Andrew ES45T User Manual

Andrew Corporation

10500 West 153rd Street
Orland Park, IL U.S.A. 60462

Telephone: [phone]
FAX (U.S.A.): 1-800-349-5444
Internet: http://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: [phone]

15 August, 2005

Copyright © 2005 by Andrew Corporation

Installation, Operation and Maintenance

Bulletin OM45T

Type ES45T

4.5-Meter ESA

4.5-Meter Earth Station Antenna

Revision F

Introduction

How to Use This

Manual

Getting Started

Installation
Procedures

Operation

Preventive

Table of Contents

2

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Proprietary Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Information and Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Parts Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Reporting Equipment Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Installation Sequence Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Foundation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A-325 Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Tripod Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ES45T-R Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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

Feed Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

ES45T-T Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Reflector Leveling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Reflector Center Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Feed Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Back Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Reflector To Mount Assembly (With Crane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Reflector To Mount Assembly (With Hoist Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Elevation and Azimuth Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Feed Support/Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Polarization Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Medium Modular Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Acquiring a Satellite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Manual Actuator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Preservation of Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Like all Andrew earth station antennas, the 4.5-meter earth station antenna provides
high gain and exceptional pattern characteristics. The electrical performance and excep­tional versatility provides the ability to configure the antenna with your choice of trans­mit/receive as well as receive-only, and for either linearly- or circularly-polarized C-Band,
linearly-polarized Ku-Band, Hybrid C-/Ku-Band or X-Band operation. Both pedestal and
tripod mount types are available (motorization for pedestal only). The versatility is pro­vided at the time of initial purchase, as well as in the future, as your satellite communi­cations requirements evolve. This manual covers the manual Tripod only.

The segmented aluminum reflector panels are precision formed for accuracy and
strength. The 6-piece reflector panel design ensures that the assembled reflector will
maintain the extremely accurate surface contour and guaranteed performance without
reflector alignment.

The versatile tripod mount features 164° of coarse azimuth coverage in four overlapping
ranges, and 90° coarse elevation adjustment. This large range of adjustment provides
the ability to view geostationary satellites from horizon-to-horizon, from any location
within the continental United States. The broad mount leg spacing enable efficient load
transfer to the foundation, providing additional mount rigidity.

The motorizable pedestal mount features self-aligning bearings for the elevation pivots,
resulting in “zero” backlash. This mount can be operated manually, but has the potential
to be upgraded for motorized operation, including steptracking/Smartrack

TM

applications.
The motorizable mount type is indicated by the ES45MP or ES45MPJ letters within the
antenna type number. The addition of the letter “J” within the antenna type number indi­cates that the mount includes azimuth/elevation machine jackscrews, instead of corre­sponding azimuth and elevation strut assemblies. The azimuth/elevation jackscrews are
equipped for integration with the optional motor drive systems.

A manual pedestal mount is also available. It provides the same strong and versatile
combination of mechanical features as the motorizable version; except that the elevation
and azimuth axes are locking types, instead of bearing mounted types. This mount type
is always equipped with manual struts and a fixed mount for the separately ordered
combining network. This mount has been designed for manual applications only and
cannot be upgraded to a motorizable mount.

The aluminum back structure and hot-dipped galvanized steel mount maintains pointing
accuracy and ensures durability and reliability. The antenna and mount will survive 125
mph (200 km/h) wind, in any position of operation, without damage or permanent defor­mation.

Andrew provides a complete line of available options, including field-installable electrical
anti-icing heaters, pressurization equipment and interconnecting HELIAX cables and
waveguide.

An optional hoisting kit, which precludes the use of a crane, is available from Andrew
and can be utilized as an installation tool for multiple installation purposes.

3

Introduction

Introduction

Proprietary Data

Information and

Assistance

Notice

Technical

Assistance

The technical data contained herein is proprietary to Andrew Corporation. It is intended
for use in installation, operation, and maintenance of Andrew equipment. This data shall
not be disclosed or duplicated in whole or in part without express written consent of
Andrew Corporation.

Andrew corporation provides a world-wide technical support network.

The installation, maintenance, or removal of antenna systems requires qualified, experi­enced personnel. Andrew installation instruction have been written for such personnel.
Antenna systems should be inspected once a year by qualified personnel to verify prop­er installation, maintenance, and condition of equipment.

Andrew disclaims any liability or responsibility for the results of improper or unsafe
installation practices.

All designs, specifications, and 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 at anytime.

Call From Call To Telephone Fax

North America (toll free) U. S. A. 1-(800)-255-1479 (800)-349-5444

Any Location U. S. A. (708)-349-3300 (708)-349-5410
(International)

Customer Service Center

The Andrew Customer Service Center gives you direct access to the information and
personnel service you need, such as the following:

• Place or change orders

• Check price and delivery information

• Request technical literature

You can call from any of the following:

Call From Telephone Fax

North America 1-800-255-1479 (toll free) 1-(800)-349-5444 (toll free)

United Kingdom 00-800-0-255-1479 (toll free) 00-800-0-349-5444 (toll free)

Australia 0011-800-0-255-1479 (toll free) 0011-800-0-349-5444 (toll free)

China 00-800-0-255-1479 (toll free) 00-800-0-349-5444 (toll free)

New Zealand 00-800-0-255-1479 (toll free) 00-800-0-349-5444 (toll free)

Hong Kong 001-800-0-255-1479 (toll free) 001-800-0-349-5444 (toll free)

Overview

Content

The scope of this manual is intended to provide station personnel with the base installa­tion (ie: mount, reflector and enclosure), operation and maintenance requirements nec­essary for a 4.5-Meter Earth Station Antenna.

Note: All antenna option instructions are included in the individual kit shipped with the
part. This manual provides a convenient reference for authorized operator/service per­sonnel requiring technical information on general system or specific subsystem equip­ment.

The tables and figures presented in this manual are used as communication aids for the
installation, operation and maintenance of the 4.5-Meter Earth Station Antenna. These
tables and figures instantly convey messages, as well as make the procedures easier to
understand. This manual uses tables and figures for the following references:

• Tables The tables allow you to locate information quickly and easily.

• Drawings The drawings supplement the installation instructions by using a

combination of graphics and verbiage to assist you in simplifying
complex procedures and clarifying components

• Photographs The photographs complement the installation instructions by

providing actual examples of the steps being performed, which 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 information. The sections con­tained in this manual are described and listed under the following technical headings:

• How to Use Describes the manual’s purpose, content, and communications aids.

This Manual Additionally, this section lists the related documentation for the 4.5-

Meter Earth Station Antenna.

• Getting Provides the preliminary information needed to perform a successful

Started installation. This section should be reviewed prior to the installation. The

warnings, recommended tools, parts verification, instructions on report­ing lost or damaged equipment and installation checklist are located in
this section.

• Installation Provides the procedures for the different phases of a 4.5-Meter

Procedures Earth Station Antenna base installation. This section will help you

easily find requirements for an individual task, as well as display the
sequence for each tasks execution.

• Operation Describes the controls, functions, and general operating procedures

required for proper operation of the 4.5-Meter Earth Station Antenna

• Maintenance Describes preventative maintenance procedures that are required to

maintain proper functional operation of your new Andrew Earth Station
Antenna.

