4096-476

October 15, 2002 Revision D

2.4 Meter 2 Assembly Manual

Piece Az/El
Installation
Instructions

2.4 METER SERIES

D Revised picture Page 10/1
1251 ANTENNA SYSTEM
22 5/02
C 1/21/
Revised Address CLT
02
11/2 PG
B Overall Update
1/97 W
Revised Hdw tables to 2/11/ PG
A
reflect B.O.M 97 W
4/10/
- ORIGINAL RELEASE RF
96
R
APP
E
DESCRIPTION DATE ROV
V
ED
.

PRODELIN CORPORATION 1500 Prodelin Drive Newton NC

28658
 2.4M SERIES 1251 ANTENNA SYSTEM

TABLE OF CONTENTS

SECTION TITLE

I GENERAL INFORMATION
1.0 INTRODUCTION
1.1 UNPACKING AND INSPECTION
1.2 MECHANICAL INSTALLATION TOOLS
1.3 SITE SELECTION
1.4 SUGGESTED MAST & FOUNDATION

II REFLECTOR AND SUPPORT ASSEMBLY

2.0 PART LIST
2.1 AZ/EL POSITIONER INSTALLATION
2.2 REFLECTOR PETAL ORIENTATION
2.3 REFLECTOR SUPPORT ASSEMBLY

III FEED SUPPORT

3.0 PART LIST
3.1 FEED SUPPORT INSTALLATION

IV ANTENNA POINTING
4.0 ALIGNMENT TO SATELLITE
4.1 INITIAL ALIGNMENT

V MAINTENANCE
5.0 MAINTENANCE OVERVIEW
5.1 PERIODIC INSPECTION
5.2 REFLECTOR
5.3 MOUNT AND REFLECTOR SUPPORT
5.4 FEED AND FEED SUPPORT
 4096-476 PRODELIN CORPORATION 2.4M
SERIES 1251 1.2 MECHANICAL
INSTALLATION TOOLS

SECTION I GENERAL INFORMATION

MAXIM
HARDW
1.0 SAE
INTRODUCTION METRIC
This manualUMdescribes the assembly and installation of Prodelin's 2.4M 2-
AREPieceWRENC WRENC REC.
Rx/Tx offset antenna system with an Az/El mount (series number1251). The Prodelin
SIZE 2.4M His SIZE
a rugged,Hreliable
SIZE antenna
TORQUsystem that will operate at C-band and Ku-band
frequencies with high efficiencyEand at the same time successfully withstand the effects of the
3 / 8”environment.
9/16” 14 mm 15 ft-lbs
1 / 2” 3 / 4” 20 mm 35 ft-lbs
5 / 8”These15instructions
/ 16” 24are
mmlisted70
byft-lbs
sections that cover all areas of assembly and installation.
1–1/ 160 ft-
3 / 4”Additional sections
28 are
mmincluded in the manual to provide information on antenna alignment to
8” lbs
the satellite and maintenance.
1–1/ 220 ft-
1” 38 mm
2” lbs
1.1 UNPACKING AND INSPECTION

1 UNPACKING & INSPECTION -The antenna containers should be unpacked and inspected at
the earliest date to ensure that all material has been received and is in good condition. A complete
packing list for each major component is supplied.

2 FREIGHT DAMAGE -Any damage to materials while in transit should be immediately directed
to the freight carrier. He will instruct you on the matters regarding any freight damage claims.

3 MATERIAL - MISSING OR DAMAGED - Any questions regarding missing or damaged

materials that is not due to freight carrier should be directed to Prodelin's Customer Service
Department at:

PRODELIN CORPORATION 1500 Prodelin Drive Newton NC 28658 USA (828) 464-4141

Also recommended for installation:

Adjustable Wrench 10” Ratchet (3 / 8” & 1 / 2” Drive) 3” Wrench ( socket, crescent or

pipe) for 2” bolt Inclinometer Compass

1.3 SITE SELECTION

In order to achieve maximum performance of your antenna system, it is important to select the
correct location for the antenna. The following guidelines should be observed when selecting a
site for the installation.

