Andrew ES45T Installation, Operation And Maintenance Manual Download Page 9

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Installation

Sequence

Checklist

Site Preparation

Tripod Ground

Mount Assembly

ES45T-R

Main Reflector

Assembly

ES45T-R

Back Structure

Assembly

ES45T Reflector-

to-Mount

Assembly

(With Crane)

Feed Installation

The 4.5-Meter Earth Station Antenna requires the installation team to perform the

assembly in the sequence presented below. Moreover, this sequence should be

reviewed beforehand to ensure a smooth installation. Use the following checklist to veri-

fy and/or determine the installation sequence. Throughout the checklist certain part num-

bers will be used. Those part numbers describe the antenna currently being installed.

The ES45T-R is a receive-only 4.5-Meter Earth Satellite Antenna with a tripod mount.

The ES45T-T is a transmit/ receive 4.5-Meter ESA with a tripod mount.

Refer to Foundation Specifications for guidance in preparing the location and the instal-

lation of the 4.5-Meter Earth Station Antenna foundation.

Mount azimuth axis support and rear anchor pads

Connect support angles

Attach support and elevation pivot assembly to support angles

Attach support angles to azimuth axis joint

Hoist support and pivot elevation pivot assembly

Fasten azimuth axis joints to azimuth axis support

Attach elevation strut to azimuth axis joint

Attach azimuth strut to appropriate rear pad

Remove protective covering from crate

Pry top crate panel off

Pry sides off crate

Pry front off crate

Unbolt reflector panels from bottom of crate

Prepare assembly area with diameter setting bands and temporary supports

Lay reflector segments on prepared assembly area

Attach opposite segments to mounting ring hub and diameter setting bands

Attach remaining segments to mounting ring hub and original panels

Attach seam hardware to panels

Attach retaining bar to mounting ring hub

Tighten joining plates in concentric circles around reflector

Attach feed strut brackets and feed struts

Attach tee plates to reflector

Attach plates to reflector

Attach support angles to tee plates

Attach support angles to plates

Connect tee plates and plates with pivot brackets

Connect tee plates with elevation axis bracket

Connect pivot brackets to elevation axis bracket with support angles

Tighten hardware with A-325 procedure

Remove diameter setting bands

Wrap crane straps around angle between pivot brackets

Align pivot brackets with support and elevation pivot assembly

Connect pivot brackets with support and elevation pivot assembly

Determine required length of elevation strut

Connect elevation strut to elevation axis bracket

Attach feed struts to feed support

Attach collar to feed horn assembly

Install feed horn assembly into feed support

Set dimension between center plate and feed horn

Getting Started

Summary of Contents for ES45T

Page 1: ...tp www andrew com Customer Service 24 hours U S A Canada Mexico 1 800 255 1479 U K 0800 250055 Republic of Ireland 1 800 535358 Other Europe 44 1592 782612 15 August 2005 Copyright 2005 by Andrew Corp...

Page 2: ...Reflector Leveling Procedure 28 Feed Strut Assembly 30 Back Structure 31 Reflector To Mount Assembly With Crane 36 Reflector To Mount Assembly With Hoist Kit 39 Elevation and Azimuth Adjustments 43 F...

Page 3: ...ero backlash This mount can be operated manually but has the potential to be upgraded for motorized operation including steptracking SmartrackTM applications The motorizable mount type is indicated by...

Page 4: ...availabilities of products and services presented in this manual are subject to change without notice 4 Introduction 24 hour Technical Assistance For technical assistance call the following numbers a...

Page 5: ...h allow you to view the installation in process The manual is divided into five distinct sections each dealing with a specific technical topic relating to either system or component subsystem informat...

Page 6: ...ation of antenna may require persons to work at elevated work stations Whenever persons are working at eight or more feet above the ground and not on a guarded platform they should wear safety belts w...

Page 7: ...ecessary for the installation process should be provided by the installation crew Andrew recommends that the following tools be used for a proper installation of the 4 5 Meter Earth Station Antenna Ta...

Page 8: ...opening your shipment you should take inventory of the parts immediately Check each item received in you shipment against the packing slip included with the shipment If any items are missing please no...

Page 9: ...h azimuth strut to appropriate rear pad Remove protective covering from crate Pry top crate panel off Pry sides off crate Pry front off crate Unbolt reflector panels from bottom of crate Prepare assem...

Page 10: ...all center plate and center pad to mounting ring hub Attach feed strut brackets and feed struts Attach tee plates to reflector Attach rib connecting plates to reflector Assemble support angles and piv...