5

How to Use This Manual

How to Use This Manual

Overview

Warnings

The installation, operation and maintenance of the 4.5-Meter Earth Station Antenna
requires qualified personnel. Andrew installation, operation and maintenance instructions
are illustrated for such personnel. Additionally, the antenna should be inspected by qual­ified personnel to verify proper installation, maintenance and condition of equipment as
described in Preventative Maintenance. The basic equipment and accessories are either
manufactured or design controlled by Andrew Corporation.

The prerequisite information necessary for the 4.5-Meter Earth Station Antenna can be
found in this section. Furthermore, this section should be reviewed before performing
the installation, operation or maintenance. Warnings, recommended tools and the anten­na parts can be verified and/or determined with such a review.

When installing the 4.5-Meter Earth Station Antenna, be conscious of the warnings pre­sented below. For further information or clarification of this information, contact the
Customer Service Center at one of the phone numbers listed. The warnings are as fol­lows:

1. Electrical shock from voltages used in this antenna system may cause personal injury
or death. Prior to making any electrical connections or performing maintenance or
repair, ensure that the power is removed. Electrical connections should only be made by
qualified personnel in accordance with local regulations.

2. Installation 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 with at least one (preferably two) lan­yards.

3. Never stand underneath any object while it is being lifted.

4. Always wear a hard hat, especially if someone is above you.

5. Make sure no person is in or under the reflector while it is being lifted or positioned;
personal injury can result if the reflector assembly falls.

6. Personnel should never be hoisted in or out of the reflector by crane; personal injury
may result.

7. Andrew earth station antennae supplied to standard product specifications will survive
125 mph winds in any operational position in moderate coastal/industrial areas. Severe
conditions require additional protection. Should it be expected that winds will exceed
125 mph, it is recommended that Andrew antennae be steered to specific azimuth and
elevation orientations to minimize wind forces upon the structure and thereby increase
the probability of survival.

8. It is recommended that all cross axis-waveguide and coaxial cables are secure such
that high winds will not cause excessive flexing. Position the antenna to an elevation of
90 degrees. The azimuth jackscrew should be placed in the center of its travel.

9. When the antenna is transmitting, severe eye injury or injury to other parts of the
body can result from exposure to radio frequency (RF) energy. The antenna must be
turned off before entering the area in front of the reflector and near the feed.

6

Getting Started

Getting Started

Recommended

Tools

Note: Failure to follow an installation procedure could result in damage to equipment or
personal injury.

Additional warnings will be displayed throughout this manual for your awareness. These
warnings can be identified in warning boxes as shown in the following sample.

Andrew disclaims any liability or responsibility for the results of improper or unsafe
installation, operation or maintenance practices.

Andrew supplies all appropriate hardware/parts required for the installation of your 4.5­Meter Earth Station Antenna. All tools necessary 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.

Table 1. Recommended Tools

Tool Size Qty.

Open End Wrench 1/4“ 2

3/8“ 2
1/2“ 2
9/16” 2
5/8” 2
3/4” 2
7/8“ 2
1-1/4” 1

Drive Sockets 7/16” 2

9/16” 1
3/4” 1
7/8” 1
1-1/16” 1
1-1/4” 1

Spud Wrench 1-1/16“ 1

Breaker Bar 1/2” 1

Screw Driver Standard 1

Phillips 1

Allen Wrench 1/2“ 1

Tape Measure Standard 1

Felt-tip Marker Standard 1

Hammer Standard 1

Rubber Mallet Standard 1

Pry Bar Standard 1

Tin Snips Standard 1

Crane 1 Ton Minimum Capacity 1

Rope/Cord (2000 lb breaking strength) 50 ft 1

Shackles 5/8“ 2

Ladder 10 Foot Extension 1

Nylon Web Sling 3” x 3’ 2

7

Getting Started

Parts Verification

Reporting

Equipment Loss or

Damage

Reporting Visible

Loss or Damage

Reporting

Concealed

Damage

Inventory

Equipment

Received

Returning

Equipment

Step 1

Step 2

Step 3

Step 4

Step 5

Upon receipt of your order, the shipment should be verified to ensure that all parts have
reached your site. This process should occur before the installation process begins.

Andrew Corporation thoroughly inspects and carefully packs all equipment before ship­ment. If you find that there are missing components, please refer to step-by-step instruc­tions on how to properly report the equipment loss.

When you have received your order, verify that all parts contained in the shipment corre­spond to the parts listed on your packing list.

If you find that the equipment was damaged during the shipping process, you should file
a claim with the carrier. Follow the “Reporting Visible Loss or Damage” or “Reporting
Concealed Damage” procedures when filing a claim with a carrier.

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.

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 an inspection by the carrier’s agent, then file a
claim with the carrier since such damage is most likely the carrier’s responsibility.

After 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 notify Andrew Corporation immediately by contacting
the Customer Service Center at one of the phone numbers listed.

Andrew Corporation tries to ensure that all items arrive safe and in working order.
Occasionally, despite these efforts, equipment is received that is not in proper working
condition. When this occurs, and it is necessary to return the equipment to Andrew
Corporation for either repair or replacement, return can be expedited by using the fol­lowing procedure:

Call the Andrew Customer Service Center and request a Return Material Authorization
(RM) number, as well as the address to which you should forward the material(s).

Tag or identify the defective equipment, noting the defect or circumstances. Also, be
sure to write the RM number on the outside of the carton. It would be helpful to refer­ence the Andrew sales order and purchase order number, as well as the date the equip­ment was received.

Pack the equipment in the original container with protective packing material. If the origi­nal container and packing material are no longer available, pack the equipment in a
sturdy corrugated box and cushion it with appropriate packing material.

Be sure to include the following information when returning the equipment:

• Your Company Name

•

Your Company Address City, State and Zip Code

• Telephone Number

• RM Number

• Problem Description

• Contact Name

Note: Absence of the RM number will cause a delay in processing your equipment for
repair. Be sure to include the RM number on all correspondence.

Ship the equipment to Andrew Corporation using UPS, U.S. Postal Service, or other
appropriate carrier, freight prepaid and insured. The material should be forwarded to the
address given by the Andrew contact in Step 1.

8

Getting Started

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 veri­fy and/or determine the installation sequence. Throughout the checklist certain part num­bers 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 instal­lation 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

9

Getting Started

Tripod Ground

Mount Assembly

ES45T-T Main

Reflector

Assembly

ES45T-T Back

Structure

Assembly

ES45T Reflector-

to-Mount

Assembly

(With Crane)

Feed Installation

Waveguide/Flex

Section Assembly

Subreflector

Installation

Feed Installation

 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 reflector rib segments to panel seams
 Tighten seam hardware in concentric circles around reflector
 Install 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 pivot brackets for installation
 Install pivot bracket assemblies
 Connect pivot brackets with support angle
 Install two support angles to elevation axis bracket
 Connect pivot brackets and elevation axis bracket with support angles
 Tighten hardware using A-325 tensioning 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 assembly
 Assemble feed horn assembly to network
 Install feed assembly into feed support
 Tighten all collar set screws

 Attach flex section to feed assembly flanges
 Attach mounting brackets to feed struts
 Attach flex section to waveguide assembly
 Tighten all mounting hardware

 Station two men inside reflector
 One man attaches subreflector to struts
 One man supports subreflector
 Tighten all strut hardware

 Attach feed assembly to main reflector hub
 Install OMT inside feed assembly

10

Getting Started

Overview

Foundation

Preparation

11

Installation Procedures

This section provides installation procedures for the 4.5-Meter Andrew Earth Station
Antenna. The installation procedures include instructions on the following antenna com­ponents.