1 The line of site to the satellite should be clear of any obstructions, such as trees or buildings.
2 The site should be relatively flat and level for ease of installation and access to the antenna.
4096-476 PRODELIN CORPORATION 2.4M
SERIES 1251 SECTION
1.4 SUGGESTED
II REFLECTOR
MAST &
FOUNDATION
AND SUPPORT ASSEMBLY

3 The site should be checked for underground obstruction, such as buried cables or pipes.
REFLECTOR AND SUPPORT
4 All local building codes should be adhered to (i.e. grounding, foundation requirements, zoning
ASSEMBLY PART LIST- TABLE
rules, setbacks, etc.).
2.0
IT PAR Q
E T DESCRIPTION T
M NO. Y
1 017 1
9-
REFLECTOR “A” SIDE
381
REFLECTOR “A” SIDE –
017
WITH SHC
9-
383
2 017 1
9-
REFLECTOR “B” SIDE
382
REFLECTOR “B” SIDE –
017
WITH SHC
9-
384
018
Az / El POSITIONER
3 1- 1
ASSEMBLY
691
015
4 9- THREADED INSERT 6
283
049
5 0- SUPPORT TUBE 1
601
025
TOP / BOTTOM
6 0- 2
CROSSARM
657
NOTES:
018 ELEVATION
17 1-2 x 2 ADJUSTMENT
x 1/4 HRS Angle and schedule 140 pipe should conform with ASTM A36 and ASTM A53 Type E
and S249
GradeASSEMBLY
B.
2 049All concrete should conform to building code standards and have a minimum compressive strength
of 3000 PSI at 28 days. (Per ACI-318-77)
8 0- CROSSARM WELDMENT 1
3 602 Soil bearing capacity should be no less than 2000 PSF.
49 820 Concrete should be poured against undisturbed soil.
3/4 ” FLATWASHER 6
5 Allow concrete 24 hours set time before installation of antenna.
6 The antenna should be properly grounded to meet applicable local codes.
7 Minimum depth as shown or extend to local frost line.
8 Foundation meets the design requirements as set forth by the uniform building code. (1982 edition)

(PRODELIN CORPORATION DOES NOT REPRESENT OR WARRANT THAT ANY PARTICULAR DESIGN OR
SIZE OF FOUNDATION IS APPROPRIATE FOR ANY LOCALITY OR EARTH STATION INSTALLATION.)
 PARTS LIST -
CONTINUED
IT PAR Q
E T DESCRIPTION T
M NO. Y
1 810 3/4” HEX NUT 6
1 6-
007
1 820 1/2” FLATWASHER 1
2 1- 2
043
1 820 1/2” FLATWASHER - 2
3 1- NARROW 8
030
1 820 1/2” LOCK WASHER 2
4 2- 0
043
1 810 1/2” HEX NUT 2
5 4- 0
007
1 803 1/2”-13 x 1.25 BOLT 1
6 3- 4
010
4096-476
PRODELIN CORPORATION 2.4M
SERIES
1251
2.1 Az / El POSITIONER
INSTALLATION
STEP 1:

CAUTION: During the assembly procedure, the sequence of instructions must be followed. Do Not
Tighten Any Hardware Until Instructed. Refer to the antenna assembly parts list and
the following steps.

Back out the [8] 5/8” set screws from the canister and slip Az/El positioner assembly over the mast
pipe. Tighten the set screws snug against the mast pipe.
Az/El Positioner Asm

5/8” Set Screws

Mast Pipe

STEP 2:

A) Loosen the 2” rotation bolt on2” Rotation Bolt top of the positioner.

B) Rotate the positioner so that the canister plate is oriented as shown.

C) Lightly tighten the 2” bolt.

90

STEP 3:

1” Nuts
A) Remove the azimuth rod from the positioner.

B) Run one of the 1” nuts up towards the tab end of the rod and removeAzimuth Rod the other 1” nut.

Tab Canister Plate Adjustment Tube

 Azimuth Rod 1” Hex nut

To Satellite (within 5 deg.)

2” Bolt

Azimuth Rod 3/4” Hardware

2.4M SERIES 1251

STEP 4:
Place the end of the azimuth rod thru the adjustment tube attached to the top of the canister plate
and replace the 1” hex nut.

STEP 5:
A) Re-attach the azimuth rod to the positioner with the 3/4” x 2.00 bolt flatwashers, lockwasher,
sleeve and nut. Tighten securely. Snug the 2” rotation bolt at this time.

