ViaSat 8116 Series Operating instructions

Series 8116/8118
16-/18-Meter Earth Station Antenna
Installation and Operation Guide
Manual Part No.42S183D
April 2004

Notice
All Rights Reserved
The information contained in this document is proprietary to ViaSat, Inc.
This document may not be reproduced or distributed in any form without
the consent of ViaSat, Inc.
The information in this document is subject to change without notice.
ViaSat, Inc. assumes no responsibility for any errors that may appear in
this document and does not warranty any specific application.
Any product names mentioned herein are used for identification purposes
only, and may be trademarks and/or registered trademarks of their
respective companies.
In all correspondence with ViaSat, Inc. regarding this publication, please
refer to:
Publication Number: 42S183D
Copyright ® 2002 ViaSat, Inc.
All rights reserved. No part of this book may be reproduced in any form
or by any means without permission in writing from ViaSat, Inc.

____________________________________________________________________________________________
TABLE OF CONTENTS
NOTE
For a further or more detailed breakdown of section
contents, refer to the title page of each section.
SECTION 1 GENERAL INFORMATION
1-1
1-1
1-3
1-4
Introduction to Manual
Description
Wind Load Options
Specifications
LOWER MOUNT INSTALLATION PROCEDURES
SECTION 2
General
2-1
2-1
2-1
2-2
2-2
2-3
2-4
2-4
2-5
2-5
2-9
2-10
2-10
2-10
2-12
2-13
2-14
2-15
2-17
2-21
2-22
2-24
2-32
2-32
2-33
2-33
What to do About Visible Loss or Damage
What to do About Concealed Damage
How to Inventory Equipment Received
How to Return Equipment
General Mechanical Safety Summary
Emergency Plan
General Electrical Safety Summary
Resuscitation
Recommended Tools and Equipment
Recommended Installation Sequency
Recommended Torque Values
Site Preparation
Assembly of Lower Mount
Azimuth Bearing Ring Assembly
Leg Installation
Bottom Skin Plate Installation
Mezzanine Installation (Optional)
Ships Ladder Assembly and Installation (Optional)
Middle and Top Skin Plate Installation
Torquing Lower Mount Fasteners
Door Assembly and Installation
Grouting Baseplate and Skin Plate to Foundation
Hot Weather Grouting
Cold Weather Grouting
Grouting Procedures
____________________________________________________________________________________________
42S183D SERIES 8116/8118 16/18-METER EARTH STATION ANTENNA iii

TABLE OF CONTENTS
____________________________________________________________________________________________
SECTION 3 UPPER MOUNT INSTALLATION PROCEDURES
3-1
3-1
3-1
3-14
3-19
3-22
3-22
3-23
3-29
3-29
3-29
3-30
General
Azimuth Drive Anchor Installation
Rotating Frame Installation
Azimuth Drive Installation
Elevation Drive Installation
Hub Assembly and Installation
Hub Assembly
Hub Installation
Installing Guardrails and Ladders
Ladders Installation
Guardrails Installation
Miscellaneous Platform Hardware
SECTION 4 INSTALLATION OF REFLECTOR, SPARS,
SUBREFLECTOR, AND FEED
4-1
4-1
4-1
General
Installation of Reflector
Installation of Panel Mounting Ring and Optional LNA
Enclosure
4-4
4-15
4-23
4-29
4-31
4-37
4-37
4-40
Installation of 18M Truss Assemblies
Installation of 16M Truss Assemblies
Installation of Panels
Final Alignment of Panels
Installation of Spars and Subreflector
Installation of Model 8118 Feed
Installation of Feed
Installation of Waveguide
SECTION 5 OPERATION
5-1
5-1
5-1
5-2
5-5
General
Satellite Pointing Procedure
Feed Polarization
Subreflector Adjustment
Azimuth Sector Change Procedure
____________________________________________________________________________________________
iv SERIES 8116/8118 16/18-METER EARTH STATION ANTENNA 42S183D