• Mount

•

Reflector

• Back Structure

• Reflector To Mount Assembly

• Subreflector

• Feed System

Note: All installation instructions for the antenna options are contained in the parts kit
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 be used as a reference by civil engineering personnel when preparing the
foundation for local soil conditions. These specifications are available before the ship­ment arrives by contacting the Customer Service Center.

Sweep foundation clean of any dirt or debris.

To ensure level, smooth surface for mount, remove excess concrete from shear caps
and anchor bolts as shown in Figure 1.

Installation Procedures

Figure 1

A-325 Tensioning

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

12

During the installation process there are several references to the A-325 hardware ten­sioning procedure. The A-325 hardware must be properly tensioned to avoid slippage
between bolted surfaces under high loads. Slippage can cause the corresponding
assembly to move, causing antenna misalignment. When designated, the A-325 hard­ware should be tightened according to the following tensioning procedure.

Note: Tensioned bolts are for final connections only and should not be loosened for
reuse.

Lubricate the bolt threads with the provided stick wax to reduce friction.

Insert the bolt, and add a flat washer - if required. Do not allow wax under the flat washer.

Add the nut and finger-tighten.

After the connections are complete, tighten the bolts until the surfaces are joined and
the nuts are snug (for example, 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 Steps 5 and 6, discard and replace with new hard­ware.

Using a felt-tip marker, mark the nuts and the ends of the bolts with a straight line as
shown in Figure A-325.

Tighten the nuts further with an extra-long wrench until the nuts are moved 1/3 turn (120
degrees) as shown in Figure 1a for bolt lengths shorter than four diameters and 1/2
turn (180 degrees) as shown in Figure 1b for bolt lengths longer than four
diameters.

Installation Procedures

Use Felt Marker

Before

Tensioning

After

Tensioning

Use Felt Marker

Before

Tensioning

After

Tensioning

For Bolts Shorter Than 4 Diameters For Bolts Longer Than 4 Diameters

Figure 1a. A-325 Tensioning Figure 1a. A-325 Tensioning

Note: Do not perform A-325 tensioning procedure during assembly process unless

specifically designated by installation instructions. Final tightening will occur after mount
is fully assembled.

Tripod Mount

Step 1

13

The three-point mount in an elevation-over-azimuth configuration optimized for geosta­tionary satellite applications. The mount enables standard elevation ranges from 2°-62°,
and 33°-90° with high-look strut configuration. Azimuth range is ±82°. Fine adjustment 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 are present. Follow the subsequent
procedures for proper installation of tripod ground mount assembly.

Loosely attach azimuth axis support (P/N 49634) and rear anchor pads (P/N 300747) to
foundation pads. Refer to Figures 3 and 4.

• Use ¾-10 x 1-¼ in. hex nuts and washers

Figure 3

Step 2

14

Installation Procedures

Figure 4

Loosely connect support angles (P/N 49624) with spacers (P/N 46560-2) to azimuth axis
support and rear anchor pads as shown in figure 5.

•

Use A-325 ½ x 1-½ in. bolts and nuts for connections. (see page 12)

• Support angles should be installed edge down with flat of the angle facing upward

Figure 5

300747

300747

300747

300747

Step 3

Step 4

15

Lay out support and elevation pivot assembly (P/N 49635) and support angles (P/N

49623) 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 ½ x 1-½ in. bolts and nuts. (see page 12)

• Angles should be attached with flat of angle facing downward

Figure 7

Step 5

Step 6

16

Loosely attach support angles (P/N 49622) to the upper azimuth axis joint (P/N 300748)
and the connection plates (part of P/N 49635)as shown in Figure 8.

• Use A-325 ½ x 1-½ 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 8

Apply a liberal amount of grease (P/N 49208) to azimuth axis support (P/N 49634) and
corresponding underside of azimuth axis joint as shown in Figure 9.

Figure 9

300748

UPPER

Step 7

Step 8

Step 9

17

Tightly knot 40 ft. rope to azimuth axis joint (P/N 300748) for hoisting to azimuth axis
support (P/N 49634).

Installation Procedures

Figure 10

Station 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 300746) and upper azimuth axis joint (P/N

300748) to azimuth axis support (P/N 49634) as demonstrated in Figure 11.

• Use 9956-1101 U-bolts, ½ in lockwasher and ½-13 hex nuts.

Figure 11

Step 10

Step 11

Step 12

18

Use a carpenter’s level to level support assembly as indicated in Figure 12. Loosen U­bolts to move support assembly up or down as 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 A­325 procedure. See A-325 procedure for technique. (see page 12)

Loosely attach elevation strut (P/N 49766) to azimuth axis joint (P/N 300746) as shown
in Figures 13 and 14.

• Use ¾ x 3-½ in. bolt, lockwasher and nut

Step 13

19

Installation Procedures

Figure 14

Determine required length of elevation strut to nearest degree increment of desired ele­vation 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 ½ in. set screws and securely tighten as pictured in Figure 15.

CAUTION: Do not extend secondary or tertiary struts into red warning areas.

Figure 15

20

Installation Procedures

Loosely attach azimuth strut end bracket (P/N 49767) to universal block (P/N 49705) as
shown in Figure 16.

• Use ¾ x 1-¼ 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 configuration of the azimuth strut shown in Figures 16 and

17.

• Use ¾ x 5-½ in. bolts, lockwashers and nuts

Figure 17

Step 16

Step 17

Step 18

Step 19

21

Connect U-bracket (P/N 49704) to appropriate connection plate.

• Use A-325 ½ x 1-½ in. bolts, flatwashers and nuts. (see page 12)

Installation Procedures

Figure 18

Determine required length of azimuth strut to nearest degree increment of desired
azimuth setting as specified in the Elevation and Azimuth Adjustments Section. Adjust
azimuth setting by withdrawing secondary strut to achieve necessary length. Install four
½ in. set screws and securely tighten 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 ¾ x 4-½ in. bolts, lockwashers and nuts

Securely tighten all A-325 ground mount hardware except the fine adjustment hardware
per A-325 tensioning procedure (see page 12).

The tripod ground mount assembly is now completed with the necessary operational
essentials. All ground mount options have separate instructional bulletins located in the
parts kit that contain the option.The next step in the installation process is the reflector
assembly. Proceed to the appropriate section for the type of reflector you are installing.

ES45T-R

Reflector

Step 1

Step 2

22

The ES45T-R-1 reflector is composed of six precision-formed panels designed for accu­racy and strength and ensure reliable surface contour which provides exceptional oper­ating characteristics in C- or Ku-frequency band.

Reflector should be assembled on a clear, flat area in front of the foundation pad. Clear
debris from area and place plastic sheeting from packing crate as shown in Figure 22.

Arrange the six diameter setting bands (P/N 49426) and temporary supports as shown
in Figure 20.

