4096-394

January 14, 2002

REVISION G
ASSEMBLY MANUAL

1.8 METER
SERIES 1194 ANTENNA SYSTEM

PRODELIN CORPORATION
1500 Prodelin Drive
Newton NC 28658
 4096-394
PRODELIN CORPORATION 1.8M SERIES 1194

1.8 METER SERIES 1194

ANTENNA SYSTEM

G Revise Address 1/14/02

F Revise Flat washers to 8 5/15/01 RAH
E Revised part list on page 8 1/22/99 RAH
D Revise Step 9 Pg. 12. ¾” was ½” nut. 03/26/98 PGW
C Revised It. 5 – pg. 8 , was 8033-012 11/05/97 PGW
B Updated 04/21/97 PGW
A Revised Page #19 10/03/95 R. Frye
- ORIGINAL RELEASE 02/02/95 R. Frye
REV. DESCRIPTION DATE APPROVED

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PRODELIN CORPORATION 1.8M SERIES 1194

1.8M SERIES 1194 ANTENNA SYSTEM

TABLE OF CONTENTS

SECTION I GENERAL INFORMATION ....................................................................... 5

1.0 INTRODUCTION ....................................................................................... 5
1.1 UNPACKING AND INSPECTION.............................................................. 5
1.2 FREIGHT DAMAGE .................................................................................. 5
1.3 MATERIAL - MISSING OR DAMAGED .................................................... 5
1.4 MECHANICAL INSTALLATION TOOLS .................................................. 6
1.5 FOUNDATION INTERFACE ..................................................................... 6
1.6 SUGGESTED MAST & FOUNDATION..................................................... 7

SECTION II ANTENNA SYSTEM ASSEMBLY............................................................. 9

2.0 ANTENNA ASSEMBLY ............................................................................ 9
2.1 FEED SUPPORT ASSEMBLY ................................................................ 14

SECTION III ANTENNA POINTING ............................................................................. 18

3.0 ANTENNA POINTING ............................................................................. 18

SECTION IV MAINTENANCE ...................................................................................... 20

4.0 MAINTENANCE OVERVIEW .................................................................. 20
4.1 PERIODIC INSPECTION......................................................................... 20
4.2 REFLECTOR........................................................................................... 20
4.3 MOUNT AND REFLECTOR SUPPORT STRUCTURE........................... 21
4.4 FEED AND FEED SUPPORT.................................................................. 21

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PRODELIN CORPORATION 1.8M SERIES 1194

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PRODELIN CORPORATION 1.8M SERIES 1194

SECTION I GENERAL INFORMATION

1.0 INTRODUCTION

This manual describes the assembly and installation of Prodelin's 1.8M Rx/Tx
offset antenna system with an Az/El mount (series number 1194). The Prodelin
1.8M is a rugged, reliable antenna system, which will operate in the 10.95 to
12.75 and 14.0 to 14.5 GHz frequency bands for Ku-Band systems with high
efficiency and at the same time successfully withstand the effects of the
environment.

These instructions are listed by sections that cover all areas of assembly and
installation. Additional sections are included in the manual to provide information
on antenna alignment to the satellite and maintenance.

1.1 UNPACKING AND 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.

1.2 FREIGHT DAMAGE

Any damage to materials while in transit should be immediately directed to the

freight carrier. He will instruct you on matters regarding any freight damage
claims.

1.3 MATERIAL - MISSING OR DAMAGED

Any questions regarding missing or damaged materials that is not due to the
freight carrier should be directed to Prodelin's Customer Service Department at:

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

1.4 MECHANICAL INSTALLATION TOOLS

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PRODELIN CORPORATION 1.8M SERIES 1194

The hardware supplied with this antenna system is U.S. SAE standard size.
However, the sizes have been chosen to allow use with compatibly sized metric
wrenches as shown in the table below.

HARDWARE SIZE SAE WRENCH METRIC WRENCH MAXIMUM REC.

SIZE SIZE TORQUE

5/16" BOLT 1/2" 13 mm 12 ft-lbs

(1.66 kg-m)
1/2" BOLT 3/4" 20 mm 45 ft-lbs
(6.20 kg-m)
3/4" NUT 1-1/8" 28 mm 160 ft-lbs
(22.07 kg-m)
1" BOLT 1-1/2" 38 mm 220 ft-lbs
(30.34 kg-m)

Also recommended for installation:

Inclinometer
Compass
Adjustable Wrench

1.5 FOUNDATION INTERFACE

The required interface from the foundation to the mount is 5" schedule 40 pipe
(5.56" or 14.12 cm O.D.). A suggested in-ground foundation is shown in
Figure 1.

