Series 8009 9-Meter Earth Station Antenna Installation, Operation and Maintenance Manual Manual Part No.
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.
Table of Contents TABLE OF CONTENTS Table of Contents .................................................................................................. iii List of Figures ......................................................................................................... v List of Tables ........................................................................................................... v Safety Summary ..........................................................................................
Table of Contents 2.4.8 Grouting Baseplate to Foundation, Models 8009A and 8009AE ...................2-30 2.4.9 Reflector Mounting ..............................................................................................2-33 2.4.10 Optional Lightning Protection Installation.......................................................2-38 2.4.11 Optional Deicing Installation..............................................................................2-39 2.4.12 Electrical Installation..............
Table of Contents LIST OF FIGURES Figure 1-1. Typical Antenna System....................................................................................................1-2 Figure 1-2. Elevation and Azimuth Angle Stow Chart for High Wind Conditions .....................1-4 Figure 2-1. 9-Meter Antenna Reflector and Subreflector Alignment............................................2-18 Figure 2-2 Installing Leveling Nuts .........................................................................................
Safety Summary SAFETY SUMMARY Notice Any service, adjustment, maintenance, or repair of this product must be performed only by authorized technical service personnel. Prior to installation and use of this product review all safety markings and instructions. When safety precautions or important information is presented in this manual, the information will normally be presented just prior to the point where the hazard is likely to be encountered.
Chapter 1 - General Information Chapter 1 General Information 1.1 Introduction This manual contains information needed to properly install, operate, and maintain the Series 8009A 9-Meter Earth Station Antenna which provides high quality receive/transmit and receive-only capabilities for both domestic and international C-band or Ku-band applications.
Chapter 1 - General Information The Series 8009A antenna mounts provide two-axis (elevation-over-azimuth) adjustment for pointing the antenna. In the elevation-over-azimuth configuration, the antenna rotates about two axes, a vertical azimuth axis and a horizontal elevation axis. Pointing to a geostationary satellite requires that the antenna be moved to a specific angle about the azimuth axis, then to a specific angle about the elevation axis.
Chapter 1 - General Information Azimuth sector changes can be accomplished in two hours by disassembling four bolts, repositioning the azimuth sector bars, and installing the four bolts in a different hole pattern in the bottom ring of the structural tube. The elevation axis will cover 0° to 90° in one continuous sector on antennas without reflector de-icing. NOTE With optional hot air de-icing installed, the minimum elevation angle is 5°.
Chapter 1 - General Information 90° Elevation Angle (Degrees) 80° 70° A A 60° B 50° C 40° 30° 20° 10° 0° C B -60°-50°-40°-30°-20°-10° 0° 10° 20° 30° 40° 50° 60° Azimuth Angle (Degrees) 120° Azimuth Segment Minimum Azimuth Actuator Length To stow the antenna To Survive 160 KM/H To Survive 121 KM/H To Survive 112 KM/H Maximum Azimuth Actuator Length Move the mount azimuth and elevation positions within the maximum survivability envelope as indicated above Line A_A in Chart above.
Chapter 1 - General Information Total azimuth coverage for the Model 8009AE (180°) mount is 180° continuous. The elevation axis for both the Model 8009AE 120° and 180° antenna will cover 0° to 90° in one continuous sector. Elevation travel will not be limited by reflector de-icing. The 30-ton azimuth actuator and 30-ton elevation actuator will allow the antenna to survive 201 km/h [125 mi/h] at any antenna orientation.
Chapter 1 - General Information 1.3 Reflector Description The reflector, in combination with its shaped subreflector and feed system, is optically designed to yield high efficiency. The reflector consists of 48 precision stretch-formed aluminum panels. The panels are bolted together in the field to form a surface of revolution. Each reflector assembly consists of a central hub assembly, to which are attached the radial trusses, intercostals, and the reflector panels.