Page 11: ...included in the shipment Before beginning the installation process on the ground mount assembly ensure that the foundation has been prepared Foundation specifications are provided by Andrew and may b...

Page 12: ...le full effort of a person using an ordinary spud wrench Do not proceed with Steps 5 and 6 unless the connection is final and is not intended to be loosened again Note If the bolts are loosened after...

Page 13: ...justment is provided in both azimuth and elevation An example of the assembled tripod mount is provided in Figure 2 Installation Procedures Figure 2 Before assembling the mount verify that all parts a...

Page 14: ...49624 with spacers P N 46560 2 to azimuth axis support and rear anchor pads as shown in figure 5 Use A 325 x 1 in bolts and nuts for connections see page 12 Support angles should be installed edge do...

Page 15: ...as shown in Figure 6 Installation Procedures Figure 6 Loosely bolt support and elevation pivot assembly P N 49635 and support angles P N 49623 to connection plates as shown in Figure 7 Use A 325 x 1...

Page 16: ...25 x 1 in bolts flatwashers and nuts see page 12 Angles should be attached with flat of angle facing upward Loosely attach support angles to azimuth axis joint P N 49629 Installation Procedures Figure...

Page 17: ...n one installer on a ladder to hoist support assembly as at least one other installer walks the assembly into the upright position as shown in Figure 10 Loosely fasten lower azimuth axis joint P N 300...

Page 18: ...needed to achieve level surface Installation Procedures Figure 13 Figure 12 Tighten anchor bolts on rear pads and azimuth axis support base plate down using A 325 procedure See A 325 procedure for tec...

Page 19: ...ele vation setting as specified in the Elevation and Azimuth Adjustments Section Adjust coarse setting by extending secondary and if necessary tertiary sections to length Install eight in set screws a...

Page 20: ...hown in Figure 16 Use x 1 in bolts flatwashers and lockwashers Step 14 Step 15 Figure 16 Loosely attach block to appropriate rear pad as based upon calculations in Appendix F to determine the mounting...

Page 21: ...n as demonstrated in Figure 19 Figure 19 Connect one end of azimuth strut P N 49767 to connection plate with U bracket P N 49704 as indicated in Figure 18 Use x 4 in bolts lockwashers and nuts Securel...

Page 22: ...nd temporary supports as shown in Figure 20 Note Proper orientation of reflector top bottom will ease reflector assembly Tighten 20 hardware at connection of bands to a snug fit Reflector should be as...

Page 23: ...arkings on the reflector segments in order to assemble the reflector in the proper sequence See Figure 21 Installation Procedures Figure 22 Figure 21 Place reflector segment A B between two setting ba...

Page 24: ...ockwashers and nuts Insert capscrews from concave side of reflector segments Loosely attach reflector segments A B and D E to diameter setting bands P N 49426 with edge joining plates P N 49424 and ca...

Page 25: ...pscrews from outside reflector rim Figure 25 ES45T R Reflector Assembly Loosely attach segment A F to mounting ring hub diameter setting bands and segment A B using joining plates P N 49425 along refl...

Page 26: ...D E with joining plates P N 49425 along reflector panel seams E E and F F Loosely attach joining plates P N 49693 on rim seams E E and F F as illustrated in Figure 26 Figure 26 Station an installer in...

Page 27: ...ensure setting bands are uniformly taut at this point If not adjust level by adding shims until no segment of the reflector can bounce and set ting bands are uniformly taut as shown in Figure 28 ES45T...

Page 28: ...hardware from plate concave side of reflector to retaining bar Insert shim P N 200215 between each reflector segment around perimeter of reflector assembly Refer to Figure 28B Tighten setting band an...

Page 29: ...31 close to but not inter fering with diameter setting bands Referring to Figure 31 mark the measuring location at each of the six temporary sup port locations with a small dot use felt tip marker to...

Page 30: ...nsure proper leveling of temporary supports With the reflector level tighten joining plate P N 49425 hardware starting at the outer perimeter of match marked position A A and continue this procedure a...

Page 31: ...teps provide the procedure for the back structure assembly CAUTION Reflector must remain on level supports positioned under center edge of each reflector segment with diameter setting bands in place d...

Page 32: ...positioning and orientation details Apply stick wax P N 200852 to A 325 bolt threads before installation to reduce fric tion see page 12 Note Do not attempt to tighten A 325 hardware prior to tensioni...

Page 33: ...rom concave side of reflector Figure 35 Loosely attach plates P N 49427 to points A C and E on convex side of reflector Loosely attach two support angles P N 49438 to each of six plates as shown in Fi...