TABLE OF CONTENTS
____________________________________________________________________________________________
____________________________________________________________________________________________
42S183D SERIES 8116/8118 16/18-METER EARTH STATION ANTENNA v
SECTION 6 MAINTENANCE
6-1
6-1
6-1
6-1
6-2
6-5
6-5
General
Periodic Maintenance
Weekly Maintenance
Monthly Maintenance
Bi-Monthly Maintenance
Yearly Maintenance
Corrosion Protection
SECTION 7 OPTIONS
7-1
7-1
7-1
General
Feed Options
Lightning Protection
APPENDIX A INSTALLATION CHECKLIST WITH MANUAL PAGE
REFERENCES
APPENDIX B MECHNCIAL ALIGNMENT SPECIFICATION AND REPORT
FOR 16/18-METER LIMITED MOTION ANTENNA
(479820A)
APPENDIX C CONTOUR ALIGNMENT SPECIFICATION AND RECORD
FOR 16/18-METER ANTENNA (479821B)

SECTION 1 GENERAL INFORMATION
1-1 Introduction to Manual
1-1 Description
1-3 Wind Load Options
1-4 Specifications
42S183D Series 8116/8118 16-/18-Meter Earth Station Antenna

____________________________________________________________________________________________
____________________________________________________________________________________________
42S183D SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 1-1
SECTION 1 GENERAL INFORMATION
This manual contains information needed to properly install,
operate, and maintain the 16-/18-Meter (16/18M) Earth Station
Antenna. This section contains general information on the 16/18M
antenna. Sections 2 through 4 contain information pertaining to
16/18M antenna installation. Sections 5 and 6 contain information
pertaining to operation and maintenance. Section 7 describes the
different configurations available for the 16/18M antenna.
Appendix A contains a complete antenna installation checklist with
page references for the detailed procedures. Appendix B and
Appendix C contain mechanical and contour alignment
specifications and report information for the antenna, respectively.
INTRODUCTION TO
MANUAL
All warnings and cautions should be reviewed before any
procedures are performed. Failure to do so may result in personal
injury or equipment damage.
Periodic maintenance and corrosion protection procedures are
contained in Section 5. For replacing components of the antenna,
refer to the installation and assembly drawings contained in
Sections 2, 3, and 4.
The 16/18M Earth Station Antenna provides a high-quality antenna
designed specifically for the INTELSAT-A station market. The
antenna is designed with many standard and optional features to
provide maximum user and application flexibility. Figure 1-1
shows an outline drawing of the 16M/18M antenna. The following
list identifies the main features of the antenna:
DESCRIPTION
• Cassegrain feed for high-efficiency performance
• Designed for minimum maintenance
• Locked-in surface accuracy through precision tooling
• Frequency reuse feed
• Minimum site preparation required
• Full 360° azimuth travel in six over-lapping sectors
• Internal access for a clean, elegant look.
The 16/18M antenna is a Cassegrain design with a reflector and
subreflector that are shaped for maximum efficiency and low
sidelobes. The circularly polarized, four-port, frequency reuse feed
assembly includes a corrugated horn, orthomode transducer,
diplexers, and connecting waveguide. The transmit frequency
band is from 5.850 to 6.425 GHz and the receive frequency band is
from 3.625 to 4.200 GHz. All the performance specifications are
in full compliance with INTELSAT-A specifications.

GENERAL INFORMATION
____________________________________________________________________________________________
Figure 1-1. 16-/18-Meter Motorized Antenna
____________________________________________________________________________________________
1-2 SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D

