has been successfully completed.
New Generation Installation Manual
Page 37 of 100
3.5 Alternative Installation to Vehicle Using Thule® Racking System For pallet mounting, the vehicle must be fitted with Thule® components that are matched to customer’s specific vehicle. The cables are fed through a specially drilled hole and clamped in a special foam grommet in order to prevent chaffing of the cables. (Note: The Thule feet and connection to vehicle must be checked regularly for a secure fit with no loose fittings). Note that 3 Thule bars, minimum are required to accommodate the three mounting points on the base. If using alternative rack method, ensure the three mounting mounts are accounted for during the planning and mounting stages. 1. Remove the top and sides of the shipping crate. 2. Remove any internal bracing and all packaged parts. The iNetVu system is an extreme load and must therefore be handled correctly and with care. If it is NOT handled correctly, it could cause a potentially hazardous situation that could result in death or serious injury. 3. Remove the bolts attaching the iNetVu® system to the bottom of the shipping crate and remove the iNetVu® system. Note that the iNetVu® is shipped pre-assembled on a base frame weldment (Base). 4. Install Thule components to vehicle. Note: The iNetVu® system is oriented with back of the reflector facing the front of vehicle. With least four people, raise and position the system on the installed Thule rack. Under no circumstances should one person attempt this alone. 5. Align mounting angles and sides of pallet and secure with at least 6 “U” brackets – not included with the iNetVu® Drive-Away Systems (a minimum of 2 per bar). 6. Run the cables neatly inside the vehicle to the iNetVu® Controller. Connection to the iNetVu® Controller can be found and referred to in the Controller Manuals. 7. Congratulations! Installation has been successfully completed.
New Generation Installation Manual
Page 38 of 100
3.6 iNetVu® Drive-Away System Wiring
If this is the first time working with the iNetVu® Drive-Away Platform it is highly recommended that you read the entire manual to get familiarized with the proper procedure for connecting the cables to the controller and iNetVu® software operation.
The System wiring varies upon the type of controller and modem used. See the iNetVuTM Controller or Vsat Service Manual for a detailed system-wiring diagram and explanation. Military Style Connectors
Fig. 27: From left to right: Sensor Cable, Motor Control Cable, RX and TX RG6 Coaxial Cables
New Generation Installation Manual
Page 39 of 100
1. Connect cables (Motor, Sensor and RX/TX) to back of controller and to the platform prior to powering on. Note: If a 90˚ elbow connector is required when connecting the coax cable to the LNB; ensure the RX Bend is down in the same direction as the rigid waveguide. Failing to properly install the 90˚ elbow will cause damaged to the LNB and or cable.
Rigid Waveguide
90º Elbow
New Generation Installation Manual
Page 40 of 100
Chapter 4: Additional Assemblies & Adjustments 4.1 Installing iNetVu® Reflector to 1201/1201-J/1202 & Ka-1202V Required Materials:
120 cm Reflector 1201/1201-J, 1202 or Ka-1202V Drive-Away Platform Rev. 1.0+ Reflector Assembly Hardware Bag Allen Key Set Miscellaneous Tools 14mm Hex Socket Wrench Handheld Controller (Optional)
Procedure: Use the following steps to attach a 120 cm Reflector to an iNetVu® 1201 or 1202 Drive-Away Platform Rev. 1.0+: 1. Remove reflector from crate and any packing materials on the Drive-Away Platform. 2. Raise the Drive-Away Platform to approximately 80 so that the Feed Arm is pointing vertically upwards using iNetVu® Mobile Software, Handheld Controller or manual hand tool, see Appendix: 3 for emergency manual movement. For more information regarding the use of the iNetVu® Mobile Software and its installation, please refer to the iNetVu® System Manual. 3. Carefully place the reflector onto the Drive-Away Platform’s Elevation Arm. 4. There are four (4) hex socket flat head cap screws for the 1201 or 4 carriage bolts with nylon nuts for the 1202 included in the Reflector Assembly Kit. 1201 Cap Screw Fastener
1202 Carriage Bolts Fasteners
Fig. 28: Reflector Fasteners
New Generation Installation Manual
Page 41 of 100
5. Insert any aligning pin through one of the bottom holes on the reflector to help align the holes, using the pin properly align the screw holes on the Reflector and Elevation Arm. 6. Insert four (4) cap screws/carriage bolts through the front of the Reflector in the location depicted below for the appropriate mount type. Insert the two (2) SHORT cap screws/carriage bolts in the UPPER holes and the two (2) LONG in the LOWER holes.
