Channel Master 960 I User manual

Type 960 Class I & II .96m Antenna System
Type 123 Class I & II 1.2m LFL Antenna System
Factory Assembled Az/El Cap Mount
US Sales Office • 1315 Industrial Park Drive, Smithfield, NC 27577 USA • Telephone:[phone] • Fax:[phone]
Germany Sales Office • Julius-Moser-Str. 13, 75179 Pforzheim, Germany • Telephone: [phone] • Fax:[phone]
©2001 Channel Master LLC ECN 9000000 P/N 8000842 8/01
Instruction and
Assembly Manual

VSAT ANTENNA/MOUNT/LNB
LIMITED TWELVE (12) MONTHWARRANTY
This CHANNEL MASTER®equipment is warranted to be free from defects in material and workmanship under
normal use and service. CHANNEL MASTER shall repair or replace defective equipment, at no charge, or at its
option, refund the purchase price, if the equipment is returned to CHANNEL MASTER not more than twelve (12)
months after shipment. Removal or reinstallation of equipment and its transportation shall not be at the cost of
CHANNEL MASTER except CHANNEL MASTER 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 CHANNEL MASTER 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 CHANNEL MASTER.
Claimants under this Warranty shall present their claims along with the defective equipment to CHANNEL
MASTER 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. CHANNEL MASTER DOES NOT AUTHORIZE ANY PERSON TO ASSUME
FOR IT THE OBLIGATIONS CONTAINED IN THIS WARRANTY AND CHANNEL MASTER 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 CHANNEL MASTER 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 CHANNEL MASTER 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.
DATE DESCRIPTION REV.
7/01 ECN 9000000 Rel.
1

IMPORTANT!!!
INSTALLATION OF THIS PRODUCT SHOULD BE PERFORMED ONLY BY A PROFESSIONAL INSTALLER AND
ISNOTRECOMMENDED FOR CONSUMER D.I.Y.(DO-IT-YOURSELF)INSTALLATIONS.
DANGER!!!
WATCH FOR WIRES! Installation of this product near power lines is dangerous. For your own safety, follow these important safety rules.
1. Perform as many functions as possible on the ground.
2. Watch out for overhead power lines. Check the distance to the power lines before starting installation.
We recommend you stay a minimum of 6 meters (20 feet) from all power lines.
3. Do not use metal ladders.
4. Do not install antenna or mast assembly on a windy day.
5. If you start to drop antenna or mast assembly, get away from it and let it fall.
6. If any part of the antenna or mast assembly comes in contact with a power line, call your local power company.
DONOT TRY TO REMOVE IT YOURSELF! They will remove it safely.
7. Make sure that the mast assembly is properly grounded.
WARNING!!!
Assembling dish antennas on windy days can be dangerous. Because of the antenna surface, even slight winds create strong forces.
For example, a 1.0m antenna facing a wind of 32km/h(20 mph)can undergo forces of 269 N(60 lbs). Be prepared tosafelyhandle these forces
at unexpected moments. Do not attempt to assemble, move or mount a dish on windy days or serious, even fatal accidents may occur.
Channel Master®is not responsible or liable fordamage or injury resulting from antenna installations.
Antennas improperly installed or installed to an inadequate structure are very susceptible to wind damage. This damage can be very serious or
even life threatening. The owner and installer assumes full responsibility that the installation is structurally sound to support all loads (weight,
wind & ice) and properly sealed against leaks. Channel Master will not accept liability for any damage caused by a satellite system due to the
manyunknownvariable applications.
The first and most important consideration when
choosing a prospective antenna site is whether or not the
area can provide an acceptable “look angle” at the
satellites. A site with a clear, unobstructed view is preferred.
Also consider obstruction that may occur in the future such
as the growth of trees.Your antenna site must be selected in
advance so that you will be able to receive the strongest
signal available. To avoid microwave interference, obstruc-
tions, etc.conduct an on-site survey with a portable antenna.
As with any other type of construction, a local building
permit may be required before installing an antenna.It is the
property owner’s responsibility to obtain any and all permits.
Before any digging is done, information regarding the possi-
bility of underground telephone lines, power lines, storm
drains, etc. in the excavation area should be obtained from
the appropriate agency.
Because soils vary widely in composition and load capacity,
consult a local professional engineer to determine the
appropriate foundation design and installation procedure. A
suggested foundation design with conditions noted is included
in this manual for reference purposes only.
2
ASSEMBLY TOOLS REQUIRED
1 - Compass 1 - 10mm Nut Driver 1 - 13mm Deep Socket (³⁄₈”Drive)
1 - Clinometer 1 - 10mm Socket (³⁄₈” Drive) 1 - 9”Magnetic Level
1 - Ratchet Wrench (³⁄₈” Drive) 1 - Phillips Screwdriver (#1 or #2) 1 - 13mm Combination Wrench
1-Torque Wrench 1 - 10mm Combination Wrench
PREINSTALLATION MATERIALS CHECKLIST
Grounding Rod Clamp & Grounding Block - As Required by National Electric Code or local codes.
Ground Wire - #10 solid copper as or required by National Electric Code or local codes (length required).
Concrete - (See Ground Pole section for quantity and grade).
#3 Rebar - (See Ground Pole section for quantity).Deformed steel per ASTM A615, grade 40 or 60.
SITE SELECTION

