Mechanical
Reflector Type
Mount Geometry
Polarization
Travel
Azimuth
1.8M Prime Focus Offset
Elevation over Azimuth
Rotation of Feed
270° for 2-Port, 240° for 4-Port
400° Optional for 2-Port or Feed Boom Mounted HPA
Elevation
Operational
0-90° or 0-65° of reflector boresight
Total
0-160°
Polarization
Speed
Slewing/Deploying
±50° for 4-Port or ±95° for 2-Port
ANTENNA SYSTEMS
2°/second
Peaking
0.2°/second
Drive System
Motors
Roto-Lok ®
24V DC Variable Speed, Constant Torque
RF Interface
Waveguide
WR 75 Cover Flange at center of azimuth axis
Coax
RG59
Electrical Interface
25 ft. Cable with Connectors for Controller
Manual
Weight
7/16 Hex Socket Wrench on All Axii
300 lbs.
Environmental
Wind
Survival
Deployed
80 mph
Stowed
Operational
Tracking
Temperature
Operational
125 mph
45 mph gusting to 60 mph at 60º F
-20°F to 125°F
Survival
-40°F to 140°F
Electrical RF
Receive
Transmit
Frequency
Gain (Midband)
R/T
11.7-12.75 GHz
14.0-14.5 GHz
45.3 dBi
46.7 dBi
45.2 dBi
46.6 dBi
1.30:1
.91
.77
4-Port
VSWR
Beamwidth (degrees)
-3 dB
-15 dB
First Sidelobe Level (Å2 dB)
Radiation Pattern
Antenna Noise Temperature
10° Elevation Angle
Polarization
Power Handling Capability
Cross-Pol Isolation
On-Axis
Off-Axis (within .5 dB BW)
Off-Axis (within 1 dB BW)
Feed Port Isolation - 4-Port Feed
RX/RX
TX/TX
TX/RX
1.91
1.62
-20 dB
-20 dB
Meets FCC requirements for 2° Spacing
43°K
Linear
35 dB
25 dB
22 dB
Linear
1KW per port
35 dB
26 dB
24 dB
ANTENNA SYSTEMS
704 North Clark Street
30dB
30 dB
60 dB
60 dB
Albion, MI 49224 USA
1.8M MVSAT Antenna
Tel: (517)629-5990
Controller
RC3000A
Full-function controller with opt. GPS and Flux-Gate
Size
Input Power
Two rack units high
110V AC, 1 ph, 60 Hz, 15 amp
Fax: (517)629-6690
E-mail: info@sepatriot.com
Web site: www.sepatriot.com
INSTALLATION &
ASSEMBLY INSTRUCTIONS
LIMITED TWELVE (12) MONTH WARRANTY
This PATRIOT ANTENNA equipment is warranted to be free from defects in material and workmanship under normal
use and service. PATRIOT ANTENNA shall repair or replace defective equipment, at no charge, or at its option,
refund the purchase price, if the equipment is returned to PATRIOT ANTENNA not more than twelve (12) months
after shipment. Removal or reinstallation of equipment and its transportation shall not be at cost of PATRIOT
ANTENNA except PATRIOT ANTENNA shall return repaired or replaced equipment freight prepaid.
This Warranty shall not apply to equipment which has been repaired or altered in any way so as to affect its stability
or durability, or which has been subject to misuse, negligence or accident. This Warranty does not cover equipment
which has been impaired by severe weather conditions such as excessive wind, ice, storms, lightning, or other natural
occurrences over which PATRIOT ANTENNA has no control, and this Warranty shall not apply to equipment which
has been operated or installed other than in accordance with the instructions furnished by PATRIOT ANTENNA.
Claimants under this Warranty shall present their claims along with the defective equipment to PATRIOT ANTENNA
immediately upon failure. Non-compliance with any part of this claim procedure may invalidate this warranty in whole
or in part.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER AGREEMENTS AND WARRANTIES, ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED IN DURATION
TO THE DURATION OF THIS WARRANTY. PATRIOT ANTENNA DOES NOT AUTHORIZE ANY PERSON TO
ASSUME FOR IT THE OBLIGATIONS CONTAINED IN THIS WARRANTY AND PATRIOT ANTENNA NEITHER
ASSUMES NOR AUTHORIZES ANY REPRESENTATIVE OR OTHER PERSON TO ASSUME FOR IT ANY OTHER
LIABILITY IN CONNECTION WITH THE EQUIPMENT DELIVERED OR PROVIDED.
IN NO EVENT SHALL PATRIOT ANTENNA BE LIABLE FOR ANY LOSS OF PROFITS, LOSS OF USE, INTERRUPTION OF BUSINESS, OR INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND.
In no event shall PATRIOT ANTENNA be liable for damages in an amount greater than the purchase price of the
equipment.
Some states do not allow limitations on how long an implied warranty lasts, or allow the exclusion or limitation of
incidental or consequential damages, so the above limitations or exclusions may not apply to you.
PATRIOT ANTENNA has the right to void the warranty when the antenna is installed by someone other then a
certified installer.