B) The positioner must be oriented correctly to the center of the satellite orbital arc. Loosen the
set screws and rotate the canister on the mast pipe to the required position. Tighten the set
screws then tighten the 5/8” lock nuts against the canister.
2.2 REFLECTOR PETAL ORIENTATION

The series 1251 reflector petals are labeled “A” and “B”. In the standard upright position, the
antenna elevation angle range is between 5 and 90 degrees. When viewed from behind in the
standard position (feed support at the bottom), the “A” petal (item 1) is on the left side and the
“B” petal (item 2) is on the right side – See Fig. 1.

However, to achieve a lower profile installation or in areas of high snow accumulation, the
reflector can be assembled inverted (feed support on top) with the “B” petal on the left side
and the “A” petal on the right side – See Fig. 2. Please note that in either situation, the angled
cross arm (item 8) must be oriented for the correct position – See Fig. 3.

“A” Petal
“B” Petal

( item 1 )

( item 2 )

Center of Reflector

Feed Rod Holes

Feed Support at Bottom

Figure 1
 Feed Support on Top
“B” Petal ( item 2 )

Feed Rod Holes

Center of Reflector
4096-476
PRODELIN CORPORATION 2.4M SERIES
1251
2
.

STEP 1: Place three

of the threaded
inserts (item 4) thru
[ 9,
the face of each
10,
reflector petal (items
11 ] [4
1& 2) and secure
Reflec ]
with 3/4” hardware
tor
(items 9, 10 & 11).
Petal
Snug only, Do not
completely tighten
at this time.
1”
Hardw
are STEP 2:
A) Remove the 1”
bolt and hardware
from the Az/El
Orientation of Angled Crossarm positioner.
for Standard Position
B) Straddle the tabs
of the reflector tube
(item 5)over the
holes in the
positioner and
replace 1” bolt and
Orientation of Angled hardware. Tighten
Crossarm for Inverted snug only and let
Position the tube fall back
Figure 3
upon the positioner.
[5
]
1”
Bol
t
Positi
oner
 [12, 14, 15 ] 4 PL STEP 3:
Attach the top and bottom crossarms (item 6) to
the reflector support tube with 1/2” hardware
(items 12,14,15,17). Note orientation of
crossarms. Do not tighten.

[ 6 ] 2 PL
[ 17, 12 ] 4 PL

STEP 4:
A) Place one reflector petal onto the Cross
arms in either the standard or inverted position
– see 2.2. Attach with 3/8” hardware (items
19,20,21)
Reflector at each crossarm. Do not tighten Petal B) Place the second reflector petal on the cross
arms and repeat above procedure.
Crossarms

Reflector Petal

Insert

Crossarm

[ 19, 20, 21 ]

STEP 5:
Check for best Attach the two petals together with 1/2”Petal Alignment
16 hardware (items 13, 14, 15, 16) at the fourteen
holes on the inner seams of the reflector petals.
Tighten these bolts securely at this time while
aligning the petals at the face of the reflector.
Petal
Petal

Suppor
[ 13, 14, 15 ] [ 16,13 ]
t Tube
3/4”
Hardw
are STEP 6: Flatw
Elevati
on Locate the elevation assembly (item [7]
Assem 7)
bly 3/4”
[ 19, 1” Hex Nut and remove the 3/4” hardware as well
Hard
20,
& as one 1” hex nut and washer.
21 ]
Suppor
t Tube
[ 12,
Adjustment
14,Tube
15 ] STEP 7:
[8] Carefully swing the reflector up into a vertical
position. Insert the elevation assembly (item 7)
[ 19,20, thru the elevation adjustment tube at the back of
21] the positioner. Replace the 1” hex nut and
[ 18, flatwasher.
12 ]

Elevation Assembly

1” Hex Nut & Flatwasher

STEP 8:
Attach tabbed end of the elevation
assembly to the tab on the back of the
reflector support tube with the
17 3/4” hardware removed in step 6.
Tighten securely.

STEP 9:
A) Attach the angled crossarm (item 8) to the reflector support tube in either the standard or
inverted position depending on the reflector orientation with 1/2” hardware (items 12, 14, 15, 18).
B) Attach the ends of the crossarm to the reflector petals at the threaded inserts with 3/8” hard-
ware (items 19, 20, 21).