Fig. 29: 1201 Reflector Mounting Locations Front View
Fig. 30: 1202 Reflector Mounting Locations Back View
New Generation Installation Manual
Page 42 of 100
7. Secure Hex Socket Flat Head Cap Screws/ Carriage Bolts evenly in a cross pattern starting with the top at each location. The Carriage Bolts have nylon nuts and washers that are used, Tighten to approximately 25 ft/lbs. 8. Verify Focal Point (ABCD) Geometry. Measure from the dimples on the top and bottom edge of the reflector, and ensure that dimensions are within ¼” of the values below. See Appendix 2, for more details. 9. Congratulations! The 1.2 m Reflector has been successfully installed on to an iNetVu® Drive-Away Platform.
New Generation Installation Manual
Page 43 of 100
4.2 Ka-75V Surfbeam TRIA Installation This procedure describes the steps involved in installing the Viasat Surfbeam TRIA on the iNetVu® Ka-75V Drive-Away Feedboom. Required Materials:
Viasat TRIA Allen Key Set Miscellaneous Tools
1. Pull back coax cable labelled TX and feed it up between stow bracket and TRIA bracket.
2. Connect TX cable to TRIA port labelled “TX” prior to fastening down of TRIA to bracket.
Note: Platforms shipped out from C-COM with Reflector installed will not include an ABCD DIM measuring stick.
New Generation Installation Manual
Page 44 of 100
3. Install TRIA using provided fasteners.
4. Validate ABCD DIMS, if adjustments are required refer to section 4.3 in this manual. Measurements are taking from reflector side dimples to arrow on bracket.
New Generation Installation Manual
Page 45 of 100
4.3 Ka-75V Feed Location Adjustment This procedure describes the steps involved in adjusting the Feedboom angle on the iNetVu® Ka-75V Drive-Away Platform. The adjustment procedure described below will be valid for A0755A also known as (Ka-75V) platforms. Required Materials:
iNetVu® A0755A (Ka-75V) Drive-Away Platform Ka service Feedboom Assembly 4mm Allen Key 8mm Wrench
1. Adjust the Feedboom angle, loosen adjustment block hold down screw and bottom nut by 1/4 turn.
Feed placement adjustment loosen 1/4 turn
New Generation Installation Manual
Block Hold Down Screw Nut, Bottom view
Page 46 of 100
2. Use adjustment screw on the bottom side of boom joint to adjust position.
3. Use the Feed Measurement Tool (provided by C-COM Satellite Systems Inc.) and measure/set Feed Horn location distance from reflector dimple(s) on both sides to arrow on TRIA bracket.
Bracket Arrow 4. Tighten adjustment block hold down screw after adjustments are complete and verify ABCD dimensions. 5. ABCD dimensions may also be measured using Feed Horn and Reflector points, See Appendix 2 for more details.
New Generation Installation Manual
Page 47 of 100
4.4 Ka-75V ETRIA Installation This procedure describes the steps involved in swapping out the Viasat Surfbeam Transceiver and installing the Viasat ETRIA on the iNetVu® Ka-75V Drive-Away Feedboom. Required Materials:
Viasat ETRIA Allen Key Set Miscellaneous Tools Threadlocker
2
1
3
4
1. Unscrew (4) Beaver Tail fasteners and remove Surfbeam Beaver Tail bracket.
New Generation Installation Manual
Page 48 of 100
2. Put back 2 Beaver Tail Bracket screws on the Feedboom Struts and hand tighten. This will keep the blocks inside the struts in the same location preventing them from moving. 1
2
3. Loosen the (4) Roller Bracket screws located on the Feedboom Struts, 2 screws on each side and remove the Roller Bracket.
4. Re-insert 2 Roller Bracket screws on each strut and hand tighten to hold blocks inside struts in place.
New Generation Installation Manual
Page 49 of 100
5. Install ETRIA on mounting bracket.
6. Remove Beaver Tail Bracket screws from Feedboom struts. These will be used to install ETRIA assembly.
7. Snip TX coax cable tie on side of Strut closes to ETRIA location to allow slack on cable. Connect TX coax cable to ETRIA.