Product Serial Number- _________________
Date Purchased- ____________
2
704 North Clark Street
Albion, MI 49224 USA
Tel: (517)629-5990
Fax: (517)629-6690
E-mail: info@sepatriot.com
Patriot Antenna Systems
23
Check oil level in gearbox.
Use of WARNINGS, CAUTIONS, NOTES, etc.
Remove cable termination, block covers, and inspect cable terminations. Tighten springs if
more than .010 gap exists.
Inspect azimuth stow limit switch.
Remove azimuth potentiometer cover and inspect azimuth potentiometer.
Check that all azimuth bearing flat head screws, azimuth gear box bolts, azimuth potentiometr,
etc. are tight.
Warnings, Cautions, and Notes are included throughout this manual to provide necessary information.
THEY SHOULD NOT BE IGNORED. You should know the use of WARNINGS, CAUTIONS, NOTES, and
other markings. Definitions are:
Warnings!
Highlights an installation, operating or maintenance procedure, practice, condition,
statement, etc., which, if not strictly observed, could result in injury to or death of
personnel.
Caution!
Highlights an installation, operating or maintenance procedure, practice, condition,
statement, etc., which if not strictly observed, could result in damage or
destruction of equipmen
t or the loss of mission effectiveness or long term
health hazards to personnel.
Note:
Highlights an essential installation, operating or maintenance procedure,
condition, or statement.
ESD:
The Electrostatic Sensitive Device (ESD) appears at the beginning of any
procedure or procedural step that includes the handling of equipment sensitive to
damage from electrostatic discharge.
Elevation
Handcrank in elevation.
Unit should handcrank with approximately 50-100 in-lbs. torque.
Check for unusual noise in elevation pivot bearings and elevation gearbox.
Run in elevation and check for unusual noise in elevation motor.
Run to up limit.
Check tracking of elevation drive cables.
General Warnings and Cautions
are also provided at the front of the manual. These warnings and
cautions should be read by anyone who is involved with installation, has access to the equipment, or is
assigned to perform maintenance on the equipment.
Check drive cables for damage.
Check for excessive backlash in gear box.
Check that anti-backlash hubs are tight.
Check oil level in gearbox.
Remove cable termination block covers and inspect cable terminations. Tighten springs if
more than .010 gap between sets of springs exists.
CAUTIONARY NOTICE
Although the manufacturer has attempted to detail in this manual all areas of possible danger to
personnel in connection with the use of this equipment, personnel should use caution when
installing, operating, and servicing this equipment. Care should be taken to avoid electrical shock,
whether the hazard is caused by design or malfunction. The manufacturer is specifically not liable
for any damage or injury arising from the technician=s failure to follow the instructions contained in
this manual or his failure to exercise due care and caution in the installation, operation, and service
of this equipment.
CAUTIONARY NOTICE
Polarization
Run in polarization and check for unusual noise in polarization motor.
The antenna and feed system supplied by AvL Technologies is designed to be integrated
with various electronic equipment. This system, if integrated with high power amplifiers or
travelling wave tubes, will be capable of transmitting microwave energy at varying power
levels. If transmitting microwave power, AvL Technologies I cautions the end-user to review
all applicable local, federal and international regulations and to comply with all such
regulations in the operation and maintenance of the integrated system.
Inspect polarization potentiometer.
PLEASE READ THE FOLLOWING PRECAUTIONS
This manual is intended as a general guide for trained and qualified personnel who are aware
of the dangers of handling potentially hazardous electrical and electronic circuits. This manual
is not intended to contain a complete statement of all safety precautions that should be
observed by personnel in using this or other electronic equipment.
22
3
6.0
WARNING
THE ELECTRICAL CURRENTS AND VOLTAGES ASSOCIATED WITH THIS EQUIPMENT,
WHETHER SUPPLIED BY AvL Technologies OR OTHERS, ARE DANGEROUS. PERSONNEL MUST
AT ALL TIMES OBSERVE SAFETY REGULATIONS.
The installation, operation, maintenance, and service of this equipment involves risks both to
personnel and equipment and must be performed only by qualified personnel exercising due
care. AvL Technologies shall not be responsible for injury or damage resulting from improper
procedures or from the use of improperly trained or inexperienced personnel performing such
tasks.
WARNING
ALWAYS DISCONNECT POWER BEFORE OPENING COVERS, DOORS, ENCLOSURES, GATES,
PANELS, OR SHIELDS. ALWAYS USE GROUNDING STICKS AND SHORT OUT HIGH VOLTAGE
POINTS BEFORE SERVICING. NEVER MAKE INTERNAL ADJUSTMENTS OR PERFORM
MAINTENANCE OR SERVICE WHEN ALONE OR FATIGUED.
During installation and operation of this equipment, local building codes and fire protection
standards must be observed.
WARNING
IN CASE OF EMERGENCY BE SURE THAT POWER IS DISCONNECTED.
Do not remove, short-circuit, or tamper with interlock switches on access covers, doors,
enclosures, gates, panels, or shields. Keep away from live circuits. Know your equipment
and do not take risks.
RF WAVEGUIDE AND ELECTRICAL CABLE SYSTEM
6.1 WAVEGUIDE SYSTEM
The waveguide system is suitable for transmit only (13.75 – 14.5 GHz). The VSWR is checked and
tuned to be better than 1.3:1 (-17.7 dB) with an insertion loss of better than .75 dB. The system is
pressurizable to a maximum of 2 psi. The leak rate is checked to be below 100 cc/minute.