GROUND POLE INSTALLATION (96cm System)
GROUND
ANT WIND VEL. DIM “d” CONC VOL. DIM “d” CONC VOL. DIM “d’ CONC VOL. DIM “d” CONC VOL. POLE
80 MPH 7” 0.9 10” 1.8 7” 1.2 7” 1.2 “A”
90 MPH 8” 1.2 13” 3.0 7” 1.2 8” 1.5
96cm 100 MPH 10” 1.8 15” 4.0 7” 1.2 10” 2.4 “A” or
110 MPH 11” 2.2 17” 5.2 7” 1.2 11” 2.9 “B”
125 MPH 14” 3.5 20” 7.2 9” 1.9 14” 4.7 “B” Only
POLE SPECIFICATIONS:
Ground Pole “A” = 3.00 O.D. x 10 G.A. x 72” Steel
Ground Pole “B”= 2⁷⁄₈ O.D. x .203 Wall x 72” Steel ASTM 120 Mech Tubing (2¹⁄₂ Sch. 40)
NOTE:
Pole not supplied and must be field drilled ⁵⁄₈”dia. for #3 rebar and drilled .218 for ¹⁄₄-20 self tapping grounding
screw (see Page 7) and galvanized or painted for protection.
1 - Pole and foundation design based on the following criteria:
a) Uniform building code exposure B or C and 1.5 stability factor.
b) Vertical soil pressure of 2000 pounds per square foot.
c) Lateral soil pressure of 400 pounds per square foot.
d) Concrete compressive strength of 2500 pounds per square inch in 28 days.
2 - CAUTION -The foundation design shown does not represent an appropriate design for any specific locality since soil conditions vary
and may not meet design criteria given in Note 1. You should consult a local professional engineer to determine your soil conditions
and appropriate foundation.
Exposure “B” Exposure “C” Exposure “B” Exposure “C”
PIER FOUNDATIONS DEEP FROST LINE FOUNDATIONS
STANDARD
PIER FOUNDATION DEEP FROST
LINE FOUNDATION
3