GENERAL INFORMATION
____________________________________________________________________________________________
The mount for both the 16- and 18-meter antennas is the same
elevation-over-azimuth pedestal. The elevation travel limits can be
set at any points between 0 and 90 degrees. The azimuth travel
range is a full 360 degrees covered in six overlapping sectors. Size
11 resolvers are supplied for position readout. Both axes are
equipped with 75 ton (667 kN) jack screws drives. As an option,
100 ton (890 kN) jack-screws can be provided to address additional
demands imposed by very high wind conditions on the 18M
antenna. Access to the drives and the reflector is gained from
inside the mount rather than from external ladders. The feed
electronics can be accessed at any elevation angle through the rear
of the hub.
The motorized package features variable-speed ac motors to
provide higher motor speeds for rapid stowing or slewing in
addition to the slow speeds required for satellite tracking. The
drives are equipped with variable-speed ac motors having a low
speed of about 0.010 degrees per second and a high speed slew rate
of about 0.1 degrees per second. The normal operational rate of
each axis is typically 0.01 to 0.015 degrees per second.
CAUTION
__________________________________________
No buildings, walls, fences, or other permanent
fixtures should be planned for installation any
closer than two meters from the antenna and
foundation envelope without consultation with
the factory.
__________________________________________
The 18-meter antenna will operate or drive to stow in winds up to
90 miles per hour (145 km/h) with the standard 75 ton (667 kN)
actuators. It will survive in any position in winds up to 105 miles
per hour (170 km/h). In the stow position (elevation axis at 90
degrees), the antenna will survive winds up to 140 miles per hour
(225 km/h). Under worst-case conditions, when the antenna is at 0
degrees elevation angle, it will take about 30 minutes to stow the
antenna using the variable speed motors. While the elevation axis
is being stowed, the azimuth axis can be turned to a more favorable
direction relative to the wind, if necessary. The azimuth axis never
needs to be stowed during adverse winds once the elevation axis is
at 90 degrees.
Wind Load Options
With the optional 100 ton (890 kN) actuators, the antenna will
operate or drive to stow in winds up to 90 miles per hour (145
km/h) but will survive in any position in winds up to 125 miles per
hour (200 km/h). In the stow position, the antenna will survive
winds up to 165 miles per hour (265 km/h).
____________________________________________________________________________________________
42S183D SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 1-3

GENERAL INFORMATION
____________________________________________________________________________________________
The 16-meter antenna will operate or drive to stow in winds up to
110 miles per hour (175 km/h). It will survive in any position in
winds up to 125 miles per hour (200 km/h). In the stow position,
the antenna will survive winds up to 175 miles per hour (280
km/h).
SPECIFICATIONS Function/Item Specification
General
Antenna Type Cassegrain, dual-reflector
Antenna Diameter 16 Meters
18 Meters
Reflector Construction
16-Meter Antenna 120 precision aluminum panels
18-Meter Antenna 168 precision aluminum panels
Mount Configuration Elevation-over-azimuth
Antenna Pointing Range
Azimuth 6 overlapping 90° sectors for a full 360°
Elevation 0 to 90° continuous
Antenna System Weight (Approximate)
16 Meter 124,000 lbs (56,233 kg)
18 Meter 127,000 lbs (57,594 kg)
Reflector Weight
16 Meter 39,000 lbs (17,686 kg)
18 Meter 42,000 lbs (19,047 kg)
Elevation Balance Angles
16 Meter 67°
18 Meter 69°
Drive Rates Variable over the range of:
Azimuth 0.0075 to 0.1125 degrees per second
(average)
Elevation 0.0044 to 0.0660 degrees per second
(average)
____________________________________________________________________________________________
1-4 SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D

GENERAL INFORMATION
____________________________________________________________________________________________
Continued
SPECIFICATIONS
Function/Item Specification
Electrical
Operating Frequency
Receive 3.625 to 4.200 GHz
Transmit 5.850 to 6.425 GHz
Feed Type Corrugated horn, frequency-reuse
Polarization Dual Circular
Gain at Midband (referenced to diplexer output ports)
Receive 55.2 + 20 log (f/4.0) dBi, 16-Meter
56.4 + 20 log (f/4.0) dBi, 18-Meter
Transmit 58.8 + 20 log (f/6.175) dBi, 16-Meter
60.1 + 20 log (f/6.175) dBi, 18-Meter
VSWR 1.25:1, Maximum
Axial Ratio
Receive 1.06:1
Transmit 1.06:1
Isolation Between Ports
Transmit 85 dB, Minimum
Receive 85 dB, Minimum
Beamwidth at Midband (nominal)
-3 dB Receive 0.32°, 16-meter
0.23°, 18-meter
-3 dB Transmit 0.21°, 16-meter
0.17°, 18-meter
First Sidelobe Level -14 dB, Maximum
Typical Antenna Noise Temperature
(Maximum @ 4 GHz referenced at output of OMT,
25°C (77°F), 50% RH, clear sky)
Elevation Temperature (K)
5° 48
10° 41
20° 34
40° 32
60° 30
Power Handling Capability 5 kW continuous, 20 kW peak
(per port)
Feed Interface
Receive CPR-229G flange
Transmit CPR-137G flange
Voltage Requirements (actuators) 120/208V ac, 3-phase, 5-wire, 60 Hz or
220/380V ac, 3-phase, 5-wire, 50 Hz
(standard - others available)
____________________________________________________________________________________________
42S183D SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 1-5