Rotary joints are provided on the azimuth and elevation axis and are rated for 1 kW of power. The
polarization axis is crossed with flex-guide rated for 750 watts continuous. Transmit power is input on
the rotating side of the azimuth rotary joint. Therefore the waveguide interface coming from the inside
of the truck must be held stationary on the passenger side of the vehicle.
6.2 CONTROL CABLES
The azimuth and elevation motor power cables are SO 16 gauge, the polarization motor cable is SO
18 gauge, multi-strand wire. The motor power cables are terminated at the motor with insulated, in-line
splices. They are terminated in a 9-pin MS connector at the controller end. The shield is grounded to
the positioner and MS connector. The ground pin is not used.
The sensor and limit switch cables are 22 gauge, shielded, stranded wire. They are terminated into 15
pin connectors. The shield / ground must “float” and not contact the positioner assembly.
6.3 RF AND AUXILIARY CABLES
SAFETY NOTICE
The following safety procedures are listed to remind those performing any work on the
antenna system that safety rules must be observed. Failure to do so may result in
serious injury or death. Always work safely and in accordance with established
procedures.
Care shall be taken in all operations to safeguard other people as well as property and
to comply with all local safety procedures as established by the customer’s site
representative.
All persons performing work on the antenna system shall also comply with the
Occupational Safety and Health Act (OSHA) standards and all other federal state and
local laws, ordinances, regulations and codes relating to designated work.
Unless the customer’s representative on site specifically designates an individual
responsible for site safety, the AvL Technologies Site Supervisor shall be responsible for
and establish a site safety program for the AvL Technologies installation work. The site
safety program shall incorporate all AvL Technologies safety procedures and
requirements, including the following:
!
Always remove all power to the system prior to working on the
antenna, the reflector assembly, the reflector backup assembly or
the feed assembly.
!
Always tag all circuits noting that the power is OFF, the date and
your name prior to commencing any work on that system.
ALWAYS WORK SAFE!
Two RG59 75ohm coax cables are furnished which run from the feed housing to 10 feet beyond
azimuth interface plane. In addition, a 6 conductor, 22 gauge shielded cable is provided to power the
LNA, operate a waveguide switch, run warning lights, disable vehicle ignition until antenna is stowed,
etc.
7.0 MAINTENANCE
The Patriot Antenna 1.8 MVSAT system is designed so that any wear should never degrade
performance below specifications and no maintenance will ever be required. However, since it is
impossible to ascertain or test for all possible environments, the following check-up can be performed
annually to assure never missing “a shot”. If any problems are observed, refer to appropriate section.
7.1 ANNUAL INSPECTION
Azimuth
Handcrank in azimuth.
Unit should handcrank easily.
Check for unusual noise in azimuth bearing and azimuth gear box.
ELECTROMAGNETIC
RADIATION
DO NOT STAND IN THE DIRECT PATH OF THE FEED SYSTEM
WHEN THE SYSTEM IS TRANSMITTING! DO NOT WORK ON
THE FEED SYSTEM WHEN THE SYSTEM IS ON!
4
Run in azimuth and check for unusual noise in azimuth motor.
Check drive cables for damage.
Check for excessive backlash in gearbox.
21
5.0
TABLE OF CONTENTS
FEED AND POLARIZATION POSITIONING SYSTEM
SECTION
5.1 GENERAL
The feed assembly consists of the feed boom, feed housing, RF components and polarization drive.
The feed pivots about the elevation axis to eliminate additional flex-guide required when pivoting at the
edge of the reflector. The pivoting is facilitated by the double bearings of the rotary joint and the delrin
pivot. The elevation to polarization waveguide runs along the feed boom tubing. The feed / OMT is
rotated by a chain drive and 12V DC motor.
1.0
5.3 POLARIZATION DRIVE
The polarization drive motor is a 12V DC gear motor. It is housed in a polarization box, which attaches
to the feed assembly itself. Since the worm gear drive will not backdrive, no brake is required.
3.0
5.4 POLARIZATION POSITION FEEDBACK
4.0
Figure 5.1
The potentiometer is mechanically set at the one-half travel position (2500 ohms) when the stow
switch is actuated. The controller may also electrically zero the potentiometer. See section 4.1 of the
Controller manual.
20
Waveguide System......................................................................................................
Control Cable ..............................................................................................................
RF and Auxiliary Cables ...............................................................................................
MAINTENANCE...................................................................................................................
7.1
7.2
8.0
General .......................................................................................................................
Feed Assembly............................................................................................................
Polarization Drive ........................................................................................................
Polarization Position Feedback.....................................................................................
RF WAVEGUIDE AND ELECTRICAL CABLE SYSTEM
........................................................
6.1
6.2
6.3
7.0
Elevation Gear Box ......................................................................................................
Elevation Motor ...........................................................................................................
Elevation Roto-Lok Cable Drive ....................................................................................
Elevation Position Feedback.........................................................................................
Elevation Stow and Limit Switches ................................................................................