Chapter 2 - Installation Chapter 2 Installation 2.1 Introduction This chapter provides instructions and guidelines for installing the 9-Meter antenna system. General safety precautions and procedures are also described. 2.1 Unpacking and Inspection 1. Inspect all shipping crates for visible damage. 2. Open the shipping crate and remove all packing material. 3. Inspect equipment for visible damage. While unpacking, carefully compare bill of lading or packing lists with equipment received.
Chapter 2 - Installation you follow these instructions carefully, ViaSat guarantees its full support of your claims to protect you against loss from concealed damage. 2.2 Equipment Return ViaSat 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.
Chapter 2 - Installation 2.3 Safety WARNING Read and Understand all safety instructions before beginning any work. Death or severe injury may result if personnel fail to observe safety precautions. 2.3.1 Emergency Plan Have an emergency plan. Know the procedures for obtaining first-aid and fire-fighting assistance. Plan your work and maintain good housekeeping; the safety and quality of the product are at stake. 2.3.
Chapter 2 - Installation 2. Always wear a hard hat if someone is above you. 2.3.3 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. Ensure that all electrical tools and equipment are properly grounded. Avoid shorting circuits when using metal tools.
Chapter 2 - Installation 2.4 System Assembly The assembly procedures presented in this section are based on the assumption that a powered lifting device of adequate size and capacity is used; therefore, the procedures given do not reflect consideration of limitations in lifting and handling equipment that might be encountered at any specific installation site.
Chapter 2 - Installation Table 2-1.
Chapter 2 - Installation Table 2-1. Tools and Equipment Required For Installation Quantity Description 1 Each Roll of masking tape or duct tape 1 Each 18.0-inch machine scale 2.4.3 Fastener Information All threaded fasteners are galvanized, ASTM A325, high-strength, hexagonalhead screws (equivalent to SAE Grade 5) or stainless steel. The anchor bolts used in the foundation are made of SAE Grade 5 steel or better.
Chapter 2 - Installation NOTE The required torque value for the foundation anchor bolts may not be accurately achieved by the turn-of-the-nut method. For these bolts, an accurate torque value of 400 to 450 lb-ft (542 to 610 Nm) is required. 2.4.4 Recommended Sequence of Assembly In order to ensure proper and trouble-free installation, the following installation sequence is recommended. The sequence is designed to minimize crane usage time. The crane is only required for items 3, 5, and 6. 1.
Chapter 2 - Installation NOTE Cleanliness of the precision mating parts that make up the reflector assembly is essential to proper fit and reflector surface accuracy. For this reason, only remove the reflector parts from their crates or pallets as required. • Examine 48 reflector panels and 24 trusses in their crates. • Identify eight spar panels for the sub-reflector spar mounting tab attached to the spar trusses.
Chapter 2 - Installation 2.4.6.1 Installation of Trusses and Intercostals Refer to drawing 517577C, 9-Meter Reflector Assembly, for the following procedure. 1. Remove hub assembly (item 31, drawing 517577) from packaging and place in upright position on stable wooden blocks or timbers. Raise the hub assembly at least 8 inches above the ground for working clearance. (Refer to drawing 517055 for hub assembly information.
Chapter 2 - Installation 10. Attach strut (item 17 drawing 517577 sheet 4, zone B-6) at next clockwise position. Secure strut with one bolt (item 25), two washers (item 27), and one nut (item 26). Secure hardware finger tight. 11. Attach spar truss (item 22 drawing 517577 sheet 4, zone B-4) to hub using one bolt (25), two washers (27), and one nut (26) and to strut using four bolts (item 28), eight washers (item 30), and four nuts (item 29). Secure hardware finger tight. 12.
Chapter 2 - Installation 22. Attach next five clockwise strut and truss assemblies as described in steps 3 and 4. After each strut and truss assembly is installed, install intercostals as described in steps 6 through 8. Secure hardware finger tight. 23. Attach next clockwise strut and spar truss assemblies as described in steps 10 and 11. Then install intercostals as described in steps 12 through 16. Secure hardware finger tight. 24.