GENERAL INFORMATION
____________________________________________________________________________________________
____________________________________________________________________________________________
1-6 SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
Continued
SPECIFICATIONS
Function/Item Specification
Electrical - continued
Pointing Error 0.028° rms [with winds of 30 mi/h (48
km/h)gusting to 45 mi/h (72km/h) (1ß)]
0.040° rms [with winds of 45 mi/h
(72km/h)gusting to 60 mi/h (95 km/h)
(1ß)]
Tracking Error 0.02° rms with winds of 30 mi/h (48
km/h)gusting to 45 mi/h (72km/h)
Environmental
Feed Pressurization Leak Rate 500 cc/hr, Maximum
Feed Pressurization Relief Valve 0.5 psig
Ambient Temperature -40 to +60°C (-40 to +140°F)
Rainfall 100 mm/h (4 in/h)
Relative Humidity 0 to 100 % with condensation
Altitude Above Sea Level 0 to 10,000 feet (0 to 3048 m)
Sand and Dust As in desert regions
Salt Spray As in coastal regions
Fungi As in tropical regions
Solar Radiation 1.14 kW sq meter (360 Btu/h/sq ft)
Vertical Shock (survival) 0.1 G
Horizontal Shock (survival) 0.3 G
Earthquake Survival Per grade 11, Mercalli scale
Wind Survival (16M)
Operate Drives 110 mi/h (175 km/h)
Any Position 125 mi/h (200 km/h)
Stow Position 175 mi/h (280 km/h)
Wind Survival (18M)
Operate Drives 90 mi/h (145 km/h) (standard or optional
actuators)
Any Position 105 mi/h (170 km/h) (standard 75 ton
actuators)
125 mi/h (200 km/h) (optional 100 ton
actuators)
Stow Position 140 mi/h (225 km/h) (standard 75 ton
actuators)
165 mi/hr (265 km/h) (optional 100 ton
actuators)
________________________________________________________________

SECTION 2 LOWER MOUNT INSTALLATION
PROCEDURES
2-1 General
2-1 What to do about Visible Loss or Damage
2-1 What to do about Concealed Damage
2-2 How to Inventory Equipment Received
2-2 How to Return Equipment
2-3 General Mechanical Safety Summary
2-4 General Electrical Safety Summary
2-5 Recommended Tools and Equipment
2-9 Recommended Installation Sequency
2-10 Recommended Torque Values
2-10 Site Preparation
2-10 Assembly of Lower Mount
2-33 Grouting Baseplate and Skin Plate to Foundation
42S183D Series 8116/8118 16-/18-Meter Earth Station Antenna

____________________________________________________________________________________________
42S183D SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-1
SECTION 2 LOWER MOUNT INSTALLATION PROCEDURES
This section contains general procedures for unpacking all of the
antenna hardware. This section also contains procedures for
installing the lower mount of the 16-/18-Meter Earth Station
Antenna. The installation of the upper mount (including rotating
frame, azimuth/elevation drives, hub, and optional work platform)
is contained in Section 3. The installation of the reflector, spars,
subreflector, and feed is contained in Section 4. General safety
precautions and procedures for the entire installation are also
described at the beginning of this section.
GENERAL
ViaSat thoroughly inspects and carefully packs all equipment
before shipment. At the time of shipment, the carrier assumes
responsibility for its safe delivery; therefore, do not return damaged
units to ViaSat. Instead, file a claim with the carrier as noted in the
paragraphs following the initial unpacking procedure given below:
1. Inspect shipping carton for visible damage.
2. Open the shipping carton.
3. Remove all packing material.
4. Inspect unit for visible damage.
5. Using packing list, check for missing items (see "How To Inventory
Equipment Received" below).
Make a note of any loss or evidence of external damage on the
freight bill or receipt, and have it signed by the carrier's agent.
Failure to adequately describe such external evidence of loss or
damage may result in the carrier refusing to honor a damage claim.
The form required to file such a claim will be supplied by the
carrier.
WHAT TO DO ABOUT
VISIBLE LOSS OR
DAMAGE
Concealed damage means damage which does not become
apparent until the unit has been unpacked. The contents may be
damaged in transit due to rough handling, even though the carton
may not show external damage. If you discover damage after
unpacking the unit, make a written request for inspection by the
carrier's agent within 15 days of the delivery date, then file a claim
with the carrier since such damage is the carrier's responsibility. If
you follow these instructions carefully, ViaSat guarantees its full
support of your claims to protect you against loss from concealed
damage.
WHAT TO DO ABOUT
CONCEALED
DAMAGE