Note: Proper orientation of reflector (top, bottom) will ease reflector assembly

• Tighten ¼-20 hardware at connection of bands to a snug fit

• Reflector should be assembled in front of foundation pad with bottom of reflector 3 ft.

from pad

• Supports should be 6-8 in. high

•

Tie three string levels to opposing sets of blocks across diameter of circle

• Adjust supports with shims until strings are level and lightly touch at center of circle

•

Once supports are level, remove strings

• Move supports 12 in. radially away from circle, carefully maintaining orientation and

height for later reuse

Installation Procedures

Figure 20

ES45T-R Reflector Assembly

Step 3

23

Note: All six reflector segments are identified individually by a two letter designation (A­B, D-E, etc). Locate the markings 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 bands with concave side down as
shown in Figure 22. Place reflector segment D-E opposite panel A-B.

ES45T-R Reflector Assembly

Step 4

Step 5

24

Installation Procedures

Raise segments and hold while loosely attaching mounting ring hub (P/N 49965) to con­vex side of center opening.

• Use ¼-20 capscrews, lockwashers 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 capscrew hardware as shown in Figure 23.

• Use ¼-20 capscrews, lockwashers and nuts

• Insert capscrews from concave side of reflector segments

Figure 23

ES45T-R Reflector Assembly

Step 6

Step 7

25

Installation Procedures

Figure 24

Loosely attach joining plate (P/N 49693) along A-A seam inside reflector rim as shown in
Figure 25.

• Insert ¼-20 capscrews 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 reflector panel seam as pictured in Figure 24.

• Place spacers (P/N 200215) between first and third segments

• Insert ¼-20 capscrews from concave side of reflector segments

Step 8

Step 9

26

Installation Procedures

Loosely attach segment E-F to mounting ring hub, diameter setting bands and segments
A-F and 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 inside reflector to finger-tighten seam hardware and attach final pan­els as pictured in Figure 27.

Figure 27

ES45T-R Reflector Assembly

Step 10

Step 11

27

Installation Procedures

Loosely attach reflector segment B-C to mounting ring hub and diameter setting bands.
Use joining plates (P/N 49425) along B-B panel seam and joining plate (P/N 49693) on
B-B rim seam.

Before last panel, lift reflector and return temporary supports to initial measuring posi­tion. Have installer inside reflector 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 set­ting bands are uniformly taut, as shown in Figure 28.

ES45T-R Reflector Assembly

To p

A

A

B

B

C

C

D

D

E

E

F

F

200215

Shim

200215

Shim

200215

Shim

200215

Shim

200215

Shim

Foundation Pad

Move Reflector Segment in This Direction

to Enable Hardware Installation at B

Move Reflector Segment

in This Direction to

Enable Hardware

Installation at C

Rear View

Reflector Rib

Segments

200215

Shim

Figure 28A

Figure 28B

28

Installation Procedures

Step 12

Step 13

Step 14

Install last reflector panel (C-D) by loosely attaching to diameter setting bands and
mounting ring hub. Loosely attach panel seam hardware as installer inside moves
reflector segment to enable segment union.

Loosely attach retaining bar (P/N 49997) to mounting ring hub (P/N 202429). Loosely
attach center plate (P/N 49964-2) to concave side of reflector.

•

Insert capscrew 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 and joining plate hardware (P/N

49693).

Panel

Seams (6)

Temporary

Supports (6)

Refer to

Figure 31

Line of Sight

(0.0° Elevation)

Steel Rule

0.03-0.06 Inch
Increment

(0.5-1.0 mm)

Pointed Measuring Rod

6’ (1.8 m)

Reflector

Diameter Setting Band

Temporary Support

12 Inch (300 mm)

Shim Stack - Not

Shown for Clarity

Approx. 10 Feet (3 m)

Theodolite,

Transit or

Laser Level

Reflector

Turn Back

ES45T-R Reflector Assembly

Figure 30

Figure 29

29

Installation Procedures

Reflector Leveling

Procedure

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Position (6) temporary supports near panel seams exactly as shown in Figure 29.
Note: Temporary supports should be large enough to adequately support the reflector
and strong enough to easily support reflector weight without compressing.

Position theodolite, transit or laser level about 10 feet [3m] from outside perimeter of
reflector (see Figure 30).

Level theodolite/transit/laser level. If using theodolite, position view scope at 0.0 degrees
elevation, lock down elevation adjustment.

Site through theodolite/transit/laser level to determine where on measuring rod to place
steel rule onto rod to allow visibility of steel rule through theodolite/transit at all (6) six
measurement locations around reflector. Securely fasten both ends of steel rule to mea­suring rod with adhesive tape (see Figure 30).

Temporary supports should be positioned as shown in Figure 31, close to but not inter­fering with diameter setting bands.

Referring to Figure 31, mark the measuring location at each of the six temporary sup­port locations with a small dot (use felt tip marker) to be used as reference point in sub­sequent measurements.

Position measuring rod point down over temporary supports and on the flat portion of
the aperture face as shown in Figures 30 and 31, using theodolite/transit/laser level
carefully measure and record relative height of each of the (6) temporary support loca­tions. Note: Measuring rod must be held in a vertical position during all measurements.

From the recorded data determine the relative height of each of the locations as com­pared to the highest measured location. The differences between the highest location
and a lower location will be the amount of shim material required to place between the
reflector and the temporary support.

Reflector
Turnback

Outside Edge

of Reflector

Setting Band

Hardware (2)

Shim Stack

(as required)

Temporary

Support

Measurement Location

Directly Above Shim Stack

Diameter Setting

Band (Hidden)

Reflector Seam

Seam Hardware Not Shown for Clarity

ES45T-R Reflector Assembly

Figure 31

Step 9

Step 10

Step 11

Step 12

Step 13

Feed Strut

Assembly

Step 1

Step 2

30

Installation Procedures

Shim each location as required to level the reflector (see Figure 31).

Continue to measure around antenna again, recording the height of each location mea­sured. As before, shim the low location points to be at the same elevation as the highest
measured location.

Continue to measure, record, compare and shim any low temporary support location
points until all (6) temporary 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 supporting the reflector. Note: As work continues on the
reflector it is essential that the shim stacks remain in position through out this process.
Also ensure that diameter setting bands are taut and evenly tensioned. If not, check to
ensure 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 around reflector in
concentric circles while progressing inward toward reflector vertex. Note: Near vertex
area, it may become necessary to push down on mounting ring hub to narrow segment
gap before tightening hardware.

Installer underneath reflector should attach four of each feed strut brackets (P/N
49694/49695) as shown in Figure 32.

•

Use A-325 ½ x 1-¼ in. bolts, flatwashers and nuts (see page 12).

• Insert bolts from concave sides of reflector

Pass feed struts (P/N 49703) to installer underneath for attachment to feed strut brackets
(P/N 49694/49695).

• Use 3/8 x 2-¼ in. bolts, lockwashers and nuts

• Secure feed struts together after attachment to feed strut brackets as shown in Figure 32

You have now completed the assembly of the ES45T-R-1 or the ES45TDR reflector. The
next step in the installation is the assembly of the back structure, which follows in the next
section.