Chapter 2 - Installation 10. Hoist the spar and subreflector assembly into the reflector and align the lower end of each spar with the attachment tab on a spar truss. Attach the spars to the truss tabs as shown in drawing 517577 sheet 2, using four screws (item 25), eight washers (item 27), and four nuts (item 26). 11. Torque all the fasteners used in the assembly and installation of the spars and subreflector to the values corresponding to the correct sizes as indicated on page 2-7. 2.4.6.
Chapter 2 - Installation 1. Install four threaded rods (item 35) one in each hole on the inner truss pad using two washers (item 9) and two nuts (item 10) on each rod. Install another nut (item 10) 2 1/8-inches (5.4 cm) above pad on each rod. Place one washer (item 9) on top of each nut. (These threaded rods will be used to mount the panels.) 2. Install two threaded rods (item 35) one in each hole on outer truss pad using two washers (item 9) and two nuts (item 10) on each rod.
Chapter 2 - Installation 8. 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 Table 2-3. (This will minimize the final adjustments.) Set the outer edge elevation angle to 87° - 26’ - 20”. Set the azimuth of the lateral edge of the panels to 0° - 02’ each side of the 15° increments. Fully tighten the adjusting nuts. Table 2-3.
Chapter 2 - Installation mounting bracket, template arm, drill template, and setting data for alignment are located in Alignment Kit #516212. 1. Verify that the theodolite is still level with respect to the panel mounting ring, at a height of 16.850 inches [42.799 cm]. 2. Pin the template arm to the tab on the slip ring below the theodolite mounting plate. NOTE The splice plates and bushing plates must face away from the surface of the reflector.
Chapter 2 - Installation 7. The Target Detail in Figure 2-1 shows the layout of the target. An ideal setting will occur when the theodolite elevation crosshair is centered on the middle diamond. Dimensions to other diamond points are given as an indication of the adjustment required to obtain the ideal setting. 8. Beginning at the inner row of targets and working outward in concentric circles, adjust the panel corner adjustment below each target.
Chapter 2 - Installation Figure 2-1.
Chapter 2 - Installation Table 2-5. 9-Meter Reflector Alignment Record Target # 1 2 3 4 5 6 7 8 9 10 11 Row 1 Row 2 Row 3 Readings 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 42S315F Summary Count .000 = .005 = .
Chapter 2 - Installation 2.4.6.6 Subreflector Alignment 1. Apply a small amount of light grease or oil to the target mirror shaft. Screw the target mirror into the hole in the apex of the subreflector a few turns. It does not need to be tightened. 2. Rotate the mirror so that the Crosshairs are aligned with the adjustment directions of the subreflector mounting frame. 3.
Chapter 2 - Installation 2.4.7.1 Model 8009A Mount/Actuator Installation Procedure NOTE Procedures in this section are specifically for the Model 8009A. If installing a Model 8009AE 120º see instructions given in section 2.4.7.2 beginning on page 2-24. If installing a Model 8009AE 180º 9-Meter Antenna System see instructions given in section 2.4.7.3 beginning on page 2-27. Drawing 519054 provides the installation drawing for the 9-Meter 120° mount/actuators.
Chapter 2 - Installation NOTE Complete steps 5 and 6 while the mount (item 1) is laying horizontal on the ground. 5. Refer to sheets 3 and 4 of drawing 519054. Attach (Qty 2) electrical grounding cables (item 17) to ground cable brackets (items 15 and 16) with .5-13 UNC screws, washers, and nuts (items 36, 37 and 38). Tighten 0.5 inch hardware to 75 ft-lb (100 Nm). 6. Secure a nylon strap to the elevation actuator assembly (item 10). Remove the 1.5 inch retainer rings, 1.