New Generation Installation Manual
Page 50 of 100
8. Install ETRIA assembly on Feedboom. Insert and fasten the screws that were removed with Beaver Tail Bracket, use medium strength threadlocker on fasteners.
9. Remove Roller Bracket screws on bottom of Feedboom struts. 10. Install Roller Mounting Bracket applying medium strength threadlocker to fasteners.
11. Tidy up the cables to prevent possible damage to them when system is stowed. 12. System conversion from Surfbeam transceiver to ETRIA transceiver is now complete.
New Generation Installation Manual
Page 51 of 100
13. Verify ABCD DIMS, by measuring from top center of feedhorn to side reflector dimples.
14. Only the D dimension is adjustable, refer to appendix 2 for dimensions and to section 4.3 for Feed Location Adjustment procedure.
New Generation Installation Manual
Page 52 of 100
4.5 Adjusting 981/Ka-98(H/G/V) Feed Horn ABCD Dimensions This procedure describes the steps involved for adjusting the Feed Horn angle on the iNetVu® 981 Ku and Ka-98(H/G/V) Drive-Away Platform. The adjustment procedure described below will be valid for A0981A (981 Ku), A0985A (Ka-98H, Ka-98G & Ka-98V) and A0985B (Ka-98G) platforms with motorized polarization axis. Required Materials:
iNetVu® A0981A (981 Ku) iNetVu® A0985A (Ka-98H/G/V)/A0985B (Ka-98G third Pol axis) Drive-Away Platform 4mm Allen Key
Procedure: 1. Measure the “D” dimension and verify the measurement, if measurement is correct (within .06”) no adjustment is required. Measurement must be taking from the top center of both the reflector and the Feed Horn. Reflector top
Feed Horn top
Note: Only the “D” verification is required for adjusting the Feedboom angle.
New Generation Installation Manual
Page 53 of 100
2. Adjust the Feedboom angle, loosen adjustment block hold down screw by ¼ turn.
3. Use adjustment screw on the bottom side of boom joint to adjust position.
New Generation Installation Manual
Page 54 of 100
4. Verify the “D” dimension and tighten the hold down screw.
5. Refer to Appendix 2, for ABCD Dimensions.
New Generation Installation Manual
Page 55 of 100
4.6 Ka-1202V ETRIA Installation & ABCD Adjustment This procedure describes the steps for installing Viasat’s ETRIA on the iNetVu® Ka-1202V Drive-Away’s Feedboom. Required Materials:
Viasat ETRIA Allen Key Set Miscellaneous Tools
1. Install ETRIA on Feedboom bracket.
2. Connect TX cable to ETRIA on Feedboom.
New Generation Installation Manual
Page 56 of 100
3. ETRIA installation is now complete, validate ABCD dimensions. Refer to Appendix for measurement values.
4. ABCD adjustments can only be done on the Feedboom gas springs. Loosen nut while holding in place the gas spring end fitting of the piston side.
New Generation Installation Manual
Page 57 of 100
5. Rotate piston end CW or CCW to achieve desired setting.
6. Perform same adjustment on the second Feedboom gas spring and tighten nut to sustain location. The tension of both gas springs should be identical.
New Generation Installation Manual
Page 58 of 100
4.7 Stow Adjustment on iNetVu® Ka-75V/981/Ka-98(H/G/V) This document is intended to provide guidance in order to center the azimuth axis after discovering the antenna is not stowing at center location. Read this document before attempting the provided steps. Required Materials:
iNetVu® A0755A (Ka-75V) or A0985A (Ka-98H/G/V) Drive-Away Platform iNetVu® A0981A (981 Ku) iNetVu® 7024B/C Controller Allen Key Set
Step 1: Stow antenna with controller. This will determine how much adjustment will be required to center the azimuth, be prepared to press the stop button to prevent damage.
Note: Antenna is not required to be completely stowed to make the required centering adjustments. Feed Arm should be at minimum touching the base plate.
New Generation Installation Manual
Page 59 of 100
Step 2: Remove AZ/EL cowling.
