General Dynamics 2.4M SERIES 1241 ANTENNA User manual

2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
Prodelin Corporation Page 1 8/17/2012
4096-859
Revision A
August 7, 2012
ASSEMBLY MANUAL
2.4M SERIES 1241 ANTENNA
GENERAL DYNAMICS
SATCOM Technologies
1500 Prodelin Drive
Newton NC 28658USA
Phone [phone]
www.gdsatcom.com

2.4M SERIES 1241 ANTENNA 4096-859
ASSEMBLY MANUAL REVISION A
Prodelin Corporation Page 2 8/17/2012
2.4M SERIES 1241 ANTENNA
ASSEMBLY MANUAL
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A Released for
production. 8/17/12 R.F.
- Original Release 8/8/2012 JWL
Revision Description Date Approved By

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TABLE OF CONTENTS
LIST OF FIGURES ..........................................................................................................................4 
LIST OF TABLES ............................................................................................................................4 
1.  INTRODUCTION ......................................................................................................................6 
1.1.  GENERAL INFORMATION ................................................................................................................................6 
1.2.  UNPACKING AND INSPECTION.........................................................................................................................6 
1.3.  FREIGHT DAMAGE ..........................................................................................................................................6 
1.4.  MATERIALS –MISSING OR DAMAGED ............................................................................................................6 
1.5.  MECHANICAL INSTALLATION TOOLS..............................................................................................................7 
1.6.  SITE SELECTION .............................................................................................................................................8 
1.7.  SUGGESTED MAST &FOUNDATION ................................................................................................................8 
2.  ANTENNA INSTALLATION.....................................................................................................9 
2.1.  AZ /EL POSITIONER INSTALLATION...................................................................................................12 
2.2.  REFLECTOR QUADRANT ORIENTATION............................................................................................13 
2.3.  REFLECTOR SUPPORT ASSEMBLY ......................................................................................................15 
3.  FEED SUPPORT ....................................................................................................................22 
4.  ANTENNA ALIGNMENT........................................................................................................22 
4.1.  ALIGNMENT TO SATELLITE...........................................................................................................................22 
4.2.  INITIAL ALIGNMENT .....................................................................................................................................22 
5.  MAINTENANCE .....................................................................................................................23 
5.1.  MAINTENANCE OVERVIEW...........................................................................................................................23 
5.2.  PERIODIC INSPECTION ..................................................................................................................................23 
5.3.  REFLECTOR ..................................................................................................................................................23 
5.4.  MOUNT AND REFLECTOR SUPPORT STRUCTURE...........................................................................................23 
5.5.  REPAIR AND /OR REPLACEMENT ..................................................................................................................23 

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List of Figures
FIGURE 1: 2.4M SERIES 1241 ANTENNA .........................................................................................................................5 
FIGURE 2: AZ /EL POSITIONER................................................................................................................................12 
FIGURE 3: REFLECTOR ORIENTATION STANDARD ........................................................................................................13 
FIGURE 4: REFLECTOR ORIENTATION INVERTED ..........................................................................................................14 
FIGURE 5: REFLECTOR SPACER INSTALLATION ............................................................................................................15 
FIGURE 6: REFLECTOR SUPPORT ASSEMBLY ................................................................................................................15 
FIGURE 7: REFLECTOR SUPPORT BRACKETS.................................................................................................................16 
FIGURE 8: REFLECTOR BTM SUPPORT BRACKETS .......................................................................................................17 
FIGURE 9: QUAD #2 INSTALLATION..............................................................................................................................18 
FIGURE 10: QUAD #3 INSTALLATION............................................................................................................................19 
FIGURE 11: COMPLETE REFLECTOR..............................................................................................................................20 
FIGURE 12: ELEVATION ROD ASSY 1............................................................................................................................21 
FIGURE 13: ELEVATION ROD ASSY 2............................................................................................................................21 
FIGURE 14: ELEVATION ROD ASSY 3............................................................................................................................21 
FIGURE 17: ANTENNA ALIGNMENT ..............................................................................................................................22 
List of Tables
TABLE 1: WRENCH AND SOCKET SIZES REQUIRED.........................................................................................................7 
TABLE 2: REFLECTOR AND MOUNT PARTS LIST .............................................................................................................9 