Chapter 2 - Installation 17. Place the lower azimuth pivot (item 3) over the foundation anchor bolts and loosely install (Qty 6) 1.0 inch galvanized washers (item 24) and (Qty 6) 1-8 UNC fluorocarbon nuts (item 26). 18. Place a surface level on the top surface of the lower azimuth pivot pin and adjust (3) equally spaced 1-8 UNC anchor nuts on the bottom side of the base plate until the pivot is level. The other (3) bottom nuts should be lowered slightly to avoid binding the base plate.
Chapter 2 - Installation 31. Install (Qty 1) grease fitting (item 32) in clevis pivot pin as shown in sheet 7, view B-B of Drawing 519054. Add grease to grease fitting and pivot pin. 32. With a level placed directly on the jack screw adjust anchor bolts until the actuator screw is level with the mount. Tighten 1.0 inch hardware. Torque anchor pin nuts to a minimum of 240 ft-lb (325 Nm) to maximum of 275 ft-lb (372 Nm). 33. Replace boot and hose clamps. 2.4.7.
Chapter 2 - Installation washers to secure each leg on anchor bolts. Disconnect crane and remove the nylon straps. 5. Secure a nylon strap to the elevation actuator assembly (item 18). Remove the cotter pins (item 16), clevis pin (item 21), spacers (item 22) and washers (item 205) from assembly. 6. Lift the assembly with a crane and position the jack clevis over attachment point on mount (item 1) as shown on sheet 6 of Drawing 517098.
Chapter 2 - Installation 11. Lift the mount assembly (3500 lb or 1588 kg) with the crane approximately 39.0 inches (1 meter) and remove the upper shipping brace. Extra care shall be taken when attaching the steel lifting cable to prevent damage to the ladder and platform (if installed). 12. Place several wood blocks under the lower end of mount while lifting the mount to a vertical position. 13. Remove the lower shipping brace. 14.
Chapter 2 - Installation 27. Remove the pin (item 214) and retainer ring (item 215) from the azimuth actuator clevis pin. 28. Attach azimuth mount (item 1) to the actuator (item 17). Install pivot pin and retaining ring (item 215). 29. Install grease fitting (item 216) in clevis pivot pin. Add grease to grease fitting and pivot pin. 30. With a level placed directly on the jack screw adjust anchor bolts until the actuator screw is level with the mount. Tighten 1.25 inch hardware.
Chapter 2 - Installation 4. Refer to sheet 2 of drawing 517097. Locate (Qty 8) 1.25 inch galvanized washers (item 218) and (Qty 8) 1.25-7 UNC (item 219). Secure a nylon strap to each leg (item 2) at approximately the center. Lift each leg with a crane and position over foundation anchor bolts. Loosely install four nuts and washers to secure each leg on anchor bolts. Disconnect crane and remove the nylon straps. 5. Secure a nylon strap to the elevation actuator assembly (item 18).
Chapter 2 - Installation 11. Lift the mount assembly (3500 lb or 1588 kg) with the crane approximately 39.0 inches (1 meter) and remove the upper shipping brace. Extra care shall be taken when attaching the steel lifting cable to prevent damage to the ladder and platform (if installed). 12. Place several wood blocks under the lower end of mount while lifting the mount to a vertical position. 13. Remove the lower shipping brace. 14.
Chapter 2 - Installation 27. With a level placed directly on the jack screw adjust anchor bolts until the actuator screw is level with the mount. Tighten 1.25 inch hardware. Torque anchor pin nuts to a minimum of 360 ft-lb (488 Nm) to maximum of 440 ft-lb (596 Nm). 2.4.8 Grouting Baseplate to Foundation, Models 8009A and 8009AE Grout is used between the concrete foundation surface and the four base plates to ensure a rigid, load-bearing connection between the mount and the foundation.
Chapter 2 - Installation 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. 2.4.8.2 Cold Weather Grouting 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.