New Generation Installation Manual
Page 60 of 100
Step 3: Loosen base hold-down (8) screws ½ turn.
New Generation Installation Manual
Page 61 of 100
Step 4: Center azimuth axis on stow block by moving the Feed Arm until visually centered.
Note: Manually moving the elevation up a few degrees may be required in order to shift and center the azimuth axis.
New Generation Installation Manual
Page 62 of 100
Step 5: Re-tighten base hold-down bolts
Step 6: Re-assemble cowling.
Step 7: Deploy and verify stow procedure
New Generation Installation Manual
Page 63 of 100
4.8 A0985A-1 (Ka-98H Transceiver) RHCP and LHCP Configuration The following steps are intended to provide guidance in order to determine or configure the Polarity on the HNS Ka Transceiver for Right Hand or Left Hand polarization. Read this document before attempting the provided steps.
Once you determine which polarization setting is required, check the position of the polarizer waveguide to determine if an adjustment is required. Looking at the rear of the radio towards the reflector one can easily determine the current polarization setting for RHCP or LHCP by seeing which side the polarizer is leaning. See procedure below for more information. Required Materials:
iNetVu® A0985A-1 (Ka-98H) Drive-Away Platform HNS Ka Transceiver Miscellaneous hand tools
New Generation Installation Manual
Page 64 of 100
Procedure: 1. Look at the Transceiver end that has the Feed Horn. The Polarizer and collar orientation will indicate the current Polarization setting.
2. Remove the two piece waveguide collar by loosening the two Allen screws. If the Feed Horn is already installed just remove the two back Allen screws. 3. Separate the polarizer from the TRIA and rotate it one quarter turn (clockwise for LHCP and counter-clockwise for RHCP), until the notch lines up with the key on the end of the TRIA. The LHCP notch is adjacent to the L and the RHCP notch is adjacent to the R on the polarizer.
4. Reseat the waveguide with the TRIA and reassemble the collar.
New Generation Installation Manual
Page 65 of 100
5. Remove protective seal from the polarizer and discard.
6. Remove the dust cap from the stem of the feed horn. 7. Install feed horn by inserting O-ring into the groove inside the stem. Position the feed horn against the waveguide as shown below.
8. Insert and tighten two Allen screws into collar securing feed horn in place. Leave nuts that are used for pointing adjustments snug.
New Generation Installation Manual
Page 66 of 100
4.9 A0985A-2 (Ka-98G Transceiver) RHCP and LHCP Configuration The following steps are intended to provide guidance in order to configure the Skyware Global Ka Transceiver for Right Hand or Left Hand polarization. Read this document before attempting the provided steps. Required Materials:
iNetVu® A985A-2 (Ka-98G) Drive-Away Platform Skyware Global Ka Transceiver Miscellaneous hand tools
Procedure: 1. Look at the Transceiver end that has the Feed Horn. There should be indicators on both the Feed Horn and the Transceiver identifying the current RHCP or LHCP Polarization configuration.
New Generation Installation Manual
Page 67 of 100
2. To flip the polarization configuration uninstall the Transceiver and Feed Horn from the Beaver tail bracket.
3. Using the indicators reinstall to the required polarization configuration.
New Generation Installation Manual
Page 68 of 100
4.10 EL Stow Switch Adjustment on Ka-75/Ka-98(H/G) Beta Only This procedure describes the steps involved in adjusting stow switch on the iNetVu® Ka-75 and Ka-98(H/G) Drive-Away Platform. Required Materials:
iNetVu® A0755A (Ka-75V) or A0985A ( Ka-98H/G) Drive-Away Platform iNetVu® 7024B/C Controller Allen Key Set
Step 1: Deploy the antenna to EL – 30, and AZ – 0, access to the landing plate bottom is required. Extra CAUTION should be taking here to avoid injury, lift the front plate with the help of a second person in order to prevent the antenna from tipping. Remove stow block screws, accessible from under stow landing plate.
New Generation Installation Manual
Page 69 of 100
Step 2: Rotate block with sensor to required position. Note: Sensor in the block is adjustable by turning the sensor in or out. Sensor may need adjustment if EL Stow limit (ST) is not displayed in the software and or EL Stow error is displayed during stow routine. Switch must be above block surface to detect properly. See step 3 for approximate height.