LOWER MOUNT INSTALLATION PROCEDURES
____________________________________________________________________________________________
2-2 SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D
Check off each item received against that list on the packing slip
included with the shipment, and verify that this list matches the
purchase order. If any items are missing, please notify ViaSat
immediately and return a copy of the packing slip with the missing
item(s) circled.
HOW TO INVENTORY
EQUIPMENT
RECEIVED
For a current list of telephone and email contract information
please refer to the Contact Information section of the ViaSat
internet site (http://www.viasat.com). Select Products, Satellite
Ground Systems and Contact Us.
ViaSat’s Satellite Ground Systems division makes every
reasonable effort to ensure that all items arrive safely and in
working order. When equipment is received, which is not in
working order, return the equipment to the factory for repair or
replacement. Return the equipment according to the following
procedure. This procedure will apply whenever equipment is
returned for warranty or other services.
HOW TO RETURN
EQUIPMENT
a) Notify ViaSat of the problem and request a Return Material
Authorization (RMA) number and shipping instructions.
b) Tag or identify the defective equipment and note defect and
circumstances, if any. If known, reference sales order, purchase
order and date equipment was received.
c) Reship equipment in original shipping container or use a strong
shipping container to protect equipment during shipment.
d) Package equipment using shock-absorbing material around all sides
of equipment.
e) Seal container securely and mark outside of container FRAGILE.
NOTE
Absence of the RMA number will cause a delay in processing
your equipment for repair. Be sure to include the RMA
number in all correspondence.
NOTE
ViaSat Inc will not accept freight collect. Be sure to ship all
items freight prepaid.

LOWER MOUNT INSTALLATION PROCEDURES
WARNING
__________________________________________
Electrical shock from voltages used in this
system can cause injury or death. Prior to
making any electrical connections or performing
maintenance and repair, ensure power is
removed. Electrical connections should be made
only by qualified personnel in accordance with
local regulation.
__________________________________________
These are general mechanical safety precautions that are not related
to any specific procedure. They are recommended precautions that
personnel must understand and apply.
GENERAL
MECHANICAL
SAFETY SUMMARY
WARNING
__________________________________________
Installation or maintenance of antennas may
require persons to work at elevated work
stations. Whenever persons are working at eight
or more feet above ground and not on a guarded
platform, they should wear safety belts with at
least one, and preferably two, lanyards, with the
exception that trained and qualified persons may
work up to 25 feet (7.6m) if on an approved
ladder. In the sentence above, approved usually
means that the ladder is tied off once the person
has climbed but before work begins.
__________________________________________
____________________________________________________________________________________________
42S183D SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 2-3

LOWER MOUNT INSTALLATION PROCEDURES
WARNING
__________________________________________
Overhead hazards, either because items may fall
or because a person may strike them
unintentionally, are typical around construction
sites or during installation of large antennas. It
is prudent to adopt the following rules:
1. Never stand underneath anything while it is
being hoisted.
2. Always wear a hard hat, especially if
someone is above you.
__________________________________________
WARNING
__________________________________________
Ensure that all electrical tools and equipment
are properly grounded.
__________________________________________
Have an emergency plan. Know the procedures for obtaining first-
aid and fire-fighting assistance. Plan your work and maintain good
housekeeping; the safety and quality of the product are at stake.
Emergency Plan
These are general electrical safety precautions that are not related
to any specific procedure. These are recommended precautions
that personnel must understand and apply.
GENERAL
ELECTRICAL SAFETY
SUMMARY
____________________________________________________________________________________________
2-4 SERIES 8116/8118 16-/18-METER EARTH STATION ANTENNA 42S183D