ES45T-R Reflector Assembly

Figure 32

ES45T-R-1

Back Structure

31

Installation Procedures

The back structure assembly attaches to the rear of the reflector. The back structure
provides stability for the reflector and maintains the parabolic accuracy of the dish. An
example of the assembled back structure is presented in Figure 33.

Figure 33

Before assembling the back structure, verify that the appropriate parts are present. The
following steps 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 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 reflector in distorted shape, back
structure will hold reflector in that shape. If standing or walking on reflector becomes
necessary, concentrate major portion of body weight towards center of reflector panel.

ES45T-R Reflector Assembly

Step 1

32

Installation Procedures

Refer to back structure Figure 34 for 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 tensioning sequence in assem­bly procedure

Figure 34

ES45T-R Reflector Assembly

Step 2

Step 3

33

Installation Procedures

Loosely attach tee plates (P/N 202447) to points B, F and D on convex side of reflector
as shown in Figure 35.

• Use A-325 ½ x 1-¼ in. bolts, flatwashers and nuts. (see page 12).

• Insert bolts from 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 Figure

36.

• Use A-325 ½ x 1-¼ in. bolts, flatwashers and nuts. (see page 12)

• Install bolts from concave side of reflector

• Angles should be installed with flat side towards back side of reflector

Figure 36

ES45T-R Reflector Assembly

Step 4

Step 5

34

Installation Procedures

Loosely attach support angles (P/N 49436) to three tee plates (P/N 202447) as shown in
Figure 37.

• Use A-325 ½ x 1-¼ in. bolts, flatwashers 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/N 49438) from plates E and A to angle (P/N 49436)
from tee plate F with pivot bracket (P/N 300758) as illustrated in Figure 38.

Figure 38

ES45T-R Reflector Assembly

Step 6

Step 7

Step 8

Step 9

Step 10

35

Installation Procedures

Loosely attach support angles (P/N 49438) from plates A and C to angle (P/N 49436)
from tee plate B with pivot bracket (P/N 300745).

Loosely connect support angles (P/N 49438) from plates E and C to angle (P/N 49436)
from tee plate D to elevation axis bracket (P/N 300749) as shown in Figure 39.

Figure 39

Loosely connect pivot brackets and elevation axis bracket with the three support angles
(P/N 49437) as pictured in Figure 40.

• Angles should be installed edge down with flat of angle away from reflector.

Figure 40

Check diameter setting bands 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 12) . Work from connections
closest to backside of reflector to those connections furthest away in this order: Start
with plates (P/N 49427) and tee plates (P/N 202447). Next tighten support angle con­nections. Tighten the pivot brackets and elevation axis bracket last.

You have now completed the assembly of the back structure and its attachment to the
reflector. Proceed to the next section for instructions on mounting the reflector to the tri­pod ground mount assembly with a crane, or the appropriate section for instructions on
mounting the reflector with the hoist kit.

ES45T-R Reflector Assembly

Reflector-to-Mount

Assembly

(With Crane)

Step 1

Step 2

36

Installation Procedures

This reflector can be installed on the mount manually or by using a crane. However,
Andrew recommends that this procedure be performed using 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 support angle between pivot brackets as illustrated by Figure

41.

• Hoist reflector slightly off ground to remove diameter setting bands

• Reattach hardware through edge joining plates

Figure 41

ES45T-R Reflector Assembly

Step 3

Step 4

37

Installation Procedures

Crane should place reflector so that pivot 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), ½ in. lockwashers and ½-13 hex nuts as shown in Figures 43 and 44.

Figure 43

ES45T-R Reflector Assembly

Step 5

38

Installation Procedures

Figure 44

Manually raise reflector to attach remaining end of elevation strut to elevation axis
bracket of main triangle assembly as shown in Figures 45 and 46.

•

Use ¾ x 4-½ 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 ES45T-R antenna, proceed to the Elevation and Azimuth
Adjustments section for instructions on aiming your antenna at its desired satellite.

ES45T-R Reflector Assembly

Reflector-to-Mount

Assembly

(With Hoist Kit)

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

39

Installation Procedures

The optional hoist kit (P/N 49080) must be assembled prior to reflector/ backstructure
assembly hoisting. Hoist assembly should not be used for antenna elevation angle
adjustment. The following steps provide the procedure for installing the reflector with the
hoist kit.

Install support tab assembly (P/N 49067) into top of azimuth axis support (P/N 49634)
as shown in Figure 47.

Figure 47

Loosely attach corresponding support assemblies (P/N 49071 and 49072) using spacers
(P/N 49059) and appropriate hardware (P/N 45980-6).

• 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 tighten support assembly hardware.

Attach entire support assembly to previously installed support tab assembly (P/N 49067)
using appropriate hardware (P/N 45980-6).

Loosely attach pick-up assemblies (P/N 49064) to support and elevation pivot assembly
(P/N 49635) as shown.

• Use supplied U-bolts with 1/2 inch (13 mm) lockwashers and nuts.

•

Pick-up assemblies are mounted with slanted tabs facing outward.

Loosely attach supports (P/N 49061) to corresponding tabs on support assemblies (P/N
49071 and 49072) using appropriate hardware (P/N 45980-1).

• Angles are installed edge down with flat of angles facing upward

ES45T-R Reflector Assembly

Step 7

Step 8

Step 9

Step 10

40

Installation Procedures

Loosely attach support (P/N 49060) and remaining ends of supports (P/N 49061) to cor­responding pick-up assemblies (P/N 49064) using appropriate hardware (P/N 45980-1).
Securely tighten all mounting hardware.

• Ensure entire hoist assembly is centered on support and elevation pivot assembly

(P/N 49635)

Securely attach winch assembly (P/N 39532) to lower portion of azimuth axis 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 allowing sufficient cable
length to reach top of main triangle assembly on reflector 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.

•

Distance between choker/winch connection and top of main triangle assembly should

be approximately 13 inches (330 mm).

ES45T-R Reflector Assembly

Step 11

Step 12

Step 13

41

Installation Procedures

Remove small portion of foam padding from reflector packing crate and install under
bottom portion of reflector assembly to prevent reflector damage during hoisting proce­dure. Position man at bottom of reflector/backstructure to guide assembly during hoist­ing procedure.

Hoist reflector/backstructure assembly to vertical position until upper joints of main trian­gle assembly contact pipe and straddle two locator bars on support and elevation
assembly (P/N 49635) as shown in Figure 49.

Figure 49

Install two U-bolts 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

ES45T-R Reflector Assembly

Step 14

Step 15

Step 16

Step 17

42

Installation Procedures

Raise lower portion of reflector/backstructure assembly and attach remaining end of ele­vation strut to elevation axis bracket of main triangle assembly.

• Use 3/4 x 4-1/2 in (114 mm) bolt, lockwasher and nut

• Mechanical means or fine adjustment assembly may be utilized to achieve elevation

angles greater than 30°.

Set fine elevation and azimuth strut positions based on the procedure 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 mounting hardware.

Remove both fine adjustment assemblies and store in a weather protected location for
future use. Continue with feed system and corresponding LNA installation.

You have now completed the attachment of the reflector to the tripod ground mount
assembly. If installing an ES45T-R antenna, advance to the Elevation and Azimuth
Adjustments section for instructions on pointing your antenna to its satellite.