Step 3: Re-attach stow sensor and test stowing.
EL Sensor
New Generation Installation Manual
Page 70 of 100
4.11 Installing BUC to iNetVu® 1201 Drive-Away using Universal Bracket Kit
This procedure describes the steps involved for installing a Block UP Converter (BUC) to the iNetVu® 1201 Drive-Away Platform. The installation procedure described below shows images for a 4W BUC, but may be utilized for any sized BUC installation. Required Materials:
iNetVu® 1201/1201-J Drive-Away Platform Universal Transmitter Mounting Bracket Kit BUC (Block Up Converter) Phillips Screwdriver Allen Key Set
Procedure: 1. Ensure Block UP Converter (BUC) includes an O-ring. 2. Remove Universal Transmitter Mounting Brackets from the underside of the feed arm, if attached. 3. Place and secure the BUC on the underside of the Feed Arm as depicted in the figure below. When securing the BUC, adjust the placement of the screws and brackets to ensure the following: a. The BUC is placed at the Top Center end of the Feed Arm (if facing the Reflector), using the holes on the Feed Arm. This will ensure that the Flexible Waveguide has enough slack and or sag and does not snap off during Stow operation. b. Ensure enough space is left between the BUC and the Feed Arm Bar where the springs are attached (if applicable) to ensure you have enough space to attach the Flexible Waveguide to the BUC. c. The RG6 Coaxial Connector end of the BUC is facing the Reflector. d. The long screws of the Universal Transmitter Mounting Bracket Kit are fed through the grooves on each side of the BUC, if applicable.
New Generation Installation Manual
Page 71 of 100
Reflector End
Fig. 31: Attaching BUC using Universal Transmitter Brackets
4. Connect ‘TX’ Coaxial cable to the BUC. 5. Connect the Flexible Waveguide to the BUC. The Flexible Wave guide should have enough slack (an arced Flexible Wave guide see images) in order to accommodate feedboom during the stow operation.
6. Congratulations! The BUC has been successfully installed.
New Generation Installation Manual
Page 72 of 100
4.12 Installing BUC Using Universal Mounting Clamp Kit This procedure describes the steps involved for installing a Block UP Converter (BUC) to the iNetVu® Platforms using a Universal Mounting Clamp Kit. The installation procedure described below shows images for a 2W BUC, but may be utilized for any sized BUC installation. Required Materials:
iNetVu® Drive-Away Platform Universal Transmitter Mounting Clamp Kit BUC (Block Up Converter) #2 Phillips Screwdriver Allen Key Set Metal Cutting Shears
Procedure: 1. Place the foam protector onto the flat surface of the BUC (or the surface that is going to be into contact with the feedarm) and cut the required length. The length of the foam piece should be approximately the length of the BUC as depicted in fig. below.
Cutting length for adhesive foam sample
New Generation Installation Manual
Page 73 of 100
2. Expose the adhesive end of the foam piece, and apply to the side of the BUC that will be making contact with the feed arm as shown in the pictures below.
Fig. 32: Exposing adhesive and attaching to BUC
3. Place the flat end of the BUC (or the end that will lay flat against the feed arm) downwards on your work surface. 4. Install one end fitting onto one side of the clamp strap using the provided truss machine screws and washers as depicted in the pictures below.
Fig. 33: One Side End Fitting Installation
New Generation Installation Manual
Page 74 of 100
5. Place the side of the strap with the installed end fitting flat on the work surface and wrap the strap firmly around the BUC (less the side in contact with the work surface). Cut the strap such that the side without the end fitting installed on it is 0.25 to 0.5 inches away from the work surface as depicted in the pictures below. Ensure to make the cut between two holes on the strap. The holes should be visible through the shrink tubing.
Fig. 34: Measuring length requirements for clamp strap
Fig. 35: Cutting the clamp strap - midpoint between two holes
New Generation Installation Manual
Page 75 of 100
6. Expose two holes from the end of the strap without the end fitting with a razor or sharp edge and install the second end fitting as depicted in the pictures below. Both end fitting installations are similar in orientation.