2.4M SERIES 1241 ANTENNA 4096-859
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Figure 1: 2.4m Series 1241 Antenna

2.4M SERIES 1241 ANTENNA 4096-859
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1. INTRODUCTION
1.1. General Information
This manual describes the assembly and installation of General Dynamics’ 2.4m Rx/Tx
antenna. These instructions cover all areas of assembly and installation. Additional
sections are included in the manual to provide information on antenna pointing and
maintenance. General Dynamics recommends that these instructions be followed
closely, and in the order shown, for proper antenna performance.
1.2. Unpacking and Inspection
The system containers should be unpacked and inspected at the earliest date to insure that
all material has been received and is in good condition. A packing list for each major
component is supplied.
1.3. Freight Damage
Any damage to materials while in transit should be immediately directed to the freight
carrier. They will instruct you on matters regarding any freight damage claims.
1.4. Materials – Missing or Damaged
Any questions regarding missing or damaged materials that are not due to the freight carrier
should be directed to General Dynamics’ Customer Service Department at:
General Dynamics
SATCOM Technologies
1500 Prodelin Drive
Newton NC 28658
USA
[phone]

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1.5. Mechanical Installation Tools
Required Tools:
•Wrenches (see Table 1)
Other Recommended Tools:
•Compass
•Inclinometer
•Adjustable wrench 10”
•3/8” drive Ratchet with Sockets and 6” extension (see
Table 1)
Table 1: Wrench and Socket Sizes Required
HARDWARE SIZE SAE WRENCH SIZE METRIC WRENCH
SIZE MAX RECOMMENDED TORQUE (±10%)
5/16” 1/2” 13mm 15 ft-lbs
(20.3 n-m)
3/8” 9/16” 14mm 20 ft-lbs
(27.1 n-m)
1/2” 3/4” 20mm 45ft-lbs
(61 n-m)
3/4” 1-1/8” 24mm 145ft-lbs
(196.6 n-m)
1” 1-1/2” 38mm 220 ft-lbs
(298.3 n-m)
NOTE: The Minimum Torque applied should not be less than 10% of maximum
recommended torque.

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1.6. 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.
3. The site should be checked for underground obstruction, such as buried cables or pipes.
4. All local building codes should be adhered to (i.e. grounding, foundation requirements, zoning
rules, setbacks, etc.).
1.7. Suggested Mast & Foundation
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)
(GENERAL DYNAMICS DOES NOT REPRESENT OR WARRANT THAT ANY PARTICULAR DESIGN
OR SIZE OF FOUNDATION IS APPROPRIATE FOR ANY LOCALITY OR EARTH STATION
INSTALLATION.)
2 x 2 1/4 HRS ANGLE
12 INCHES LONG
TYPICAL 2 PLACES
A A
54.0
54.0
SEE NOTE #7
12.0
24.0
2-5
TYP 2
SECTION A-A
6” SCH 40 PIPE
(6.625” OD)

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2. ANTENNA INSTALLATION
Table 2: Reflector and Mount Parts List
ITEM PART NO. DESCRIPTION QTY
1 0179-447
Reflector, 2.4m RT 4pc Quad #1 1
2 0179-448
Reflector, 2.4m RT 4pc Quad #2 1
3 0179-444
Reflector, 2.4m RT 4pc Quad #3 1
4 0179-445
Reflector, 2.4m RT 4pc Quad #4 1
5 0185-3607
AZ / EL Positioner 1
6 0168-415
Elevation Adjustment Block 1
7 0211-1265
Reflector BTM Bracket LH 1
8 0211-1266
Reflector BTM Bracket RH 1
9 0211-1267
Reflector Top Bracket LH 1
10 0211-1268
Reflector Top Bracket RH 1
11 0211-1269
Reflector Center Bracket 2