GROUND POLE INSTALLATION (1.2m System)
4
GROUND
ANT WIND VEL. DIM “d” CONC VOL. DIM “d” CONC VOL. DIM “d’ CONC VOL. DIM “d” CONC VOL. POLE
80 MPH 8” 1.3 13” 3.4 8” 1.6 10” 2.5 “A” or
90 MPH 10” 2.0 16” 5.1 8” 1.6 12” 3.6 “B”
1.2M 100 MPH 12” 2.9 18” 6.5 8” 1.6 13” 4.2 “B” or
LFL 110 MPH 14” 3.9 21” 8.8 10” 2.5 16” 6.4 “C”
125 MPH 17” 5.8 24” 11.5 12” 3.6 19” 9.0 “D”
POLE SPECIFICATIONS:
Ground Pole “A”= 2.88 O.D. x .154 Wall (Sch 40) x 72” ASTM A53 or A501 Pipe
Ground Pole “B” = 3.00 O.D. x 9 Ga. (.148 Wall) x 72” Steel - CM PN 611685101
Ground Pole “C” = 2.88 O.D. x 2.88 O.D. x .276 Wall (Sch 80) x 72” Steel ASTM A53 or A501 Pipe
Ground Pole “D” = 3.00 O.D. x .250 Wall x 72” Steel ASTM 120 Mech Tubing
NOTE:
Pole “B” is supplied from factory powder painted and with hole for #3 rebar and grounding screw.
Poles “A”, “C” and “D” are not supplied and must be field drilled ⁵⁄₈” dia. for #3 rebar and drilled .218
for ¹⁄₄-20 self tapping grounding screw and galvanized or painted for protection.
1 - Pole and foundation design based on the following criteria:
a) Uniform building code exposure B or C and 1.5 stability factor.
b) Vertical soil pressure of 2000 pounds per square foot.
c) Lateral soil pressure of 400 pounds per square foot.
d) Concrete compressive strength of 2500 pounds per square inch in 28 days.
2 - CAUTION -The foundation design shown does not represent an appropriate design for any specific locality since soil conditions vary
and may not meet design criteria given in Note 1. You should consult a local professional engineer to determine your soil conditions
and appropriate foundation.
Exposure “B” Exposure “C” Exposure “B” Exposure “C”
PIER FOUNDATIONS DEEP FROST LINE FOUNDATIONS

ASSEMBLYANDINSTALLATION
INSTALLING AZ/EL CAP MOUNT ONTO POLE
The AZ/EL Cap is factory preassembled, therefore, no
assembly is required. Before installing AZ/EL Cap onto
ground pole, a concrete foundation should be in place
and cured.
MODEL 611612001 (Fine Tune Option)
Loosen (8) Carriage Bolts and nuts securing the “U”
Bracket to the Top Bracket and “U” Bracket to (2) half
clamps and swivel nut, hex nut (for optional fine tune fea-
ture). (Ref. Fig. 1.0). Install AZ/EL Cap Mount onto
Ground Pole. Equally tighten (4) Clamp Bolts so that
Cap is held stationary on Ground Pole, but can be
swiveled with slight pressure (approximately 2 ft-lbs (2.7
N-m). Retighten and torque (4) Carriage Bolts and nuts
securing “U” bracket to half clamps to 18 ft-lbs (24.4 N-
m). Leave loose (4) Carriage Bolts and Swivel Nut, Hex
Nuts, for fine tune option.
MODEL 611612002 (w/o FineTune Option)
Make sure (4) carriage bolts and nuts securing the
(2) Half Clamps to top bracket are loose.(Ref. Fig.
1.1) Place AZ/EL Cap onto Ground Pole and tighten (4)
Half Clamp Bolts to approximately 2 ft-lbs (2.7 N-m) (just
enough to allow AZ Clamp to turn on pole with slight
pressure). Tighten and torque (4) Carriage Bolts and
Nuts in Top Bracket to 18 ft-lbs (24.4 N-m) (loosened
above).
ASSEMBLING REFLECTOR ONTO AZ/EL CAP MOUNT
96cm System
Install two M8 x 2.21 (56.1mm) Plow Bolts into holes
in Reflector Face and two 3.58 (90.9mm) into bottom
holes.Lift Reflector and insert exposed portion of bolt
into holes into Antenna Bracket Flange.Install 4 Lock
Washers and Hex Nuts on bolts. (Ref. Fig. 1.2)
1.2m System
Install four M8 x 3.58 (90.9mm) Plow Bolts into top
holes in Reflector Face. Lift Reflector and insert
exposed portion of bolt to holes in Antenna Bracket
Flange. Install 4 Lock Washers and Hex Nuts on
bolts. (Ref. Fig. 1.2)
Assemble Extension Plate to AZ/EL Housing using
two M6 x 22mm Round Head Square Neck Bolts,
Lock Washers, and Hex Nuts. (Ref. Fig. 1.3) Tighten
and torque to 6 ft-lbs (8 N-m).
Tighten and torque Reflector bolts to 11 ft-lbs (15 N-m).
IMPORTANT: Note orientation of bolt holes in Reflector
Flange. Holes should be located on each side and bot-
tom of the Reflector as shown in Figure 1.2.
FIG. 1.0 - Model 611612001 AZ/EL w/FineTune
Option
FIG. 1.2 - Assembling Reflector to AZ/EL Mount
and Ground Pole (.96cm Shown)
FIG. 1.1 - Model 611612002 AZ/EL w/o Fine
Tune Option
5