Fig. 36: End fittings installation
7. Place and secure the BUC on the underside of the Feed Arm as close to the top as possible. When securing the BUC, adjust the placement of the screws and clamp strap to ensure the following: a. Leave enough space between the BUC and the Feed Arm Bar to ensure you have enough space to attach the Flexible Waveguide to the BUC. The Flexible wave guide should have an arc in the center to ensure enough slack exists when the system stows. Note: It may be easier to Install the waveguide (if applicable) onto the BUC before securing to the feed arm. See step 10 for details.
New Generation Installation Manual
Page 76 of 100
b. The long button cap screws of the Clamp Mounting Bracket Kit are fed through the BUC mounting plate on the feed arm and into the end fittings on each side of the BUC as depicted in the pictures below. Ensure the provided lock and flat washers are installed on the button cap screws. See note below for installing strap on an angle if holes do not align.
Fig. 37: 2 Watt BUC mounting
New Generation Installation Manual
Page 77 of 100
Fig. 38: 2 Watt BUC Mounting Top View – standard washers
Note: The Aluminum Square Beveled Washers provided could be utilized on the button cap screws with the provided lock washers for installing the strap on an angle for BUC sizes that don’t allow for direct mounting hole to end fitting alignment.
Fig. 39: Larger BUC mounting with beveled washers
New Generation Installation Manual
Page 78 of 100
Fig. 40: Beveled washers installed with lock washer on cap screw
8. Repeat the strap installation process with an extra clamp strap on the opposite end of the BUC as depicted in the picture below. Remember that the beveled washers allow for angular installation of the clamp strap if required.
Fig. 41: Second mounting strap installed
9. Connect ‘TX’ Coaxial cable to the BUC. 10. IF not already installed, connect the Flexible Waveguide to the BUC. Ensure that the Flexible Waveguide flange is aligned with the BUC output. Also ensure the “O” ring is in place on the BUC (if applicable). Notice arc in the Flexible wave guide in image above. Enough slack on Flex waveguide should exist to allow full extension of the stow arm which will prevent possible damage to Flexible wave guide otherwise. 11. Congratulations! The BUC has been successfully installed.
New Generation Installation Manual
Page 79 of 100
4.13 Installing/Routing Flexible Waveguide on iNetVu® 981 DriveAway Platform This procedure describes the steps involved in installing or ensuring the Flexible Waveguide is properly set on the iNetVu™ 981 New Gen Drive-Away System. It is always recommended to read the instructions and or the information herein before attempting the installation procedure. Required Materials for iNetVu™ 981 New Gen Drive-Away Platform:
Miscellaneous hand tools Flexible Waveguide
4.13.1
Version 2.1 or older
Procedure: 1. Connect Flexible Waveguide to OMT ensuring correct polarization between OMT and Flexible Waveguide. 2. Route Flexible Waveguide down between roller assembly and feed mounting bracket. Ensure the Flexible Waveguide is looped as shown.
Note: It may be easier to Install the waveguide (if applicable) onto the BUC first and properly routing it back to the OMT before securing BUC to the feed arm.
New Generation Installation Manual
Page 80 of 100
3. Connect the Flexible Waveguide to the BUC. Ensure the polarization on the Flexible Waveguide is exactly as that of the BUC before tightening. 4. Apply a tie wrap to the Flexible Waveguide securing it to the Feed Guard Loop Bracket using the 2 holes in the bracket.
5. Carefully test the Polarization Assembly movement and Antenna stow after installing the Flexible Waveguide. 6. Contact C-COM Satellite Systems for Assistance if required.
New Generation Installation Manual
Page 81 of 100
4.13.2
Version 3.0 or Newer
1. Install Flexible Waveguide if not already installed on OMT. Slide waveguide between bridge and waveguide clamp plate. Ensure Waveguide loops as shown.
2. Install Flexible Waveguide Leave enough space between the BUC and the Feed Arm Bar to ensure you have enough space to attach the Flexible Waveguide to the BUC. 3. Ensure that the Flexible Waveguide flange is aligned with the BUC output. Also ensure the “O” ring is in place on the BUC (if applicable). 4. Ensure the flexible waveguide is properly clamped and installed to the polarization cage such that the OMT is capable of rotating to polarization mechanical extremes (90.0 and +90.0). 5. Contact C-COM Satellite Systems for Assistance if required.