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Parts List Continued
12 0490-1010
2.4m 4pc Reflector Support Weldment 1
13 0247-445
2.4m 4pc Crossarm 2
14 0490-1014
Weldment, El Rod – 2.4m 1
0200-948 Reflector Spacer Kit
15 0159-265
Reflector Spacer #65 4
16 8110-007
Nut, 7/8-9 Hex Jam 4
17 8201-052
Flat washer, 7/8 USS STD 4
18 8202-068
Lock washer, 7/8 Internal Tooth 4
0200-1865 AZ / EL Hardware Kit
19 8036-016
Bolt, 1-8 x 2.00 Hex 2
20 8036-024
Bolt, 1-8 x 3.00 Hex 3
21 8201-049
Flat Washer, 1” SAE STD 6
22 8202-046
Lock washer 1” STD 4
23 8317-106
Screw Assy, 5/8-11 x 1.50 6
24 8107-007
Nut, 1-8 Hex 5
0200-1828 Reflector Seam Hardware Kit
25 8031-012 Bolt, 5/16-18 x 1.50 Hex 24
26 8201-071
Flat washer, 5/16” SAE Narrow 48

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Parts List Continued
27 8202-041 Lock washer, 5/16” STD 24
28 8101-009
Nut, 5/16-18 Hex 24
0200-1829 Reflector Support Hardware Kit
29 8032-010
Bolt, 3/8-16 x 1.25 Hex 14
30 8201-042 Flat washer, 3/8” USS STD 28
31 8202-042
Lock washer 3/8” STD 14
32 8102-007
Nut, 3/8-16 Hex 14
33 8033-010
Bolt, 1/2-13 x 1.25 Hex 4
34 8201-043
Flat washer, 1/2 USS STD 4
35 8202-043
Lock washer, 1/2" STD 4

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2.1. AZ / EL POSITIONER INSTALLATION
CAUTION: During the assembly procedure, the sequence of instructions
must be followed. DO NOT TIGHTEN ANY HARDWARE UNTIL
INSTRUCTED.
STEP 1:
Insert the 5/8” Set Screws (ITEM 23) into the canister and slip AZ/EL positioner (ITEM 5) over the mast
pipe. Tighten the set screws snug against the mast pipe.
STEP 2:
Insert elevation tube (ITEM 6) using 1” hardware (ITEMS 19, 21, 22). Lightly tighten at this time.
STEP 3:
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.
Figure 2: AZ / EL POSITIONER
Mast Pipe
To Satellite
(within 10 deg.)
19, 21, 22
23
5
6

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2.2. REFLECTOR QUADRANT ORIENTATION
The series 1244 reflector quadrants are labeled #1, #2, #3 and #4. These
numbers may be found molded into the back of each quadrant at the inside
corner. Note that each quadrant has a longer side (major axis) and a shorter side
(minor axis). 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), quadrant #1 should be in the upper left; #2 is lower
left; #3 is lower right and #4 in the upper right position. See Figure 3.
However, to allow a lower profile installation or in areas of high snow
accumulation, the reflector can be assembled in the inverted position (feed
support at the top). In this position, quadrant #1 would be in the lower right; #2
upper right; #3 in upper left and #4 in lower left position. See Figure 4.
When assembling for the inverted position, the Back Frame (item 14) must be turned 180
degrees from its standard position prior to its mounting to the Az/El positioner – see Step 2. Also
note that the optional feed stabilization kit cannot be used when the reflector is used in the
inverted position.
Figure 3: Reflector Orientation Standard
Center Line
of Reflector
Feed Rod
Holes
Feed Support at Bottom
Q1
Q4
Q3
Q2

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Figure 4: Reflector Orientation Inverted
Center Line
of Reflector
Feed Rod
Holes
Feed Support at Top
Q1
Q4
Q3
Q2

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2.3. REFLECTOR SUPPORT ASSEMBLY
STEP 1:
Figure 5: Reflector Spacer Installation
Figure 6: Reflector Support Assembly
STEP
1
Locate quadrant #1 and insert threaded insert
(item 15) thru the hole on the face of the
reflector. Secure insert with 7/8” hardware (items
16, 17, 18). Snug only to allow freedom of
movement for the back frame assembly. Repeat
step for quadrants #2, #3 & #4.
Reflector
Petal
15
16, 17, 18
STEP
2
Straddle the tabs of the reflector
support (item 12) over the holes in
the positioner and secure using 1”
bolts and hardware (items 19, 21,
22, 24). Tighten snug only and let
the tube fall back upon the
positioner.
12
21, 22, 24
INSTALL
180°FOR
INVERTED
MOUNTING
19, 21
19, 21
21, 22, 24