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PRODELIN CORPORATION 1.8M SERIES 1194

1.6 SUGGESTED MAST & FOUNDATION

5” (12.7cm) SCH 40 PIPE

5.56”OD (14.12cm OD)2
TYP
2-5
42.0”
TYP 2 (107 cm)
2-5

42.0”
(107cm)
See Note #7
24.0”
(70cm)
A A
SECTION A-A

2” x 2” x 1 / 4” HRS Angle 12.0”

12” Long (TYP 2 PLACES) (30.5cm)
5cm x 5cm x .65cm Angle
30.5cm Long (TYP 2 PLACES)

FIGURE 1.

NOTES:
1. 2 x 2 x 1/4 HRS Angle and schedule 40 pipe should conform with ASTM A36 and ASTM
A53 Type E and S Grade B.
2. All concrete should conform to building code standards and have a
minimum compressive strength of 3000 PSI at 28 days. (Per ACI-318-77)
3. Soil bearing capacity should be no less than 2000 PSF.
4. Concrete should be poured against undisturbed soil.
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.)

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PARTS LIST - 1.8M ANTENNA ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY
1 VARIES 1.8M Reflector 1
2 0181-648 Az/El Positioner Assembly 1
3 0181-649 Reflector Support Tube 1
4 0247-169 Reflector Cross Arms 2
5 8043-014 1/2” x 1.75 Crg Bolt 4

6 8043-032 1/2” x 4.00 Carriage Bolt 4

7 8104-007 1/2” Hex Nut 8

8 8202-043 1/2” Lockwasher 8

9 8201-043 1/2” washer 8

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PRODELIN CORPORATION 1.8M SERIES 1194

SECTION II ANTENNA SYSTEM ASSEMBLY

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.

2.0 ANTENNA ASSEMBLY

STEP 1:

A). Remove azimuth rod from positioner

assembly.
B). Set azimuth rod and related hardware aside.

Positioner Assembly

Azimuth Rod

Existing Hardware

STEP 2:
Positioner
A). Loosen rotation bolt on top of positioner.

Rotation B). Rotate the positioner so that the canister

Bolt plate is oriented as shown.
Canister C). Lightly tighten rotation bolt.
Plate

90

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PRODELIN CORPORATION 1.8M SERIES 1194

To Satellite (within +/- 10° ) STEP 3:

A). Place positioner assembly onto mast
pipe.

B). Orient the positioner assembly

approximately towards the center of
Positioner Assembly the satellite orbital arc to within +/- 10°
as shown.
Canister Screws
Lock Nuts C). Securely tighten [8] canister screws.

D). Tighten [8] lock nuts against canister.

Mast Pipe

STEP 4:
3 / 4” Nuts Azimuth
Rod
A). Locate azimuth rod (step 1.) and loosen
the 3 / 4” nuts to allow movement of the azimuth
tube.

Azimuth Tube B). Remove 1 / 2” hardware from azimuth

1 / 2” Hardware tube and set aside.

STEP 5:
Azimuth Tube
A). Locate end hole on canister plate.
B). Position azimuth tube in hole and secure
with 1 / 2” hardware from step 4.

Canister Plate

1 / 2” Hardware

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PRODELIN CORPORATION 1.8M SERIES 1194

1 / 2” Hardware STEP 6:

Positioner A). Rotate azimuth rod or the positioner so

that the hole in the azimuth rod and the hole in the
tab on the side of the positioner
are lined up.
B). Secure the azimuth rod to the positioner
with the 1 / 2” hardware removed in step 1.
Azimuth Rod
C). Lightly tighten all of the azimuth adjustment
hardware at this time.

STEP 7:

A). Remove 1” hardware form the reflector

Reflector support tube.
Support Tube
B). Remove 1 / 2” hardware from the elevation
adjustment block and set aside.
1” Hardware

1 / 2” Hardware

Elevation Adjustment Block

STEP 8:
A). Place the reflector support tube in between
the large tabs on the positioner as shown.
Reflector Support
Tube
B). Line up the holes on the tabs with the
holes in the reflector support tube.
Large Tabs
C). Secure the support tube to the positioner
with the 1” hardware.

1” Hardware

STEP 9:

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PRODELIN CORPORATION 1.8M SERIES 1194

A). Loosen 3/4” nuts on elevation rod

to allow movement of the elevation
block.
3/4” Nuts
Elevation Rod
B). Slide elevation block down the elevation
rod and position the block in between
the small tabs on the positioner so that
the holes in both block and tabs are
Elevation Block aligned.

1 / 2” Hardware
STEP 10:
Elevation Block A). Secure elevation block to Positioner with
1 / 2” hardware set aside in step 7.
Positioner

STEP 11:

A). Attach reflector cross arms to the

reflector support tube with 1 / 2”
hardware ( items: 5,7,8,9).

Note the orientation of cross arms.

Cross Arm

[5]
Reflector Support Tube
4 places

[ 7,8,9 ] 4 places

Cross Arm

Top of Reflector STEP 12:

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PRODELIN CORPORATION 1.8M SERIES 1194

A). Locate the top of the reflector and insert

2 carriage bolts ( item 6 ) thru top two
holes on face of reflector as shown.