New Generation Installation Manual
Page 82 of 100
Appendix 1: Default Limits and Configuration Data Tables Compass Reading Elevation
COMPASS READING ELEVATION
A1201A
A1205A
32
32
PLATFORM TYPES A0981A A0985A 24
24
A0985B
A0755A
24
24
Table 1: Default Elevation Offsets. All values are + 2 after Target Calibration
Elevation Offset EL OFFSET
A1201A 17
A1205A 23.5
A0981A 18.5
A0985A 18.5
A0985B 18.5
A0755A 20.5
Table 2: Default Elevation Offsets. All values are + 2 after Target Calibration.
AZ Potentiometer AZ ZERO
A1201A 282.8
A0981A 282.8
A0985A 282.2
A098B 282.2
A0755A 282.8
Table 3: Azimuth Potentiometer Default Values
PL Tilt Sensor PL ZERO
A1201A/A0981A 90
A1205A NA
A0985A NA
A0985B 90
A0755A NA
Table 4: Polarization Potentiometer Default Values
Default Platform Speeds and Limits
EL SLOW EL CURRENT6 EL CURRENT9 AZ SLOW AZ CURRENT6 AZ CURRENT9 PL SLOW PL CURRENT6 PL CURRENT9
PLATFORM TYPES A1201A A0981A 8 3 3500mA 7000mA 4500mA 10000mA 9 9 1800mA 1800mA 2000mA 2000mA 2 2 300mA 300mA 500mA 500mA
A0755A /A0985A 3 7000mA 10000mA 9 1800mA 2000mA NA NA NA
A0985B 3 7000mA 10000mA 9 1800mA 2000mA 2 300mA 500mA
Table 4: Default values for speed and current limits
New Generation Installation Manual
Page 83 of 100
Appendix 2: Platform ABCD Dimensions A0755A (Ka-75V) Left/Right Dimple to Arrow – 28.97” Beaver Tail Arrow
Reflector
Right Dimple
Left/Right Dimple to ETRIA – 25.68” Feedhorn ETRIA D – 29.49” A0985A-1 (Ka-98H) HNS
Left Dimple
D – 41.52” Fig. 42: 755A Geometry Dimensions via Dimple(s) and Arrow
A0985A-2/B-2 (Ka-98G) SKYWARE D – 41.75”
A0985A-3 (Ka-98V) Viasat SB2 Right Dimple
ETRIA Feed Horn
D – 42.37”
A0981A (981 Ku) A – 27.12” B – 28.92” C – 42.66” D – 40.70”
Left Dimple
Fig. 43: 755A Geometry Dimensions via Dimple(s) and Feed Horn
A – 38.06” B – 40.45” C – 56.13” D – 54.37”
D Reflector
C B
A1201A (1201)
Feed Horn
**A1205C (1201-J/1202) A – 38.06” B – 40.45” C – 56.13” D – 54.37”
A Fig. 44: ABCD Geometry Dimensions **Equipped with Skyware Reflector
New Generation Installation Manual
Page 84 of 100
A1205A-3 (Ka-1202V) D
A – 36.09” B – 37.62” C – 52.67” D – 51.31”
C
B
A
New Generation Installation Manual
Page 85 of 100
D
C
A1505C (1501) A – 42.11” B – 45.34” C – 60.99” D – 58.12”
B
A
New Generation Installation Manual
Page 86 of 100
Appendix 3: Manual/Emergency Movement 1. Manual movement maybe required in case of an emergency where no power to motors exists or any of the two (EL or AZ) motors fail. 2. To manually move the platform use a 14mm Hex Socket wrench or any tool with a Hex attachment. Place wrench on Hex Socket and rotate in the desired direction. This method of manual movement is valid on Ka-75V/981/Ka-98(H/G/V), 1201 and 1202.
Hex Socket
If your system did not ship with the Hex Sockets installed on the motor reducer shafts contact C-COM Satellite Systems Inc.
Fig. 45: Using a Hex Socket Wrench to operate AZ & EL motors
New Generation Installation Manual
Page 87 of 100
Manual Movement Using Power Driver Note: A power drill/driver is NOT recommended as this may cause damage to the gear reducer. If you choose to use a power driver take extra caution to ensure the torque setting and drive speed are set to low (with Panasonic EY7410 driver, set torque to 5 and speed to slow). 3. Remove EL access plug if your system is equipped with one, otherwise remove cover.