6
ASSEMBLYANDINSTALLATION
FEED AND FEED LEG INSTALLATION
NOTE: Long formed end of Side Feed Leg attaches to
the Reflector rim, short formed to side of Feed Support
Terminal.
Assemble Bottom Feed Leg to bottom of Reflector rim.
From the inside of Reflector rim, insert M6 x 16mm Hex
Bolt thru hole in rim and attach Bottom Feed Leg.Secure
with Lock Washer and Hex Nut.
NOTE:Bottom Feed Leg is the one with slight bend, with
lance, on one end, and is shorter than the Side Feed
Legs.
Leave all hardware loose. Insert Bottom Feed Leg end
with lance into socket hole in center of Feed Support
Terminal. Twist to engage lances. Attach left and right
Feed Support Legs to Feed Support Terminal, securing
with M6 x 16mm Hex Bolts and Lock Washers. Refer to
Instruction for Feed Assembly to assemble Feed
Assembly and ODU to Terminal Block. Tighten and
torque all hardware to Terminal Block and Reflector to
4 ft-lbs (5.4 N-m). Tighten two screws in Terminal Block
socket equally.
FEED AND FEED SUPPORT TUBE INSTALLATION
MEDIUM DUTY
Assemble “U” Clip to bottom of Reflector using M6 x
22mm Round Head Square Neck Bolt, LockWasher and
Hex Nut. Insert bottom Feed Support Tube into “U” Clip
and secure with M6 x 55mm Round Head Square Neck
Bolt and elastic Lock Nut. (Ref.Fig. 1.5 & 1.6) Assemble
Feed Support Block (supplied with Feed package) to
Feed SupportTube, using two M6 x 16mm Hex Bolts and
Lock Washers.
96cm System (Ref. Fig. 1.5)
Attach Side Feed Legs and Braces to left and right
sides of Reflector using M6 x 20mm Hex Bolts, Lock
Washers and Hex Nuts. (NOTE: Long formed end of
Feed Leg attaches to Reflector. Short formed end of
Brace attaches to inside of Reflector rim.) Attach flat-
ten end of Brace to top of Mount Housing using M6 x
22mm Round Head Square Neck Bolts, Tooth Lock
Washers, Flat Washers and Hex Nuts. Round Head
Square Bolt fits on the underside of Mount Housing
top, flatten end of Brace on top side of Mount
Housing, Tooth Lock Washer on top of flatten end of
Brace, then Flat Washer and Hex Nut.
Attach Side Feed Legs to support Block using M6 x
20mm Hex Nuts and Lock Washers. Leave all hard-
ware loose.
FIG. 1.3 - Installation of Extension Plate to AZ/EL
Housing (1.2m medium Duty Only)
FIG. 1.5 - Installation of Feed/Feed Support Legs
to Antenna (96cm Medium Duty)
FIG. 1.4 - Installation of Feed/Feed Support Legs
to Antenna (Light Duty, 96cm Shown)