Chapter 2 - Installation 2.4.8.3 Grouting Procedures Perform the following procedures to grout the four base plates to the foundation: 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 or equivalent mixing container and slowly add water. Stir the mix and add grout or water as required to obtain a good paste.
Chapter 2 - Installation CAUTION Grout (item 18) must be installed between all base plates and foundation surface to comply with the design loads specified per drawing 519921. 2.4.9 Reflector Mounting NOTE The assembly and alignment of reflector must be completed per instructions in paragraph 2.4.6 of this manual before installing antenna hub to mount. 1.
Chapter 2 - Installation Figure 2-5.
Chapter 2 - Installation 5. Attach a rope to the elevation actuator protection tube and thread rope through the eye bolt installed in step 2. 6. Swing the elevation jack toward the upper hub pivot and install (Qty 2) pins (item 12) and retainer (item 13) with .25-20 UNC hardware as shown in VIEW D-D sheet 9 of Drawing 519054. 7. Tighten .25 inch hardware to 9 ft-lb (12 Nm). 8. Add grease to grease fitting installed in pins (item 12). 9.
Chapter 2 - Installation CAUTION Wear only soft-sole shoes or socks while inside the reflector. Only step on the seams between panels where the structure is strongest, never in the middle of a panel. Perform the following procedure to install and align the feed: 1. Choke two nylon straps around the feed assembly and attach to lifting hook of crane as shown in Figure 2-6. Figure 2-6. Hoisting Feed 2.
Chapter 2 - Installation NOTE To correct orient the feed refer to the feed installation drawings. With linear feeds it is necessary to orient the feed such that the vertical elements are positioned near the center of the polarization drive. For circular feeds it is only necessary to orient the feed so that waveguide ports can be easily connected to the system waveguides without excessive bending. 2.4.9.
Chapter 2 - Installation The customer interface to the transmit input ports are located at the top of the leg brace of the mount. The interface flange provided with the feed is WR-75 cover grooved flange or CPR137 grooved flange. The customer interface to the receive ports is located inside the reflector hub. Systems integrated with LNA packages must be attached to the receive ports and supported to prevent damage to the waveguide flanges.
Chapter 2 - Installation 2.4.11 Optional Deicing Installation All components that are supplied with de-icing are wired to a junction box located in the antenna hub. Run the cables from the components to the junction box and consult the Controls manual supplied with the system for additional installation and check-out procedures. 2.4.12 Electrical Installation Controller, motors, limit switches, and wiring installation instructions are not contained in this manual.
Chapter 2 - Installation Blank 42S315F 2-40
Chapter 3 - Operation Chapter 3 Operation 3.1 General With this elevation-over-azimuth mount, pointing the antenna is accomplished by jogging the antenna in elevation and jogging antenna in azimuth. The azimuth and elevation angles are first established approximately by reference to the indicator provided for each axis, then aligned precisely by peaking on a signal received from a satellite of known position.
Chapter 3 - Operation 3.2.3 Signal Peaking Procedure With the RF components functioning, perform the signal peaking procedure as follows: (The initial setting of the elevation angle should be very nearly correct, having been set to a horizontal reference.) 1. Jog the antenna in azimuth until the satellite signal is peaked. 2. Loosen and calibrate the azimuth angle indicator by adjusting and fixing the pointer at the known azimuth angle of the satellite.
Chapter 3 - Operation 3.3 Subreflector Adjustment The following procedure should be used in the event that the antenna performance demonstrates that a subreflector adjustment is necessary. The purpose of the physical measurements to various points on the antenna is to minimize any tilt, or lateral displacement of the subreflector with respect to the main reflector surface and also to position the subreflector to its optimum optical location along the adjustment axis. 1.
Chapter 3 - Operation 3. If tilt was not adjusted using theodolite, measure the distance between the edge of the subreflector and each corner of the feed horn as shown in Figure 3-1, distance B. Using the subreflector adjustment mechanism, adjust the subreflector until all four distances are equal; this removes any tilt with respect to the feed. 4.