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Figure 7: Reflector Support Brackets
STEP
3
(A) Place the cross arms (item 13) on the reflector support (item 12) as shown. Place the RH
and LH top brackets (items 9, 10) on the top cross arm and secure with 3/8 hardware (items 29,
30, 31, 32) as shown. Snug hardware by hand only at this time.
(B) Place the RH and LH bottom brackets (items 7, 8) on the bottom cross arm and secure with
3/8 hardware (items 29, 30, 31, 32) as shown. Snug hardware by hand only at this time.
(C) Place the two center brackets (item 11) on the reflector support as shown and secure with 3/8
hardware (items 29, 30, 31, 32) as shown. Snug hardware by hand only at this time.
Note: If installing with an inverted reflector, the locations of brackets (items #7,8 and
items #11,13) will be reversed from location shown.
13
29, 30
30, 31, 32
13
7
8
9
11
11
11
12
Shown with 1240
series positioner for
illustration only

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Figure 8: Reflector BTM Support Brackets
STEP
4
Note: Make sure the BTM brackets (items 7, 8), and the cross arm (item 13),
are fully seated against the reflector support with no gaps between any of the
components before completing the next procedure.
Insert 3/8” hardware (items 29, 30) thru the reflector support (item 12) and the BTM
brackets (item 7, 8) as shown. Secure with 3/8” washers and hex nuts (items 30, 31,
32). Tighten this hardware to recommended torque to secure the BTM brackets.
(See table 1).
12
8
30, 31, 32
29, 30
30, 31, 32
29, 30
7
See Note

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Figure 9: Quad #2 Installation
2
33, 34, 35
25
STEP
5
Note: Installing the lower quads (#2, #3) first will ease installation.
(A) Place Quad #2 on the cross arm (item 13) with the seam ribs between the reflector brackets
(items 7, 8, 11). Note that the longer side should be aligned with the major axis. Note the
location of the feed support mounting hole at the bottom of the reflector in Figure 9.
(B) Insert a 5/16 bolt (item 25) thru the seam rib and the center bracket (item 11) to temporarily
hold the petal.
(C) Insert the ½” bolt and washers (item 33, 34, 35) thru the cross arm and into the reflector
spacer. Hand snug only at this time.
DETAIL VIEW
8
7
2
DETAIL VIEW
11
11
2
Shown with 1240
series positioner for
illustration only
Note location of
feed support
mounting hole

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Figure 10: Quad #3 Installation
2
3
STEP
6
(A) Place Quad #3 on the cross arm (item 13) with the seam rib against the seam rib of quad 32
and between the reflector brackets (items 2, 7, 8, 11). Note that the longer side should be aligned
with the major axis.
(B) Insert 5/16” bolts with washers (items 25, 26) thru the brackets and the major seam ribs as
shown. Secure with 5/16” hex nuts and washers (items 26, 27, 28). Hand snug only.
(C) Insert the 1/2” bolt and washers (item 33, 34, 35) thru the cross arm and into the reflector
spacer. Hand snug only at this time.
(D) Remove the temporary 5/16” bolt placed thru the center bracket in STEP 5 after Quad #3 is
supported by the major seam bolts and the 1/2” hardware.
33, 34, 35
13
25, 26
26, 27, 28
Shown with 1240
series positioner for
illustration only

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Figure 11: Complete Reflector
STEP
7
(A) Install Quad #1 and Quad #4 using the same procedures as outlined in STEP 6. After all the
seam bolts are installed, begin tightening the 5/16” seam bolts from the center out until all the
seam bolts are tightened to the recommended torque. (See table 1)
Note: Make sure the Reflector brackets (items 7, 8, 9, 10, 11), and the cross arm (item 13),
are fully seated against the reflector support with no gaps between any of the components
before completing the next procedure.
(B) Next tighten the 3/8” cross arm and center bracket hardware to the recommended torque.
(See table 1)
(C) To complete the reflector assembly, tighten the four reflector insert nuts and the four 1/2"
reflector bolts to the recommended torque. (See table 1)
5/16”
Seam Bolts
1
2
4
3
3/8” Cross Arm
Hardware
1/2" Reflector
Bolts
Shown with 1240
series positioner for
illustration only