FEED AND POLARIZATION SYSTEM................................................................................. 5
5.1
5.2
5.3
5.4
6.0
Azimuth Bearing ..........................................................................................................
Azimuth Gear .............................................................................................................
Azimuth Motor .............................................................................................................
Azimuth Roto-Lok Cable Drive ......................................................................................
Azimuth Position Feedback ..........................................................................................
Azimuth Stow and Limit Switches..................................................................................
ELEVATION POSITIONING SYSTEM...................................................................................
4.1
4.2
4.3
4.4
4.5
5.0
General .......................................................................................................................
Installation to Vehicle ...................................................................................................
Controller Installation ...................................................................................................
Controller / Positioner Verification Tests ........................................................................
Elevation Stow Switch Verification ................................................................................
Final Calibration of System...........................................................................................
LNA/LNB Installation ....................................................................................................
AZIMUTH POSITIONING SYSTEM.......................................................................................
3.1
3.2
3.3
3.4
3.5
3.6
The polarization position feedback is produced by a 3 turn, 5K ohm potentiometer driven by the chain
drive with small spur gears. The resolution and accuracy is 0.3°. The potentiometer is rated for IP 65
environment – wind, rain, dust, etc. (Figure 5.1)
Technical Description...................................................................................................
Specifications ..............................................................................................................
INSTALLATION AND SET-UP ..............................................................................................
2.1
2.2
2.3
2.4
2.5
2.6
2.7
The feed assembly consists of a feed horn and OMT. The feed / polarization drive box is mounted to
the feed assembly. The feed horn is mechanically positioned with a template within 1/8” of the
theoretical focal point of the reflector. This positioning assures the RF system provides the gain and
FCC compliance as stated in the specifications.
PAGE
INTRODUCTI0N...................................................................................................................
1.1
1.2
2.0
5.2 FEED ASSEMBLY
DESCRIPTION
Annual Inspection ........................................................................................................
Spare / Replacement Parts List ....................................................................................
WARRANTY........................................................................................................................
5
1.0
INTRODUCTION
4.5 ELEVATION STOW AND LIMIT SWITCHES
The purpose of this manual is to provide information for the installation, operation and maintenance of
the Model 1.8 MVSAT. Should any problems arise which are not discussed within this manual, such
problems should be referred to the equipment manufacturer:
Patriot Antenna Systems
704 North Clark Street
Albion, Michigan 49224 USA
Telephone: 517-629-5990
FAX:
517-629-6690
If the antenna is mounted facing the front of the vehicle, remove the passenger side cover on the
elevation axis pivot shaft to gain access to the elevation stow, down and up limit switches. The switches
are fixed to reference ground (the elevation pivot blade) and are actuated by a cam on the rotating
elevation shaft. (Figure 4.4)
1.1 TECHNICAL DESCRIPTION
GENERAL
The Patriot 1.8 MVSAT system is a light weight, reliable system. The cable driven
system provides a near-zero backlash and highly reliable movement, all driven by a special
minimum / adjustable backlash gearbox powered by light, but rugged, DC drive motors. All drive
components are high strength steel in lightweight housings which result in the most reliable, stiff
system with the minimum of weight. The feed boom pivots at the elevation axis, allowing an option
of providing waveguide rotary joints on both the elevation and the azimuth axis. Also, pivoting the
feed boom at the elevation axis provides maximum space for a feed boom mounted amplifier or
transceiver. The Patriot Antenna System weighs only 220 lbs (100Kgs).
DRIVE SYSTEM
The drive system utilizes highly reliable aircraft control cables in a redundant configuration to
achieve a near-zero backlash, lightweight, very stiff drive system. It achieves this high tech
performance using low-tech components and simply wrapping the cable around the driver
capstan several times before wrapping the larger driven drum. The method used to wrap the
capstan results in a minimum length of free cable. The cables are pre-tensioned and spring
loaded at the main drum attachment point, eliminating backlash during antenna positioning.
SECONDARY DRIVE SYSTEM
The Azimuth and Elevation drive systems are driven by an adjustable cable, minimum
backlash worm gear set with a 40:1 ratio. The factory set and easily adjusted backlash of the
worm gear set is 1 – 2 arc minutes which is reduced further by the cable drive ratio resulting in
a backlash of only 0.005 degrees seen by the reflector system. Since the worm gear does not
back drive, an additional brake is not required on the motor. The worm-input shaft is extended
with a hex head end to allow manual deployment in case of power failure. Maximum gear
efficiency and minimum wear is achieved by sealing the gear sets in continuously lubricated
housings.
MOTOR DRIVES
Lightweight reliable servo quality DC motors with integral gearboxes are used for the Azimuth
and Elevation drive systems. These motors were selected because they provide the best
torque to weight ratio. Maximum reliability is achieved from the printed circuit armatures.
These motors produce constant torque over the speed range with uninterrupted travel at low
speeds, ensuring smooth operation during antenna peaking. The 18V DC design provides
current limiting torque control and will allow, if necessary, vehicle-battery powered operation.
The motors have their own weather tight covers but are covered with secondary covers to
assure maximum weather protection.
CONSTRUCTION
The trunnion, backing structure, feed booms and covers are all of aluminum construction.