Page 34: ...atwashers and nuts see page 12 Install bolts from concave side of reflector Angles should be installed with edge in and flat side away from reflector as shown Figure 37 Loosely attach support angles P...

Page 35: ...ds to ensure that they are uniformly taut If not check leveling of temporary supports and make necessary adjustments by adding or subtracting shims Begin A 325 hardware tensioning procedure see page 1...

Page 36: ...ng a crane The following steps provide the procedure for installing the reflector to the mount using a crane Ensure all connections on reflector and back structure are tight Wrap crane straps around s...

Page 37: ...ivot brackets align with support and elevation pivot assembly as shown in Figure 42 Figure 42 Attach pivot brackets to support and elevation pivot assembly with U bolts P N 9956 65 in lockwashers and...

Page 38: ...bly as shown in Figures 45 and 46 Use x 4 in bolt lockwasher and nut Figure 45 Figure 46 You have now completed the attachment of the reflector to the tripod ground mount assembly If assembling a ES45...

Page 39: ...80 6 Angles should be installed edge down with flat of angles facing upward Install sheaves P N 49087 at each end between support assemblies using pins P N 39527 with cotter pins P N 9958 6 Securely t...

Page 40: ...s support P N 49634 using supplied U bolts lockwashers and nuts as shown in Figure 48 Keep winch cable aligned with sheaves Figure 48 Begin releasing winch cable Route cable through both sheaves allow...

Page 41: ...ture to guide assembly during hoist ing procedure Hoist reflector backstructure assembly to vertical position until upper joints of main trian gle assembly contact pipe and straddle two locator bars o...

Page 42: ...performed in the Elevation and Azimuth Adjustments section If fine alignment is not performed at this time continue the assembly procedure at Step 16 Securely tighten U bolts and elevation strut mount...

Page 43: ...f neces sary tertiary strut sections from primary strut to achieve required strut length Install eight 1 2 inch 13 mm set screws in holes provided and securely tighten Note Do not extend secondary or...

Page 44: ...After fine adjustments are complete ensure strut set screws are securely tightened to 50 60 ft lbs and spray with zinc rich paint Securely tighten hex nuts and U bolts on both elevation and azimuth f...

Page 45: ...ation described in this manual Note All antenna options such as feeds shields anti icing etc possess installation instructions within the individual kits contained in the shipment Attach feed struts t...

Page 46: ...n in Figure 56 Arrange diameter setting band assembly P N 49612 and temporary supports as shown in Figure 54 Tighten 20 hardware at center connection until snug Reflector should be assembled in front...

Page 47: ...proper sequence See Figure 55 Figure 55 Place reflector segment A B between two setting bands with concave side down as shown in Figure 56 Place reflector segment D E opposite panel A B Figure 56 Rai...

Page 48: ...ng hub diameter setting bands and segment A B using edge joining plates P N 49424 Place spacers P N 200215 between first and third segments Insert 20 capscrews from concave side of reflector segment T...

Page 49: ...49424 on panel seams E E and F F Loosely attach joining plates P N 49693 on rim seams E E and F F Loosely attach joining plate P N 49693 along A A seam inside reflector rim as shown in Figure 58 A A...

Page 50: ...nds Use edge joining plate P N 49424 on B B panel seam and joining plate P N 49693 on B B rim seam Before attaching last panel lift reflector and return temporary supports to initial measur ing positi...

Page 51: ...segment around perimeter of reflector assembly beginning with seam A A Refer to Figure 28B Page 27 Begin tightening seam hardware at outer perimeter of reflector starting with seam A A Continue tight...

Page 52: ...easuring rod to place steel rule onto rod to allow visibility of steel rule through theodolite transit laser level at all 6 six measurement locations around reflector Securely fasten both ends of stee...

Page 53: ...porary location points are within 0 030 inches 0 75 mm elevation from each other Recheck the shim stacks required for leveling the reflector to ensure they are properly positioned and are adequately s...

Page 54: ...atwashers under both screw head and corresponding nut as shown in Figure 64 Tighten mounting hard ware allowing only slight compression 0 060 max of center pad material Use remain ing nylon nuts as lo...

Page 55: ...iameter setting bands in place during assembly of back structure Once back structure is attached and all bolts tightened reflector will be held in its assembled shape If back structure is added with r...

Page 56: ...0745 Attach opposite ends of support angles to tee plates P N 202447 at points A and C Angles should be installed edge up with flat of angle toward reflector Loosely attach support angle P N 49436 bet...

Page 57: ...ding edge joining plates P N 49294 installed using existing hardware You have now completed the assembly of the back structure and its attachment to the reflector Proceed to the next section for instr...