ES45T-R Reflector Assembly

Elevation and

Azimuth

Adjustments

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

43

Installation Procedures

Proper antenna pointing requires specific coarse and fine elevation and azimuth strut
length adjustments which can be determined using the graphs provided in Appendix F.
Adjustable azimuth and elevation struts are initially set in coarse setting as near as pos­sible to pre-determined lengths. Fine elevation and azimuth settings are accomplished
with threaded rod on elevation and azimuth struts.

CAUTION

Never loosen strut set screws and fine 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
temporary reflector support while third installer loosens two U-bolts on each end of ele­vation pivot assembly (P/N 49635) and removes 3/4 x 4-1/2 inch (114 mm) bolt, lock­washer and nut connecting elevation strut to bottom of main triangle assembly. Carefully
lower reflector to vertical position.

Determine required length of elevation strut to nearest degree increment of desired ele­vation setting. Adjust coarse elevation setting by withdrawing secondary and, if neces­sary, 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 tertiary strut sections into red warning areas.

Carefully raise reflector and attach elevation strut to bottom of main triangle assembly
using previously removed 3/4 x 4-1/2 inch (114 mm) bolt, lockwasher and nut.

Note: Mechanical means or fine adjustment assembly may be used to achieve elevation
angles greater than 30°.

Coarse Azimuth Adjustment. Loosen to U-bolts on both upper (P/N 49630) and lower
(P/N 49629)azimuth axis joints. Remove 3/4 x 4-1/2 inch (114 mm) bolt, lockwasher and
nut connecting azimuth strut to U-bracket (P/N 49704).

Determine required length of azimuth strut to nearest degree increment of desired
azimuth setting. Adjust coarse azimuth setting by withdrawing secondary strut section
from primary strut to achieve desired strut length. Install four 1/2 inch (13 mm) set
screws in holes provided and securely tighten.

Note: Do not extend secondary strut section into red warning area.

Carefully pivot reflector as required and attach azimuth strut to U-bracket using previ­ously removed 3/4 x 4-1/2 inch (114 mm) bolt, lockwasher and nut.

Note: Apply grease (P/N 49208) around bottom area of lower azimuth axis joint assem­bly (P/N 49629) before changing azimuth position of antenna.

ES45T-R Reflector Assembly

Step 8

Step 9

Step 10

Step 11

Step 12

Step 13

Step 14

44

Installation Procedures

Attach fine adjustment assembly between adjacent azimuth strut sections as shown in
Figure 51 using appropriate brackets, U-bolts, brass hex nuts, flatwashers and threaded
rod. Securely tighten all adjustment assembly hardware.

Note: Fine adjustment assembly on azimuth strut should be positioned away from
ground mount angles.

Set fine elevation and azimuth strut positions by loosening strut set screws and selected
out fine adjustment hex nut. Turn corresponding inner hex nut in appropriate direction
until required strut length is achieved. Securely tighten strut set screws and correspond­ing outer hex nut.

During final electrical tuning, adjust elevation and azimuth struts appropriately to length­en or shorten struts for optimal signal strength.

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 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 location for
future use.

You have now finished aiming your antenna at the desired satellite. Proceed to the feed
support installation section for instructions on assembling and attaching the feed support
assembly to the reflector.

Fine Adjustment. Attach fine adjustment assembly between adjacent elevation strut
sections as shown in Figure 50 using appropriate brackets, U-bolts, brass hex nuts, flat­washers and threaded rod. Securely tighten all adjustment assembly hardware.

Note: Adjustment assembly may also be attached in alternate position shown depend­ing on required elevation angle.

Figure 50

Figure 51

ES45T-R Reflector Assembly

Feed Support

Assembly

Step 1

Step 2

45

Installation Procedures

By now, you can see that your installation of the 4.5-Meter Earth Station Antenna is
almost complete. The feed system is the last phase of the base installation 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 to 222930 feed support as shown in Figures 52 and 53.

• Use 3/8 x 2 in. bolt, lockwasher and nut

Install supplied feed system according to installation instructions provided with applica­ble feed system.

Figure 52

Figure 53

ES45T-T-1

Reflector

Step 1

Step 2

46

Installation Procedures

The ES45T-T-1 reflector is composed of six precision-formed panels designed for accu­rate strength, and ensures a reliable surface contour that provides exceptional operating
characteristics in C-, X- or Ku-frequency bands.

Reflector should be assembled on a clear, flat area in front of the foundation pad. Clear
debris from area and place plastic sheeting from packing crate as shown in Figure 56.

Arrange diameter setting band assembly (P/N 49612) and temporary supports as shown
in Figure 54.

• Tighten ¼-20 hardware at center connection until snug

• Reflector should be assembled in front of foundation pad with bottom of reflector 3 ft.

from pad

• Temporary supports should be 6-8 in. high

•

Tie three string levels to opposing blocks across diameter of circle

• Adjust supports with shims until strings are level and lightly touch at center of circle

•

Once supports are level, remove strings

• Move supports 12 in. radially away from circle, carefully maintaining orientation and

height for later reuse

Figure 54

ES45T-T Reflector Assembly

Step 3

Step 4

47

Installation Procedures

Note: All six reflector segments are identified individually by a two letter designation (A­B, D-E, etc). Locate the markings on the reflector segments in order to assemble the

reflector in the 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

Raise segments and hold while loosely attaching mounting ring hub (P/N 202429) to
convex side of center opening.

• Use ¼-20 capscrews. lockwashers and nuts

•

Insert capscrews from concave side of reflector segments

ES45T-T Reflector Assembly

Step 5

Step 6

48

Installation Procedures

Loosely attach reflector segments A-B and D-E to diameter setting bands (P/N 49612)
with edge joining plates (P/N 49424) and capscrew hardware as indicated in Figure 57.

Figure 57

Loosely attach segment A-F to mounting ring 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 ¼-20 capscrews from concave side of reflector segment

To p

D

Match

Markings

Reflector
Segment

49424

Edge Joining

Plate

Capscrew
Hardware

Diameter

Setting

Band

Top View

Rear View

Foundation Pad

Match

Markings

Side View

Reflector

Segments

202429
Mounting
Ring Hub

Capscrew
Hardware

E

A

B

ES45T-T Reflector Assembly

Step 7

Step 8

49

Installation Procedures

Figure 58

Loosely attach segment E-F to mounting ring hub, diameter setting bands, and seg­ments A-F and D-E with joining plates (P/N 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.

AA

To p

Match

Markings

F

F

D

D

C

Match

Markings

Foundation Pad

Rear View

Adjacent

Reflector Segments

Side View

Capscrew
Hardware

49693

Joining

Plate

ES45T-T Reflector Assembly

Step 9

Step 10

Step 11

50

Installation Procedures

Station an installer inside reflector to finger-tighten seam hardware and attach final pan­els as shown in Figure 59.

Figure 59

Loosely attach reflector segment B-C to mounting ring hub and diameter setting bands.
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 measur­ing position. Have installer inside reflector check tension on diameter setting bands. If
not uniformly taut, adjust level by adding shims until no segment of the reflector can
bounce and bands are uniformly taut, as shown in Figure 60.