[6]

Top of Reflector STEP 13:

A). With a person on each side of the reflector,
lift the reflector up.
Cross Arm B). Position the reflector so that the 2 carriage
( TOP ) bolts (step 12) pass thru the two holes in
the top cross arm.

C). Loosely attach 1 / 2” hardware (items,7,8,9).

Note: the reflector is fully supported at
[ 7,8,9 ] this time.
4 places
D). Insert the 2 remaining carriage bolts (item 6)
thru the two bottom reflector mounting
holes and thru holes in the bottom cross
[6] arm
Cross Arm
( BOTTOM ) E). Secure with items: 7, 8 & 9.

F). Tighten all reflector mounting hardware per

torque specifications listed on page 6.

Reflector Support Tube

2.1 FEED SUPPORT ASSEMBLY

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PRODELIN CORPORATION 1.8M SERIES 1194

These instructions are intended as a general reference for feed support

assembly. If your antenna system has specific feed support installation
instructions, then refer to them at this time.

PARTS LIST - 1.8M FEED SUPPORT

ITEM NO. PART NO. DESCRIPTION QTY
1 VARIES Feed Rod 2
2 VARIES Feed Support Tube 1
3 8031-008 5 / 16” x 1.00” Bolt 3

4 8031-026 5 / 16” x 3.25” Bolt 1

5 8201-041 5 / 16” Flatwasher 10

6 8202-041 5 / 16” Lock Washer 6

7 8101-009 5 / 16” Hex Nut 6

8 8038-006 5 / 16” x .75” Carriage Bolt 2

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PRODELIN CORPORATION 1.8M SERIES 1194

CAUTION: During the assembly procedure, the sequence of instructions must

be followed. Do Not Tighten Any Hardware Until Instructed.
Refer to the feed support parts list and the steps shown below.

STEP 1:
A). Attach feed rods to reflector with
( items: 3, 6, 7 ) and with [ 2 ] of
( item 5 ).
See Detail A
NOTE: The 2.00” flat end of the feed
mounts to the outside rim of
the reflector

Feed Rods

STEP 2:

A). Mount feed support tube between the

feed support brackets with [ 2 ] of
( items: 8, 5, 6, 7 ).

Feed Support Tube

See Detail B

STEP 3:

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PRODELIN CORPORATION 1.8M SERIES 1194

A). Connect the feed rods to the feed

support tube with ( items: 4, 6, 7 )
and with [ 2 ] of ( item 5 ).

Feed Rod

See Detail C

Feed Support Tube

STEP 4:
A). Attach feed support tube to the
reflector with ( items: 3, 6, 7 )
and with [ 2 ] of ( item 5 ).

B). Tighten the hardware at the reflector

rim snugly ( Detail A ).

C). Tighten the hardware connecting

the feed rods to the feed support
Feed Support tube ( Detail C ).
Tube
D). Tighten the hardware that connects
the feed support tube to the feed
support brackets ( Detail B ).
See Detail D
E). Tighten the hardware connecting
the feed support tube to the reflector
( Detail D ).

F). Refer to separate instructions for the

specific feed/ODE assembly to feed
support.

DETAIL A

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[5]
[ 5, 6, 7 ]

[7]
Reflector

Feed Rod DETAIL B

Feed Support
Brackets

[ 5, 6, 7 ] Feed Support Tube

[ 5, 6, 7 ]

[8]
DETAIL C
Feed Rod

[5] [ 5, 6, 7 ]

[4]
DETAIL D
Feed Support Tube Reflector

Feed Support
Bracket [ 5, 6, 7 ]

[5]

[3]
Feed Support Tube

SECTION III ANTENNA POINTING

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PRODELIN CORPORATION 1.8M SERIES 1194

3.0 ANTENNA POINTING

The 1.8meter reflector contains an elevation offset look angle. Therefore, when
the reflector aperture is perpendicular to the ground, the antenna is actually
looking 17.3° in elevation. Refer to Figure 2.

Step 1: Place an inclinometer on the reflector support tube as shown in Figure 2.

The surface allows for the offset look angle and therefore a direct reading
can be taken for elevation.

Step 2: Adjust the reflector up or down in elevation by turning the two 3/4" hex
nuts at the elevation block until the desired elevation is read on the
inclinometer. Snug the hardware.

Step 3: Azimuth Adjustment: With the electronics set to acquire the satellite,
rotate the antenna in azimuth until the satellite is found. Snug the azimuth
adjustment hardware.

Step 4: Peak the antenna signal by fine adjustments made in both azimuth and
elevation until the optimum signal is achieved.

Step 5: Tighten all hardware used for adjustment.

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ELEVATION
ADJUSTMENT

AZIMUTH
ADJUSTMENT

INCLINOMETER

FIGURE 2.

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SECTION IV MAINTENANCE

4.0 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 in-
house maintenance staff. The materials used in the construction of this Earth
Station Antenna virtually eliminate any maintenance repairs.

4.1 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.

4.2 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.

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4.3 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.

4.4 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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