Optional aluminum gear housings are available for minimum weight. Precision ground
bearings are used in all axes to assure long life and smooth positioning. The reflector is a
carbon fiber composite sandwich construction manufactured in a multiple lay-up operation.
The lay-up mold surface provides the surface accuracy required for optimum performance.
6
Figure 4.4
The elevation stow switch is actuated by the adjustable screw on the cam. It should be verified after
the system is installed on the truck so the reflector still clears the feed horn by approximately 1 inch.
Adjust the switch in small increments to allow for possible coasting of the elevation drive after power is
cut.
The elevation down limit switch is located at the 6 o’clock position. It rides up on the cam when the
elevation angle is below 5°. This prevents lowering the reflector / feed system below 5° until the
azimuth and polarization positioning systems are in their stow position.
The elevation up limit is located at the 10 o’clock position. It electrically terminates upward movement at
approximately 87°. The mechanical limit is 90° and may be achieved if desired by bending the actuator
slightly.
19
1.2/1.5/1.8-METER SPECIFICATIONS
MECHANICAL
1.2/1.5/1.8-METER MECHANICAL SPECIFICATIONS
Azimuth Travel
+130°continuous travel
Elevation Travel
5° - 90° of reflector boresight
0° - 65° for CE approved
Polarization Travel
+95° (for 2-port feed)
Drive Rates
2° / second (Az/El/Pol.)
+55° (for 4-port feed)
0.1° / second (peaking – Az/El)
Reflector
Carbon
Fiber
Aluminum
Feed
2 port and 4 port Ku band, Co and Cross pol
Finish
White
Weight
220 lbs (100 kgs)
Stow Height
18 inches (460 mm)
Electrical Interface
25 foot (7.6 m) cable pre-connectorized for various controller options
ENVIRONMENTAL
1.2/1.5/1.8-METER ENVIRONMENTAL SPECIFICATIONS
Operational Winds
Pointing Loss*
Figure 4.3
If the antenna is mounted facing the front of the vehicle, remove the driver side cover on the elevation
axis pivot shaft to gain access to the inclinometer. The inclinometer is covered with an aluminum cover
to protect it from weather and mechanical damage.
One mounting screw hole is slotted. The inclinometer is mechanically set at the correct boresight
position of 12.8° for the 1.2m, 15.8° for the 1.5m and 18.8° for the 1.8m antenna when the reflector face
surface is perpendicular to gravity. This is accomplished by loosening the allen screw (9/64 allen
wrench) and rotating the inclinometer. The inclinometer may also be electrically zeroed using the
controller. See section 4.1.1 of the Controller manual.
20 mph (32 km/h) winds
30 mph (48 km/h) winds gusting
to 45 mph (72 km/h)
Survival Winds (any position)
1.2-Meter
1.5-Meter
1.8-Meter
0.10 dB RMS loss
0.15 dB RMS loss
0.23 dB RMS loss
0.32 dB RMS loss
0.50 dB RMS loss
0.72 dB RMS loss
80 mph (128 km/h)*
Survival Winds (stow position)
120 mph (192 km/h)*
Ambient Temperature
Operational: +5° to 122°F (-15° to 50°C)
Rain (Operational and Survival)
Up to 4 in/h (10 cm/h)
Survival: -22° to 140°F (-30° to 60° C)
Relative Humidity
0% to 100% with condensation
Solar Radiation
360 BTU/h/ft (1000 Kcal/h/m )
Radial Ice (Survival)
1 inch (25 mm) on all surfaces, ½ inch (12 mm) on all surfaces
with 80 mph (128 km/h) wind gusts*
Corrosive Atmosphere
As encountered in coastal regions and /or heavily industrialized
areas.
•
18
45 mph (72 km/h) gusts to 60 mph (97 km/h)*
2
2
Loss does not include contribution of deflection due to the foundation mount.
7
2.0
INSTALLATION AND SET-UP
2.1 GENERAL
The 1.8 MVSAT antenna has been fully tested with the controller
prior to shipment. All position feedback, limit sensing, limit switches and motors have been calibrated
or set. The installation involves securing to vehicle, connecting waveguide, installing LNB’s,
connecting coaxial cable, connection of control cables to controller and connecting auxiliary control
cable as necessary.
The vehicle roof should be reinforced with a substructure capable of handling the wind loads as
specified on the interface drawings for each size antenna.
A 12-inch diameter hole should be in the mounting surface. The mounting surface must be flat within
0.005 inch to prevent binding the azimuth bearing after torquing the mounting bolts. No obstruction
should be above the interface surface in a 20-inch diameter envelope. Any other roof-mounted
equipment such as air conditioners should be more than 92 inches from center of interface bolt
pattern.
The 16-inch diameter, 12-bolt pattern must be oriented properly with two bolts 15° on either side of the
centerline of the vehicle. Reference vehicle interface drawing for proper orientation.
2.2 INSTALLATION TO VEHICLE
Remove the top of the shipping crate. Remove the narrow side at the azimuth platform end of the
crate. Using the hand crank furnished, hand crank the elevation axis until the reflector support
structure is vertical.
