C2SAT - Installation Manual 4m Radome _501_1730_ 2009a

Version: 09A Assembly Manual 4m Radome (501-1730)

Marine Stabilised Antenna System

4m Radome (501-1730)

Assembly Manual Version 2009a

Assembly Instruction of C-band Radome 2 (12) Uppgjord (även faktaansvarig om annan) - Prepared (also subject responsible if other) Nr - No. Datum - Date

C2SAT Production AB Anders Strömberg C2SATP-08:011 Uen 2009-05-10 Dokansv/Godk - Doc respons/Approved Kontr - Checked Rev File name

C2SAT communication AB Erik Dalin 09A Assembly Manual 4m Radome (501_1730).pdf

Table of Contents

1 GENERAL 3

2 RADOME INSTALLATION 3

2.1 PREPARATION FOR INSTALLATION 3

2.2 RADOME DOOR 4

2.3 ASSEMBLE PANELS OF LAYER 1 4

2.3.1 BOTTOM RIM SEALING 4

2.3.2 PANEL TO PANEL SEALING TAPE 5

2.3.3 PANEL ASSEMBLY 5

2.4 ASSEMBLE PANELS OF LAYER 2 6

2.5 ZENITH PANEL 7

2.6 INSPECT THE BOLTS 7

2.7 SEALING THE JOINTS WITH SILICONE 7

2.7.1 PANEL TO PANEL SEALING 7

2.7.2 BASE RIM SEALING 8

2.8 CLEANUP AFTER INSTALLATION 8

3 INSTALLATION PROCEDURE FLOW CHART 9

4 PANEL ASSEMBLY SEQUENCE DRAWING 10

5 TOTAL DRAWING FOR 4M RADOME 11

6 LADDER 12




Introduction The Assembly manual for 4 meter radome provides a description of the procedure of radome assembly. The radome consists of 11 panels which form a rigid sphere shell that protects the antenna from the marine environment. It is composed of pentagonal shaped FRP panels with a foam-sandwich structure. The panels are bolted together to form a truncated sphere with stainless steel bolts.

1 GENERAL � Radome assembly should be operated by the qualified installation team. � The chief of installation team should check the goods (panels, fasteners, washers, etc.) in the crates

according to the Packing Lists. � All workers who work in high altitudes must wear safety belt or safety lines to prevent falling

accidents. � Define a scaffolding assembly scheme (steel pipes or bamboo poles) according to the installation site. � Extinguisher should be putted on site. Smoking or open flames is not allowed on the site. � Check the weather forecast in advance. Do not perform the installation if wind velocity is over 20m/sec. � Estimated installation time: 2 days

� Each panel weighs about 35 kg. The weight of the complete radome is 410 kg. � The service hatch/door to the radome is 60x100cm.

2 RADOME INSTALLATION

2.1 Preparation for installation

� Equip the assembling staff. � Check that ladders, scaffolding and crane used for installation is available on site. � Check that all parts of radome on the Packing List (panels, fasteners, washers, etc.) have arrived on

site. � Check that all tools and other materials for radome installation on the Packing List have arrived on

site.




2.2 Radome door

The radome has a door on one side which is used to enter the radome. It is important that you assemble the radome so that the radome door is located towards the stern of the ship.

2.3 Assemble panels of layer 1

Remove the PVC packing film after taking out of the Base Panels from the crates.

2.3.1 Bottom rim sealing

Put a piece of hard sealing rubber gasket on the platform where the Base Panels will be placed. Put base panel on sealing gasket, and tighten the base bolts.




sealing rubber gasket

bolt

base panel

sealing rubber gasket sealing glue

100 mm 6 mmBase (Ship Deck)

2.3.2 Panel to panel sealing tape

Apply sealing rubber tape on the joint edges the Base Panels when they are assembled together.

Panel-to-panel joint is an overlapping joint. Put 2 pieces of rubber sealing tape on both sides of bolt along panel-to-panel joint. Tightening the bolts will compress the sealing tape.

2.3.3 Panel assembly

Assemble the Base Panels according to the Panel Assembly Sequence Drawing in chapter 4. Start with the door panel and than put the panel 1:1 to the left, continue with 1:2 etc.