4. Insert Power Drive extension onto reducer shaft.
New Generation Installation Manual
Page 88 of 100
5. Slowly move the elevation arm, if direction is correct continue until desired elevation position. To continue moving on elevation, removing and re-inserting power driver is required to allow operator to continue to drive the unit as it moves up or down.
6. To move mount on the AZ axis remove cover side panels on the side where the cable exit the cover.
7. Place power drive extension on the reducer shaft and watchfully move the mount to the desired position.
8. Once manual movement is complete and no other movement is required, reinstall the side panel and top cover plug. New Generation Installation Manual
Page 89 of 100
Appendix 4: Pod Installation on 120 cm and 98 cm platforms Note: Please be aware that each Pod is custom fitted for a specific platform before it left C-COM facility. In case of multiple units delivery please check the label on the packaging box or the Pod itself to confirm the S/N of the matching platform.
Installation of POD on 1201&1202 Platforms 1. Remove pod from packing case. 2. Place pod on base railings lining up the holes 3. Place spacers plus washers (2 each) between Transverse pod support bar and base railings.
New Generation Installation Manual
Page 90 of 100
4. Some systems may require spacers to be placed on the front end of the base bars in order to elevate the front end of the pod. If your system was received with 2 additional spacers, place these at the front in order to elevate the pod as shown, otherwise this step can be skipped.
New Generation Installation Manual
Page 91 of 100
5. Insert and tighten screws, ensure spacers align properly before tightening.
6. Line up holes and Install 2 screws at top end of the Pod. Do NOT tighten at this stage.
New Generation Installation Manual
Page 92 of 100
7. Line up back holes, lightly pull on pod to align holes and insert screw plus washer hand turning the screw until it catches. Do the same on the other side.
New Generation Installation Manual
Page 93 of 100
8. Stow the system, be ready to click the STOP button to halt stow routine if reflector does not properly align in the Pod. Check gaps and adjust as required. 9. The gaps, if any will be between pod and reflector, if reflector sits properly there should be no large or excessive gaps, if adjustment is required loosen the screws and shift the pod in the desired direction.
10. Tighten the fasteners on both top and bottom ends of pod. Stow the system, ensure adjustments were successful in eliminating excessive gaps.
New Generation Installation Manual
Page 94 of 100
11. Pod is now installed, follow the reverse process to remove and store.
New Generation Installation Manual
Page 95 of 100
Installation of POD on 981 Series Platform (Includes 981, Ka-98(H/G/V) and Ka-98G (third axis))
1. Remove all crate mounting bolts.
Extra care should be taken in the next step(s) to avoid injury and or damage to the system. Since the weight will be at the back end after elevating the front, may tip the system. 2. Lift front end of platform and place a support item beneath the stow plate. 3. Remove pod from packing case. 4. Place pod on base railings lining up the holes at front end, insert specified screws from bottom up hand tighten.
New Generation Installation Manual
Page 96 of 100
5. Slide back brackets onto base bars align holes and insert specified screws from top down. Firmly hand tighten at this stage.
6. Remove item that was used to elevate mount and slowly lower so unit sits flat.
New Generation Installation Manual
Page 97 of 100
7. Stow the system, be ready to press STOP button to halt stow routine if reflector does not properly align in the Pod. Check gaps and adjust as required. 8. The gaps, if any will be between pod and reflector, if reflector sits properly there should be no large or excessive gaps, if adjustment is required shift the pod in the desired direction.
9. Tighten the fasteners on the back brackets. Stow the system, ensure adjustments were successful in eliminating excessive gaps.
New Generation Installation Manual
Page 98 of 100
10. Lift front end and tighten fasteners. Lower front end and stow the system.
Note: if installing system on a flat mobile surface the pod must be installed prior to placing system on flat roof top. Access to front and back fasteners will be difficult and or close to impossible; it is not recommended to tilt the system while working on vehicle roof top. Pod maybe installed while on roof top if system installation includes roof rack bars (not part of iNetVu system) as access to fasteners will be possible.
New Generation Installation Manual
Page 99 of 100
Appendix 5: Declaration of Conformity
New Generation Installation Manual
Page 100 of 100