Page 58: ...ivot brackets align with support and elevation pivot assembly as shown in Figure 68 Figure 68 Attach pivot brackets to support and elevation pivot assembly with U bolts P N 9956 65 in lockwashers and...

Page 59: ...n in Figures 71 and 72 Use x 4 in bolt lockwasher and nut Figure 71 Figure 70 Figure 72 You have now completed the attachment of the reflector to the tripod ground mount assembly Proceed to the Elevat...

Page 60: ...sing pins P N 39527 with cotter pins P N 9958 6 Securely tighten support assembly hardware Attach entire support assembly to previously installed support tab assembly P N 49067 using appropriate hardw...

Page 61: ...backstructure Route P N 43909 or customer supplied 18 foot 5500 mm choker assembly behind both pivot brackets of main triangle assembly as shown Attach end of choker to winch or crane cable hook Dista...

Page 62: ...olts at each pivot bracket of main triangle assembly Use 1 2 inch 13 mm lockwashers and nuts Securely tighten U bolts allowing for some reflector movement Raise lower portion of reflector backstructur...

Page 63: ...e adjustment assembly U bolts simultaneously Doing so may result in severe bodily harm and equipment damage Coarse Elevation Adjustment Station at least two installers at reflector rim to provide temp...

Page 64: ...of lower azimuth axis joint assembly P N 49629 before changing azimuth position of antenna Fine Adjustment Attach fine adjustment assembly between adjacent elevation strut sections as shown in Figure...

Page 65: ...th fine adjustment assemblies Securely tighten eight U bolts on elevation pivot assembly and upper and lower azimuth axis joints Remove both fine adjustment assemblies and store in weather protected l...

Page 66: ...ntain appropriate feed window to center pad dimension during polarization adjustment Rotate feed assembly in one direction until signal level drops 1 dB Mark this position Rotate feed in opposite dire...

Page 67: ...Medium Modular Mount Refer to bulletin 237151C for Installation Instructions 67...

Page 68: ...drain hole should be positioned downward for proper water drainage Ensure that the locking strut support setscrew is firmly tightened on the strut assem bly as shown in Figure 100b Remove the two indi...

Page 69: ...2 Figure 1 Figure 2 The following steps provide the procedure for acquiring a satellite Manually move the antenna in the azimuth scanning back and forth to achieve the maximum greatest amplitude trans...

Page 70: ...aked on a side lobe in azimuth and or elevation move the antenna in azimuth while observing the spectrum analyzer screen as shown in Figure 3 Figure 3 If the signal amplitude diminishes and does not i...

Page 71: ...on der signals 12 horizontal and 12 vertical are noted the polarization adjustment is set incorrectly and must be modified If 12 transponder signals are noted they may or may not be the properly polar...

Page 72: ...r assembly Remove the manual actuator assembly by first removing the hardware securing the actuator to the base angle Note The adjustment kit assembly should be removed after the antenna has been adju...

Page 73: ...llowing paragraphs describe the inspection and preventative maintenance proce dures for the earth station These instructions include general cleaning and inspection the preservation of metal parts and...

Page 74: ...n noted during inspection that may preclude continued proper operation of the earth sta tion prior to the next scheduled inspection should be noted The discrepant condition should be corrected repaire...

Page 75: ...stortion and other deformation Check for evidence of water inside the enclosure If any water is in evidence check that all seals are intact and if not use a coating of RTV 108 silicone rubber sealant...

Page 76: ...interface for security the cable rouging for secure hanger attachment and the cable insulation for cuts cracking abrasion and other deterioration Check the LNA or LNBs and the resolvers for a secure m...

Page 77: ...hat significantly varies by more than five percent from the preestab lished reference values necessitates trouble shooting the particular system involved to determine the cause and required corrective...

Page 78: ...to OFF Repeat the preceding step 5 with the ELEVATION DOWN UP switch in the alternate operating position Repeat steps 3 through 6 with the Az El speed in the SLOW position If all voltage and current...

Page 79: ...n be applied with a brush roller or pressurized spray If necessary thin the paint with the appropriate thinner to the proper consistency Thoroughly pain over the primed surfaces and blend with the exi...

Page 80: ...lybdenum disulfide Operating Lubricant temperature range is 85 degrees to 300 degrees Fahrenheit 29 degrees to 149 degrees Celsius Periodically inspect lifting screws on jackscrew assemblies to insure...

Page 81: ...ing fill and drain Change 3 months 5 Panning frame tube Lubricate 3 months Aerosol Dry Moly Surface 207911 assembly and Spray Lubricant Coverage thrust pads Inspection requires checking for visible si...

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