NOTE: All installations to conform to latest issue of
National Electrical Code.
Ground antenna mount assembly and feed cables in
accordance with current National Electrical Code and
local electrical codes. Figure 2.0 and 2.1 illustrates
typical grounding methods for the ground pole and
feed cables.
Clamps that provide a solid connection between ground
wire and ground source should be used.
Tighten and torque all hardware.
IMPORTANT:Sealing RF Coaxial Connector: The
copper-plated center conductor in the RF coaxial cable,
which connects receiver to LNB, can experience
electrolysis corrosion at the LNB connector. Moisture
and DC current causes this type of corrosion.To prevent
corrosion, apply a moderate coat of silicon grease to the
center conductor and wrap the entire connection with
COAX-SEAL®tape to seal.
ASSEMBLYANDINSTALLATION
1.2m System (Ref. Fig. 1.6)
Attach Side Feed Legs and Braces to left and right
sides of Reflector using M6 x 20mm Hex Bolts, Lock
Washers and Hex Nuts. (NOTE: Long formed end of
Feed Leg attaches to Reflector. Short formed end of
Brace attaches to inside of Reflector rim.) Attach flat-
ten end of Brace to Extension Plate, using M6 x
22mm Round Head, Square Neck Bolts, Tooth Lock
Washers, Flat Washers and Hex Nuts. Round Head
Square Bolt Fits on the top of Extension Plate. Tooth
Lock Washer fits between the flatten end of Brace
and Extension Plate, then Flat Washer and Hex Nut.
Attach Side Feed Legs to Support Block using M6 x
20mm Hex Nuts and Lock Washers. Leave all hard-
ware loose.
Tighten and torque hardware securing Braces, Side
Legs, and “U”Clip to Reflector and Support Block to 4 ft-
lbs (5.4 N-m).Tighten and torque M6 x 55mm “U” Bolt to
18-22 in-lbs (2-2.5 N-m).
FIG. 1.6 - Installation of Feed/Feed Support Legs
to Antenna (1.2m Medium Duty)
FIG. 2.0 - Typical Electrical Grounding for
Antenna Ground Pole
GROUNDING
FIG. 2.1 - Grounding Feed Cables
7

8
Alignment with the satellite is obtained by setting polariza-
tion, elevation and azimuth.Charts 1, 2 & 3 are to determine
these values for your earth station antenna site. “∆L” is the
difference between the earth station antenna site longitude
and the satellite longitude. Use “∆L” and your earth station
latitude to obtain polarization, elevation or azimuth setting.
POLARIZATION OF THE FEED
Loosen Feed Horn Clamp Bolts and turn Feed clockwise or
counterclockwise, depending on being east or west of the
satellite as shown on Chart 1. For course setting, align
marks on the Horn Scale (Ref. Fig. 3.0). Polarization chart
assumes antenna system polarization is Tx vertical and
satellite vertical Pol is perpendicular to plane of geostation-
ary arc. For horizontal Tx of antenna, Feed must be rotated
90˚ from values shown. (Starting point for polarization
adjustment is 0˚, as shown in Figure 3.0.) Use a signal
strength measuring device for final polarization setting and
tighten horn clamp bolts to 4 ft-lbs (5.4 N-m).
ELEVATION
Use Chart 2 and determine your elevation setting. Loosen
Elevation Pivot Bolts and Bolts in curved slots (both sides)
of AZ/EL housing approximately ¹⁄₂ turn (Ref. Fig. 3.1). Turn
Elevation Adjustment Bolt clockwise to decrease elevation
and counterclockwise to increase elevation. Align the edge
of the Clamp with appropriate mark on housing at the
desired elevation reading. This will be an approximate set-
ting. Optimum setting achieved when fine tuning.
NOTE: Degree values shown on Elevation Scale are Beam;
there is no need to compensate for any offset angle. (See
Appendix A, Outline Drawing).If clinometer is used, you must
compensate for offset angle.
AZIMUTH
Use Chart 3 and determine your azimuth setting. Values in
chart must be adjusted for magnetic deviation for your loca-
tion for correct compass reading. Rotate Reflector and
Mount pointing it to the correct compass reading. Slowly
sweep the antenna in azimuth until signal is found. If the
desired signal is not found, increase or decrease elevation
setting and repeat the azimuth sweep (Ref. Fig.3.2).Tighten
Half Clamp Bolts .
FINE TUNING
Use Signal Tuning Device for final adjustments to obtain
maximum antenna performance. Alternate between eleva-
tion and azimuth fine tuning to reach maximum signal
strength, until no improvement can be detected. Certain
models utilize the optional azimuth fine tune feature (refer to
Figure 3.2).This allows the azimuth to be fine tuned by loos-
ening the (4) Carriage Head Bolts and Swivel Nut which
allows adjusting the Azimuth FineTune Adjusting Bolt for the
peak signal. When fine tuning is complete, tighten and
torque all AZ/EL hardware to 12 ft-lbs (16.3 N-m). Do not
exceed 12 ft-lbs (16.3 N-m).Torque Half Clamp Hardware to
18 ft-lbs (24.4 N-m) in alternating sequence.
IMPORTANT: Recheck and repeat torque on all Half
Clamp Bolts, in alternating sequence, until all Bolts are
equally torqued.
FIG. 3.0 - Polarization of the Feed
FIG. 3.1 - Setting the Elevation
FIG. 3.2 - Rotating Antenna for Azimuth
ANTENNA ALIGNMENT PROCEDURE