Base bolts

Panel bolts




Tighten base bolts initially with spanner. Apply a momentum to all base bolts of 50Nm ± 10Nm. Tighten the panel bolts with spanner on the edges of the panels of layer 1.

Close up of bolts on the inside Close up of joint on outside Continue assembling all base panels until layer 1 is fully assembled.

Layer 1 assembly finished

2.4 Assemble panels of layer 2

A fold-up ladder (and/or scaffoldings) will be necessary for the assembly of panels of layer 2 (and the zenith panel). Make sure that the ladder is long enough to reach the top layer. Make sure that the ladder can be extracted through the service door in the radome after the assembly is finished. See chapter 6 for suggested ladder dimensions.




Assemble the panels according to the corner label of the panels, use the same principle as layer 1 regarding placement, sealing tape and bolt tightening. see the Panel Assembly Sequence Drawing´in chapter 4.

Tighten panel joint bolts with spanner. Apply a momentum to all bolts of 10Nm ± 1Nm.

2.5 Zenith Panel

Assemble the zenith panel with the same procedure until last layer is fully assembled. You may need a crane for this placement.

2.6 Inspect the bolts

Tighten all panel bolts with a momentum of 10Nm ±1Nm from bottom to top. Re-tighten all base bolts with a momentum of 50Nm ±10Nm.

2.7 Sealing the joints with silicone

2.7.1 Panel to panel sealing

After the whole radome is assembled, installers climb on the outside of the radome and apply sealing glue to the exterior joint from top to bottom.

10 mm

4 mm

interior surface

exterior surfacestainless bolt

sealing glue

sealing tape




Seal the panel joints with white silicone from the top. Seal the panels inside the radome first and

then seal the outside seam.

Apply the sealing glue into the joints evenly with the use of tools or fingers. Protect the hands by wearing soft plastics gloves.

When sealing the seam of base panels, if the seam width is too large to apply one lay of glue, you can apply one lay of glue on both sides of the seam first, and after it has hardened, apply glue on the seam again. Before the silicone has hardened clean off the remains on tools or fingers.

During sealing, if you need to step on the radome when climbing outside the radome, please place your feet on the panel joints. Do not step on the middle of a panel since that is the weakest point and also most prone to surface damage and/or coating damage. Ensure that the panels or surface is not damaged. Please wear shoes with a soft rubber sole.

2.7.2 Base rim sealing

Apply sealing glue to the exterior joint between base panel and platform.

bolt

base panel

sealing rubber gasket sealing glue

Base (Ship Deck)

2.8 Cleanup after installation

Disassemble scaffoldings inside the radome, don’t touch the panel laminates and antennas. After completing the installation, remove dirt, stain and oil on the radome inside or outside surface, remove all rubbish on site, and keep the environment clean.




3 INSTALLATION PROCEDURE FLOW CHART Chapter

Installation team enters the site

↓

Prepare for installation 2.1

↓

Check items on packing list 2.1

Equip team with tools, ladders, scaffolding and crane 2.1

↓

Place sealing rubber gasket for base rim on platform 2.2.1

↓

Assemble base panels (layer 1) Place sealing tape between panels.

2.2.2 and 2.2.3

↓

Erect scaffoldings

↓

Assemble layer 2 Place sealing tape between panels.

2.3

↓

Tighten all bolts when the assembly of each layer is complete

↓

Assemble zenith panel 2.4

↓

Make a primary inspection when radome is assembled 2.5

↓

Sealing of panel to panel joints with silicone 2.6.1

↓

Sealing of bottom rim with silicone 2.6.2

↓

Disassemble scaffoldings

↓

Clean the site 2.7

↓

Radome installation is finished




4 PANEL ASSEMBLY SEQUENCE DRAWING




5 TOTAL DRAWING FOR 4M RADOME




6 LADDER Suggested dimensions of ladder that can be used inside the radome

180 cm = 70 inches

240 cm = 95 inches

C2SAT - Installation Manual 4m Radome _501_1730_ 2009a

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