Figure 60

ES45T-T Reflector Assembly

Step 12

Step 13

Step 14

Step 15

Step 16

Reflector Leveling

Procedure

Step 1

51

Installation Procedures

Install final reflector panel (C-D) by loosely attaching to diameter setting bands and
mounting ring hub. Loosely attach panel seam hardware as installer inside moves
reflector segment to enable segment union.

Begin attaching corresponding reflector rib segments at match-marked position A-A
using reflector segment seam hardware.

•

Insert capscrews from concave side - firmly push bolts through holes until bolt head is

flush with reflector surface

Note: Slight pressure on reflector segment may be necessary to enable proper align­ment. Do not attempt to thread bolts into holes

Insert shim (P/N 200215) between each reflector 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 tightening in concentric circles from reflector rim toward the mounting ring hub.

Note: Near center area it may become necessary to push down on mounting ring hub to
narrow segment gap before tightening hardware.

Tighten mounting ring hub and diameter setting band hardware. Diameter setting bands
should be uniformly taut at this point. If not, add or subtract shims to ensure proper lev­eling of supports.

Position (6) temporary supports near panel seams exactly as shown in Figure 61. Note:
Temporary supports should be large enough to adequately support the reflector and
strong enough to easily support reflector weight without compressing.

Figure 61

Panel

Seams (6)

Temporary

Supports (6)

Refer to
Figure 7

ES45T-T Reflector Assembly

Step 2

Step 3

Step 4

Step 5

Step 6

52

Installation Procedures

Position theodolite, transit or laser level about 10 feet [3m] from outside perimeter of
reflector (see Figure 62).

Figure 62

Line of Sight

(0.0° Elevation)

Steel Rule

0.03-0.06 Inch
Increment

(0.5-1.0 mm)

Pointed Measuring Rod

6’ (1.8 m)

Reflector

Diameter Setting Band

Temporary Support

12 Inch (300 mm)

Shim Stack - Not
Shown for Clarity

Approx. 10 Feet (3 m)

Theodolite,

Transit or

Laser Level

Reflector

Turn Back

Level theodolite/transit/laser level. If using theodolite, position view scope at 0.0 degrees
elevation, lock down elevation adjustment.

Site through theodolite/transit to determine where on measuring 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 steel rule to mea­suring rod with adhesive tape (see Figure 62).

Temporary supports should be positioned as shown in Figure 63, close to but not inter­fering with diameter setting bands.

Referring to Figure 63, mark the measuring location at each of the six temporary sup­port locations with a small dot (use felt tip marker) to be used as reference point in sub­sequent measurements.

Reflector
Turnback

Outside Edge

of Reflector

Setting Band
Hardware (2)

Shim Stack

(as required)

Temporary

Support

Measurement Location

Directly Above Shim Stack

Diameter Setting

Band (Hidden)

Reflector Seam

Seam Hardware Not Shown for Clarity

Figure 63

ES45T-T Reflector Assembly

Step 7

Step 8

Step 9

Step 10

Step 11

Step 12

Step 13

Reflector Center

Plate Assembly

Step 1

53

Installation Procedures

Position measuring rod point down over temporary supports and on the flat portion of
the aperture face as shown in Figures 62 and 63, using theodolite/transit/laser level
carefully measure and record relative height of each of the (6) temporary support loca­tions. Note: Measuring rod must be held in a vertical position during all measurements.

From the recorded data determine the relative height of each of the locations as com­pared to the highest measured location. The differences between the highest location
and a lower location will be the amount of shim material required to place between the
reflector and the temporary support.

Shim each location as required to level the reflector (see Figure 63).

Continue to measure around antenna again, recording the height of each location mea­sured. As before, shim the low location points to be at the same elevation as the highest
measured location.

Continue to measure, record, compare and shim any low temporary support location
points until all (6) temporary 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 supporting the reflector. Note: As work continues on the
reflector it is essential that the shim stacks remain in position through out this process.
Also ensure that diameter setting bands are taut and evenly tensioned. If not, check to
ensure proper leveling of temporary supports.

With the reflector level, tighten seam hardware starting at the outer perimeter of match
marked position A-A and continue this procedure around reflector in concentric circles
while progressing inward toward reflector center. Note: Near center area, it may
become necessary to push down on mounting ring hub to narrow segment gap before
tightening hardware.

Install center plate (P/N 49964-2) over reflector center opening and retaining bar (P/N

49997) behind reflector center opening as shown using supplied capscrew hardware as
shown in Figure 64.

Reflector

202429

Mounting Ring

Hub

49997

Retaining Bar

1/4 x 1-1/2” (38

mm)

Screw, Flatwashers,

Nut and Locknut

(Nylon)

Reflector

49929-2

Center Pad

Capscrew

Hardware

Toward Feed

Window

49964-2

Center Pad

1/4 x 1-1/2” (38

mm)

Screw, Flatwashers,

Nut and Locknut

(Nylon)

Figure 64

ES45T-T Reflector Assembly

Step 2

Feed Strut

Assembly

Step 1

Step 2

54

Installation Procedures

Figure 65

Pass feed struts (P/N 221491-1) to installer underneath for attachment to feed strut
brackets.

• Use 3/8 x 2-¼ in. bolts, lockwashers and nuts

• Secure feed struts together at center after attachment to feed strut brackets

You have now completed the assembly of the ES45T-T-1 reflector. The next step in the
installation is the assembly of the back structure, which begins in the next section.

Position white surface of center pad toward feed window and attach pad to center plate
using supplied ¼ x 1-½ in. nylon screw, flatwashers and nuts. Install flatwashers under
both screw head and corresponding nut as shown in Figure 64. Tighten mounting hard­ware allowing only slight compression (0.060” max.) of center pad material. Use remain­ing nylon nuts as locknuts and distort excess screw thread to prevent disassembly.

Loosely attach corresponding feed strut brackets (P/N 49694/49695) to concave side of
reflector at points B, C, E, and F as shown in Figure 65.

• Use A-325 ½ x 1-¼ in. bolts, flatwashers and nuts. (see page 12)

• Insert bolts from concave side of reflector

Allen

Wrench

Feed

Strut

3/8 x 2-1/4”

Bolt,

Lockwasher

Side View
Feed
Struts

49694/49695

Feed Strut Brackets

F

E

B

C

49695

Feed Strut

Bracket

49694

Feed Strut

Bracket

49694

Feed Strut

Bracket

49695

Feed Strut

Bracket

Front View

Feed Struts

(align over setting

Secure Feed

Struts Together

ES45T-T Reflector Assembly

ES45T-T-1

Back Structure

Step 1

55

Installation Procedures

Figure 66

The back structure assembly attached to the rear of the reflector. The back structure
provides stability for the reflector and maintains the parabolic accuracy of the dish.

Before assembling the back structure, verify that the appropriate parts are present. The
following steps 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 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 reflector in distorted shape, back
structure will hold reflector in that shape. If standing or walking on reflector becomes
necessary, concentrate major portion of body weight towards center of reflector panel.

Refer to back structure Figure 66 for 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 tensioning sequence in assem­bly procedure.

ES45T-T Reflector Assembly

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

Step 10

56

Installation Procedures

Loosely attach tee plates (P/N 202447) and corresponding rib connecting plates (P/N

202444) to points B, C, D, E, and F.