Remove the bolts attaching the positioner to the shipping base. Adjust the forks on a fork lift to just
straddle the azimuth ring and under the elevation pivot assemblies. Place cardboard pieces
between the positioner and the forks.
Carefully raise the antenna out of the crate and guide the control cables to prevent their catching on
the crate. Safety strap antenna to the fork lift truck. Remove the wooden antenna interface board from
the antenna. To serve as guides to position azimuth ring directly over the vehicle’s bolt circle, cut two
5/16-18 all thread rods to a length sufficient to allow protrusion into the vehicle interior for removal
once the antenna is seated into position. Grind one end of each rod to a rounded point to further help
guide antenna into the vehicle interface holes. Install these guides into holes diametrically opposed in
the antenna azimuth bearing. Maneuver the antenna to a position approximately two feet above the
vehicle interface. Note: Antenna must be installed with azimuth cable spring block aligned o
centerline of vehicle.(Figure 2.1)
IF INTERFACE SURFACE ISNOT FLAT apply a thin layer of structural epoxy grout between azimuth
ring and vehicle surface. Thread control cables into the 12-inch diameter hole. Lower the antenna to
the antenna interface. APPLY LOCKTITE 242 OR EQUIVALENT TO BOLTS,
install and snug bolts
finger tight. Allow epoxy to cure before final tightening.
Figure 4.2
4.4 ELEVATION POSITION FEEDBACK
IF INTERFACE SURFACE IS FLATAPPLY A THIN COAT OF SILICONE BETWEEN AZIMUTH
RING AND SURFACE. Thread control cables into the 12-inch diameter hole. Lower the antenna to
the antenna interface. APPLY LOCKTITE 242 OR EQUIVALENT TO BOLTS,
install and snug bolts
finger tight.
The elevation position feedback is produced by an electronic inclinometer. Since the drive has nearly
no backlash, the position feedback is as accurate as the resolution and accuracy of the inclinometer
The inclinometer has a resolution of 0.1 degrees with the accuracy / linearly of 1% in the 0 - 45° range
and monotonic in the 45 - 90° range. The inclinometer is rated for an outdoor environment. (Figure 4.3)
TIGHTEN ALL 12 BOLTS TO 18
-20 FT. LBS.
3 CONTROLLER INSTALLATION
Install controller into electronics rack. Connect P1 and P2 to J1 and J2. Note cables and jacks are
marked. Connect MS motor power cable to MS jack. Confirm voltage is correct. Connect AC power
cable to controller.
Figure 2.1
8
17
The motor drives the input worm via a quill / female hole and square key. The worm shaft is extended
with a hex shape for the hand crank. The dual elevation drive shafts are driven with a square key. Zero
backlash hubs are used to eliminate any backlash between keyed shafts. They are factory tightened
and should never be tightened again. Over-tightening can bind gearbox bearings. The elevation
capstan is secured to the dual output shafts with four cap screws. These screws are the “safety link”
and will shear under excessive loading conditions to protect the elevation drive system if the reflector
is not stowed and hits an obstacle while the vehicle is in motion.
The low backlash is achieved with a variable pitch worm. The width of the worm tooth slowly increases
along the worm. Since only one small portion of the worm tooth is meshing with the worm gear moving
the worm axially allows one to vary which section / width of the worm tooth is being used to drive the
worm gear. Therefore the backlash can always be minimized to 1 – 3 arc minutes. (Figure 3.2)
The gear box contains synthetic oil filled half way to the level plugs. Due to the design capacity of the
gear box, low rpm and comparative limited cycles experienced by an SNG system, no wear or
maintenance is expected.
2.4 CONTROLLED / POSITIONER VERIFICATION TEST
Turn power on. Wait for self-check to complete. Hit mode button once to reach display / function
mode. Since positioner is vertical, the display should read:
SLOW
ELEVATION
AZIMUTH
POLARIZATION
20.0 DEGREES
0.0 DEGREES
0.0 DEGREES
(APPROXIMATELY)
STOW (WITHIN 1°)
STOW (WITHIN 1°)
Press speed button to change speed to FAST
Caution! HAVE SOMEONE OUTSIDE AND ELEVATED SO THEY CAN OBSERVE ANTENNA
MOVEMENT DURING TEST!
Push El UP button. Antenna elevation reading should increase. Move until elevation reading is 18.8
degrees for the 1.8M.
Push Az CW and reading should increase. Run to CW Limit (120°).
4.2 ELEVATION MOTOR
Observe antenna movement for potential interference.
The elevation drive motor is a flat armature, servo quality, 18V DC motor with integral 75:1 spur gear
train. The motor armature rotates at up to 7000 rpm causing a high frequency noise that will vary
depending on the loading condition of the motor. (Figure 4.1)
The maximum output speed is 80 rpm. The output shaft is a standard keyed shaft. The output torque
capacity of the motor is rated for the operational wind load.
Since the low backlash worm gear drive isolates the backlash from the motor, any backlash between
the square key or motor gear train will never be seen by the reflector boresight. Any backlash at any of
these points is of no consequence to the system performance. No maintenance or wear of the
elevation motor is expected.