Chapter 3 - Operation 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.
Chapter 3 - Operation Figure 3-2 Typical Antenna Patterns for Various Subreflector Position 42S315F 3-6
Chapter 4 - Maintenance Chapter 4 Maintenance 4.1 General The 9-Meter Earth Station Antenna is designed for use in many different environmental conditions. 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.
Chapter 4 - Maintenance CAUTION If it has been some time since electrical power was applied to the actuator motors, go to the antenna, remove all electrical power, manually release the motor brake, and rotate motor shaft. Once it is determined that the brake will release and the shaft will turn freely, then apply electrical power to the motors. Failure to check brake and shaft may result in motor damage. 4.2.3 Bi-Monthly Maintenance Perform the following procedures at least once every two months. 1.
Chapter 4 - Maintenance c. If the screw is coated with grease and the grease is in good condition, no further action is required. d. If the screw is not adequately coated, or if the grease is dry, hard, or contaminated, the lubricant must be renewed. Do not add new grease to old grease on the screw. Clean the screw of old grease using a solvent. Dry the screw with clean cloths. Apply a thin uniform film coating of one of the following lowtemperature, clay-based greases.
Chapter 4 - Maintenance a. Use a clean, lint-free cloth lightly moistened with a diluted solution of mild soap and water to remove foreign material from the radome. Wipe dry using a clean, dry lint-free cloth. b. Remove dust from accessible areas. Figure 4-1.
Chapter 4 - Maintenance Figure 4-1. Lubrication Points (Sheet 2 of 2) 4.2.5 Yearly Maintenance Perform the following procedures at least once every year. 1. Inspect foundation pad for structural cracks and repair as required. 2. Replace flexguide every third year.
Chapter 4 - Maintenance 4.3 Corrosion Protection Perform the following procedures after completing the installation and every 12 months thereafter. a. Evaluate corrosion protection on all anchor bolts, mount hardware, reflector hardware, feed hardware, and subreflector hardware. If protective finish is damaged, clean with a wire brush, remove all rust, and apply a coat of Rust-Oleum (or equivalent) primer and semi-gloss white paint.
Chapter 4 - Maintenance 2. Application: a. Wipe damaged portion of finish and surrounding area with solvent. Do not allow solvent to stand on painted areas. Simply wipe surface to remove oily deposits. b. Wash area thoroughly with detergent, rinse thoroughly with water, and allow to dry. c. Sand area to remove rust and "feather" a smooth finish from existing painted surface into areas to be repainted. Be sure to remove all loose paint and rust. d.
Chapter 4 - Maintenance 2. Application: a. Clean entire area around damaged portion with solvent cleaners followed by thorough wash with detergent and water. Rinse well and dry with clean cheesecloth. Do not recoat for 30 minutes or until surface is completely dry. b. Damaged coatings may be repaired by fairing the damaged edges with 320 grit or finer sandpaper. Primer system must be reapplied if damage extends into the bare metal. c.
Chapter 4 - Maintenance NOTE All galvanized fasteners, nominal size 1/2-inch and larger, are high-strength structural fasteners meeting the American Society for Testing and Materials (ASTM) A325 specification. If for some reason one has to be replaced, it is imperative that one be obtained that meets the ASTM A325 specification. If unable to locate, contact the factory for either a suggested source or a replacement.
Chapter 4 - Maintenance Table 4-1.
Chapter 5 - Drawings Chapter 5 Drawings 5.1 Introduction This chapter provides assembly drawings, schematic diagrams and parts listings. Drawings are presented in hierarchical order with the highest order drawings shown first. 5.2 Drawing Index A drawing index is provided in Table 5-1. The drawing number, revision, drawing title and page location of each drawing is included in the index. A dash in the revision column indicates the original release of the drawing. 5.
Chapter 5 - Drawings Table 5-1. Drawing Index Drawing Rev.