9

10

11

12

13
PARTS LIST
QTY.
NO. DESCRIPTION 96cm 1.2m
1 BOLT, PLOW, SPECIAL, M8 x 1.25 x 2.21 2 -
BOLT, PLOW, SPECIAL, M8 x 1.25 x 3.56 2 4
2REFLECTOR, .96m 1 1
REFLECTOR, 1.2m LFL 1 1
3 BOLT, HEX HD, SS, M6 x 1.0 x 20mm 4 4
4 WASHER, LOCK, SS, ⁵⁄₁₆ 4 4
5 NUT, HEX HD M8 x 1.25 4 4
6 BOLT, RD HD SQ NK M6 x 1.0 x 22mm 1 5
7PLATE, EXTENSION - 1
8 WASHER, LOCK, SS ¹⁄₄ (Light Duty) 5 5
WASHER, LOCK, SS ¹⁄₄ (Medium Duty) 7 9
9 NUT, HEX HD, M6 x 1.0 (Light Duty) 3 3
NUT, HEX HD, M6 x 1.0 (Medium Duty) 5 7
10 BRACE, R.H..96m AZ/EL MT 1 -
BRACE, 1.2m LFL AZ/EL (Medium Duty) - 2
11 BRACE, L.H..96m AZ/EL MT 1 -
12 WASHER, EXT TOOTH LOCK, ¹⁄₄ 2 2
QTY.
NO. DESCRIPTION 96cm 1.2m
13 WASHER, FLAT, SS, ¹⁄₄ (Medium Duty) 3 3
14 MOUNT ASSEMBLY, 1.2m LFL (Light Duty) 1 1
15 NUT, M6 x 1.0, ESNA 1 1
16 “U”CUP, BOOM - 1
17 BOLT, RD HD SQ NK, M6 x 1.0 x 55mm 1 1
18 FEED SUPPORT (Medium Duty) 1 -
FEED SUPPORT (Medium Duty) - 1
19 BOLT, HEX HD, SS, M6 x 1.0 x 16mm (Light Duty) 3 3
BOLT, HEX HD, SS, M6 x 1.0 x 16mm (Medium Duty) 4 4
20 SIDE FEED LEG, .96m ANTENNA 2 -
SIDEFEEDLEG, 1.2m, ANTENNA - 2
21 BOTTOM FEED LEG (.96m Light Duty) 1 -
BOTTOM FEED LEG (1.2m Light Duty) - 1
22 TERMINAL, FEED SUPPORT (Light Duty) 1 1
23 CLAMP, MTG BLOCK (Light Duty) 1 1
24 WASHER, FLAT M6 (Light Duty) 2 2
25 BOLT, HEX HD, M6 x 1.0 x 30mm 2 2

14
HARDWARE SORTER