4.3 ELEVATION CABLE DRIVE
The elevation drive produces a near zero backlash, high stiffness, low wear, no lubrication, maximum
reliability drive system. The system consists of sixteen 3/32, 9 x 17 stainless steel aircraft control
cables reverse wrapped three times around the capstan with a solid connection on one end and high
force, belleville springs on the other end occurring at the elevation cable termination block. It requires
only eight of the cables to provide enough capacity to withstand the required 80-mph wind load. The
additional cables are used to provide increased stiffness and drive redundancy. If a cable becomes
damaged during use merely cut off cable and continue to use the positioner. The cable may b
replaced as time permits at a typical mainten
ance facility.
The cables are sized to last the life of the positioner. No replacement from wear is expected. The
spring package at one end will automatically compensate for any elongation of the cable.
At installation the belleville springs are collapsed until no “air” is seen between the springs. You should
check this condition yearly to account for the slow settling of the cable strands. Use a 3/16 open
wrench or pliers to hold stud and 7/16 box end wrench to tighten nut. Care should be taken to not
over tighten the assembly, the belleville springs should be almost fully collapsed to provid
the necessary tension on the cables.
(Figure 4.2)
16
Push Az CCW and reading should increase. Run to CCW Limit (-120°).
The Az CCW and CW limits can be increased depending on waveguide and control wire clearance at
truck interface. Refer to Section 3.6 of this manual and Section 4.1.3 of controller manual.
Push Az CW and reading should increase. Run to approximately -15°.
Push Pol CW and reading should increase. Run to CW Limit (55°).
Push Pol CCW and reading should decrease. Run to CCW Limit (-55°).
Push STOW, then BACKSPACE. Antenna should begin moving to 0° Polarization in slow speed. It
should stop at approximately 0° (+ / - 5°). STOW indication should occur in polarization.
Antenna should begin moving in fast speed in azimuth and slow down when approaching 0°. STOW
indication should occur in azimuth. If not, see Section 3.6.
Antenna should begin moving down in fast speed.
PRESS STOP WHEN ELEVATION DOWN LIMIT IS REACHED!
Verify that both azimuth and polarization CW and CCW are disabled.
2.5 ELEVATION STOW SWITCH VERIFICATION
NOTE: This step is provided in the event that the stow height must be adjusted. The stow switch is
set at the factory.
If the antenna is mounted facing the front of the vehicle, remove passenger side cover on the
elevation axis to gain access to elevation limit switches.
Press SPEED button to change to slow speed.
Press El Down button and watch system stow.
9
Have personnel on both sides of truck observing orientation of gas strut U-joints. Watch reflector
surface approach feed horn.
STOP WHEN REFLECTOR GETS WITHIN 6 INCHES OF FEED HORN.
NOTE: Elevation display has been disabled because electronic inclinometer produces erroneous
information at these angles.
Adjust stow switch adjustment screw in small increments until stow indication occurs at controller
when reflector surface is approximately 1” from padded reflector support. Check that padded rest
screws are tight.
Raise in elevation approximately 10°, change speed to fast, and run down. Keep finger on STOP
button! Motors will stop when switch is actuated but the reflector will coast very slightly.
Continue to adjust stow limit actuation until reflector is preloaded against padded support and clearing
feed horn by at least ½”. The feed boom should be depressing roof very slightly. The padded rest may
be adjusted in height if necessary.
Due to the fact that stow switch actuation occurs at slightly different positions depending on the
direction of approach, clockwise or counterclockwise, the azimuth stow may vary approximately 1°
from the actual 0° heading.
The mount has the mechanical capability of 270°. However, the limits must be set at +120° per section
4.1.2 of controller manual to prevent damage to the azimuth rotary joints on a 4-port system.
4.0
ELEVATION POSITIONING SYSTEM
The elevation pivot assembly consists of two elevation drum assemblies pivoting between two clevis
blades that house the precision aircraft torque tube bearings. These bearings are precision ground
with lifetime seals. They are permanently lubricated with synthetic grease. No wear or maintenance is
expected.
4.1 ELEVATION GEAR BOX
The elevation gearbox is a patented low backlash worm gear box. The worm gear drive si olates
backlash in the motor drive from the system. Also, since it is a 40:1 ratio it will not backdrive
eliminating any need for a brake on the drive train. (Figure 4.1)
Raise reflector 30-45°, and observe in full stow mode by pressing STOW, BACKSPACE.
Retighten cradle screws. A roll-pin pilot hole is provided for pinning the cradle if desired.
Reinstall elevation limit switch cover.
2.6 FINAL CALIBRATIONOF SYSTEM
If feed / reflector is not stowed centered on truck roof, the azimuth stow switch may be adjusted to
center on roof. Stow with positioner having to approach stow from both directions. See Section 3.6 if
azimuth stow position needs adjusting. If azimuth readout is not zero + / -2° when azimuth antenna is
stowed adjust zero voltage per Section 4.1.1 of controller manual.
2.7 LNA/LNB INSTALLATION
Install LNB/LNA’s to the ports in the feed boom housing.
Figure 4.1
10
15
3.0 AZIMUTH POSITIONING SYSTEM
3.1 AZIMUTH BEARING
The azimuth bearing is a precision ground Slim Line ball bearing with a dynamic and static moment
capacity of over four times the worst-case wind load specification. It is press / shrink fit into a special
aluminum bearing ring consisting of main internal and external rings with clamping rings. Both sides of
the bearing are sealed against contaminants with Teflon O-rings. The bearing is packed with Mobil 1
synthetic grease at assembly.