C) Tighten the reflector support hardware by first tightening the 3/4” hardware at the six reflector
inserts followed by the 3/8” bolts holding the reflector to the three crossarms. Next tighten six 1/2”
bolts holding the crossarms to the reflector support tube. Do not tighten the elevation hardware
until after satellite alignment.
4096-476 PRODELIN CORPORATION 2.4M
SERIES 1251 3.1 Feed Support
Installation STEP 1:

SECTION III FEED SUPPORT ASSEMBLY

The following instructions are for installing a typical C-band or Ku-band feed support to Prodelin's 2.4
meter antenna system.
Attach the feed rods loosely to the reflector with 3/8” hardware (items4, 6, 7 & 8 ). See detail A

Feed Rods

STEP 2:
Position the feed support in front of the reflector and attach to the ends of the two feed rods with 3/8”
hardware ( items 5, 6, 7 & 8 ). See Detail B. Do not tighten.

See Detail B Feed Support Tube

 STEP 3:
Lift the end of the feed support tube and attach to the bottom of the reflector with
3/8’ hardware (items – 4, 6, 7 & 8). See Detail C. Tighten all feed support hardware
at this time.

Feed Rod

Feed Support Tube

DETAIL A
 Feed rods attach
to last hole in feed support
DETAIL B

DETAIL C [ 6, 7, 8 ]
 Fe
ed Support Tube

Reflector
[4]

NOTE: At this time you are ready to install your C-band or Ku-band feed system. For feed
installation, reference any instructions that are enclosed with your specific feed support.
SECTION IV ANTENNA POINTING

4.0 Alignment To Satellite

The 2.4M offset reflector contains a 22.3° elevation offset angle. Therefore, when the reflector
aperture is perpendicular to the ground, the antenna is actually looking 22.3° in elevation. The
following alignment procedure is intended only as a general reference guide for this antenna. For
proper antenna performance, accurate alignment is critical. Therefore, it is recommended that your
own detailed procedure be used or contact Prodelin’s Technical Support Department for additional
recommendations.

4.1 Initial Alignment

1) Place an inclinometer on the

reflector support as shown in Figure
4. Remember to add 22.3 degrees to
the reading to allow for the reflector’s
offset angle ( or subtract 22.3
degrees if inverted)
2) Raise or lower the antenna to find
the desired elevation by turning the
1" nuts located at the elevation
block. Position the top nut so that it
will not interfere with adjustment.
Turn the bottom nut clockwise to
increase elevation and
counterclockwise to decrease
elevation.
3) After the correct elevation angle is
set, rotate the antenna in azimuth by
loosening the 1” nuts on the azimuth
adjustment rod. Rotate azimuth until
a signal is reached.
4) Peak the antenna signal by fine
adjustments made in both azimuth
and elevation.
Tighten all of the hardware used for
5)
Figure 4
SECTION V MAINTENANCE

5.0 Maintenance Overview

After installation, the antenna requires only periodic inspection. It is anticipated that
maintenance, if required, will be minimal and easily handled by a local or inhouse maintenance
staff. The materials used in the construction of this Earth Station Antenna virtually eliminate
any maintenance repairs.

5.1 Periodic Inspection

It is suggested that a periodic inspection be performed at least every six months. NOTE: After

any very severe weather conditions, inspection of the antenna

should be performed to determine if foreign objects have caused damage or if survival

specifications have been exceeded. This inspection should include the following: 1) Check all

bolting locations - all bolts should be tight. 2) Check all structural members - repair or replace if

damaged. 3) Check the foundation anchor bolts - they must be secure and with no

failure signs in foundation. 4) Check for corrosion - on the reflector structure and mount.

5.2 Reflector

Prodelin's reflector does not require any maintenance. The composite construction of the
reflector is virtually impervious to any damages that could be caused by weather or other
atmospheric conditions.

It is only necessary to inspect for any physical damage done by vandalism or very severe
weather conditions.

Should any damage be detected to a portion of the reflector, contact the Customer Service
Department at Prodelin for recommendations involving reflector repair.
5.3 Mount And Reflector Support Structure

The mount and reflector support structure supplied with this antenna is of steel construction
and has a hot-dipped galvanized finish.

If inspection shows any signs of structural failure, the mount members that are damaged
should be repaired or replaced.

Corrosion: Any corrosion on steel members may be repaired with a cold, zinc-rich galvanizing
paint.

5.4 Feed And Feed Support

The feed support system should be inspected to insure that all hardware is secure. The
feed/radio mounting bolts should be tight.

The feed horn window should be inspected to insure that it is intact so that no moisture can
collect inside the feed horn. Replace if damaged.
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