Because of the excess capacity, low rpm, and low number of cycles compared to the bearings B10
design life, no wear is expected. No maintenance should be required over the life of the positioner. A
grease fitting is furnished for the azimuth bearing to flush out contaminants if the positioner is operated
in extreme environments.
Over time, some of the oil in the grease will separate from the binder. Since this oil is very thin, it may
seep past the 0-rings. It will be red in color. If this occurs it is considered quite normal and should not
be considered a problem unless it is excessive. If so, use a standard grease gun with Mobil 1 synthetic
grease to repack bearings. Pump in grease very slowly as the unit rotates in azimuth. Look for grease
to begin to seep past O-ring seal between az platform and az bearing ring.
3.2 AZIMUTH GEAR BOX
Figure 3.4
The azimuth gearbox is a patented low backlash worm gear box. The worm gear drive isolates any
backlash in the motor drive from the system. Also, since it is a 40:1 ratio it will not backdrive
eliminating any need for a brake on the drive train. (Figure 3.1)
The potentiometer is mounted in an adapter that sits down into the bearing bore of the azimuth
gearbox. Since the torque required to turn a potentiometer is minimal, the mounting adapter is held in
place by a setscrew. The potentiometer is protected with an aluminum cover from the weather and the
use of the elevation handcrank.
The azimuth potentiometer is slotted and driven with a cross pin in the output of the worm gear box.
The potentiometer is mechanically set at the one-half travel position when the azimuth cable
termination block is directly across from it. This is accomplished by loosening the setscrew (1/8 allen
wrench) and rotating the adapter. The potentiometer may also be electrically zeroed by the controller.
See section 4.1 of Controller manual.
3.6 AZIMUTH STOW AND LIMIT SWITCHE
S.
The Controller uses the azimuth potentiometer voltage to determine limits. Therefore, the positioner is
equipped with only an azimuth stow position switch. Limit switch mounting holes are provided if
needed for other brand controllers.
The azimuth stow and limit switches are mounted under the azimuth platform accessible through the
12 inch diameter access hole on the base. The switches are fixed to reference ground (the truck) and
are actuated by falling into a concave notch in the azimuth bearing clamp ring. The azimuth stow
switch holes are slotted for + / - 2° adjustment.
Figure 3.1
The motor drives the input worm via a quill / female hole and square key. The worm shaft is extended
with a hex shape for the handcrank. The azimuth capstan is secured to the output shaft with a square
key and zero backlash hub.
14
11
The low backlash is achieved with a variable pitch worm. The width of the worm tooth slowly increases
along the worm. Since only one small portion of the worm tooth is meshing with the worm gear, by
moving the worm axially, you can vary which section / width of the worm tooth is being used to drive
the worm gear. Therefore the backlash can always be minimized to 1-3-arc minutes. (Figure 3.2)
The gearbox contains synthetic oil filled half way to the level plugs. Because of the design capacity of
the gearbox, low rpm and comparative limited cycles experienced by an SNG system, no wear or
maintenance is expected. If azimuth backlash of the positioner ever exceeds 0.020°, it may be
brought back to 0.005° factory setting by adjusting backlash in gearbox. (Figure 3.2).
Figure 3.3
Figure 3.2
Since all systems seek the condition of lowest potential energy, the cables after an adequate time for
break in will eventually stop stretching. At installation the belleville springs are collapsed until no “air”
is seen between the springs. You should check this condition yearly to account for the slow settling of
the cable strands. Use a 3/16 open wrench or pliers to hold the stud and 7/16 box end wrench to
tighten nut. Be sure not to over tighten the cables, but the belleville springs should almost be
fully collapsed.(See Figure 3.3)
3.4 AZIMUTH CABLE DRIVE
The azimuth drive produces a near-zero backlash, high stiffness, low-wear, no lubrication, maximum
reliability drive system. The system consists of four 3/32, 9 x 17 stainless steel aircraft control cables
reverse wrapped twice around the grooved capstan with solid connections on one end and high force,
belleville springs on the other end occurring at the azimuth spring block. One cable has the capacity to
withstand the 80-mph wind load. The additional cables are used to provided increased stiffness and
drive redundancy. If a cable becomes damaged during usage, merely cut off cable and continu
to use positioner. The cable can be replaced whenever time permits at a typical maintenanc
facility.
The cables are sized to last the life of the positioner. No replacement from wear is expected. The
spring’s package at one end will automatically compensate for any elongation of the cable. (Figure
3.3)
12
3.5 AZIMUTH POSITION FEEDBACK
The azimuth position feedback is produced by a 10 turn, 1K ohm potentiometer driven by the output
shaft of the worm gear box. Since the drive has nearly no backlash, the position feedback is as
accurate as the resolution and accuracy of the potentiometer and the backlash between the
potentiometer and the output shaft of the worm gear box. The potentiometer is rated for IP 65
environment – wind, rain, dust, etc. (See Figure 3.1 and 3.4)
13