• Use A-325 ½ x 1-¼ in. bolts, flatwashers and nuts. (see page 12)

• Insert bolts from concave side of reflector

CAUTION: Do not install A-325 ½ x 1-¼ in. hardware in center hole of rib connecting
plates (P/N 202444) at positions B, D, or F only.

Loosely assemble two support angles (P/N 49438) to pivot bracket (P/N 300758). Attach
opposite ends of support angles to tee plates (P/N 202447) at points A and E.

• Angle should be installed with edge up and flat of angle toward reflector

Loosely attach support angle (P/N 49436) from tee plate at F to pivot bracket (P/N

300758).

• Angle should be installed edge down with flat of angle away from reflector

Loosely assemble two support angles (P/N 49438) to pivot bracket (P/N 300745). 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) between tee plate at point B and pivot brack­et (P/N 300745).

•

Angle should be installed edge down with flat of angle away from reflector

Loosely attach support angle (P/N 49437) between pivot brackets (P/N 300745/300758).

•

Angle should be installed edge down with flat of angle away from reflector

Loosely assemble support angles (P/N 49438) to elevation axis bracket (P/N 49429-2).
Attach opposite ends of support angles to tee plates at points C and E.

• Angles should be installed edge up with flat of angle toward reflector

Loosely attach support angle (P/N 49436) between tee plate at point D and elevation
axis bracket (P/N 49429-2).

•

Angle should be installed edge down with flat of angle away from reflector

Loosely attach support angles (P/N 49437) between elevation axis bracket and the two
pivot brackets.

• Angles should be installed edge down with flat side away from reflector

ES45T-T Reflector Assembly

Step 11

Step 12

Step 13

Reflector-To-

Mount Assembly

(With Crane)

Step 1

Step 2

57

Installation Procedures

Check diameter setting bands to ensure they are uniformly taut. If not, check leveling of
temporary supports and make necessary adjustments by adding or subtracting shims
until bands are uniformly taut.

Begin A-325 hardware tensioning sequence (see page 12) with tee plates (P/N 202447)
and rib connecting plates (P/N 202444). Next tighten support angle (P/N 49436) con­nections. Tighten the pivot brackets and elevation axis bracket last.

Remove diameter setting bands leaving corresponding 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 instructions on mounting the reflector to the tri­pod ground mount assembly.

This reflector can be installed on the mount manually or by using a crane. However,
Andrew recommends that this procedure be performed using 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 support angle between pivot brackets as illustrated by Figure

67.

• Hoist reflector slightly off ground to remove diameter setting bands

Figure 67

ES45T-T Reflector Assembly

Step 3

Step 4

58

Installation Procedures

Crane should place reflector so that pivot 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), ½ in. lockwashers and ½-13 hex nuts as shown in Figures 69 and 70.

Figure 69

ES45T-T Reflector Assembly

Step 5

59

Installation Procedures

Attach remaining end of elevation strut to elevation axis bracket of main triangle assem­bly as shown in Figures 71 and 72.

• Use ¾ x 4-½ 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 Elevation and Azimuth Adjustments section for instructions on
pointing your antenna towards the desired satellite.

ES45T-T Reflector Assembly

Reflector-To-

Mount Assembly

(With Hoist Kit)

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

60

Installation Procedures

The optional hoist kit (P/N 49080) must be assembled prior to reflector/ backstructure
assembly hoisting. Hoist assembly should not be used for antenna elevation angle
adjustment. The following steps provide the procedure for installing the reflector with the
hoist kit.

Install support tab assembly (P/N 49067) into top of azimuth axis support (P/N 49634)
as shown in Figure 73.

Figure 73

Loosely attach corresponding support assemblies (P/N 49071 and 49072) using spacers
(P/N 49059) and appropriate hardware (P/N 45980-6).

• 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 tighten support assembly hardware.

Attach entire support assembly to previously installed support tab assembly (P/N 49067)
using appropriate hardware (P/N 45980-6).

Loosely attach pick-up assemblies (P/N 49064) to support and elevation pivot assembly
(P/N 49635) as shown.

• Use supplied U-bolts with 1/2 inch (13 mm) lockwashers and nuts.

• Pick-up assemblies are mounted with slanted tabs facing outward.

Loosely attach supports (P/N 49061) to corresponding tabs on support assemblies (P/N
49071 and 49072) using appropriate hardware (P/N 45980-1).

• Angles are installed edge down with flat of angles facing upward

Loosely attach support (P/N 49060) and remaining ends of supports (P/N 49061) to cor­responding pick-up assemblies (P/N 49064) using appropriate hardware (P/N 45980-1).
Securely tighten all mounting hardware.

• Ensure entire hoist assembly is centered on support and elevation pivot assembly

(P/N 49635)

ES45T-T Reflector Assembly

Step 8

Step 9

Step 10

Step 11

61

Installation Procedures

Securely attach winch assembly (P/N 39532) to lower portion of azimuth axis support
(P/N 49634) using supplied U-bolts, lockwashers and nuts as shown in Figure 74.

• Keep winch cable aligned with sheaves

Figure 74

Begin releasing winch cable. Route cable through both sheaves allowing sufficient cable
length to reach top of main triangle assembly on reflector 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.

• Distance between choker/winch connection and top of main triangle assembly should

be approximately 13 inches (330 mm).

Remove small portion of foam padding from reflector packing crate and install under
bottom portion of reflector assembly to prevent reflector damage during hoisting proce­dure. Position man at bottom of reflector/backstructure to guide assembly during hoist­ing procedure.

ES45T-T Reflector Assembly

Step 12

Step 13

Step 14

62

Installation Procedures

Hoist reflector/backstructure assembly to vertical position until upper joints of main trian­gle assembly contact pipe and straddle two locator bars on support and elevation
assembly (P/N 49635) as shown in Figure 75.

Figure 75

Install two U-bolts 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/backstructure assembly and attach remaining end of ele­vation strut to elevation axis bracket of main triangle assembly.

• Use 3/4 x 4-1/2 in (114 mm) bolt, lockwasher and nut

• Mechanical means or fine adjustment assembly may be utilized to achieve elevation

angles greater than 300.

ES45T-T Reflector Assembly

Step 15

Step 16

Step 17

Elevation and

Azimuth

Adjustments

Step 1

Step 2

Step 3

Step 4

Step 5

63

Installation Procedures

Set fine elevation and azimuth strut positions based on the procedure performed in the
Elevation and Azimuth Adjustment section.

• If fine alignment is not performed at this time, continue the assembly procedure at

Step 16.

Securely tighten U-bolts and elevation strut mounting hardware.

Remove both fine adjustment assemblies and store in a weather protected location for
future use. Continue with feed system and corresponding LNA installation.

You have now completed the attachment of the reflector to the tripod ground mount
assembly. Proceed to the Elevation and Azimuth Adjustments section for instructions on
pointing your antenna to its satellite.

Proper antenna pointing requires specific coarse and fine elevation and azimuth strut
length adjustments which can be determined using the graphs provided in Appendix F.
Adjustable azimuth and elevation struts are initially set in coarse setting as near as pos­sible to pre-determined lengths. Fine elevation and azimuth settings are accomplished
with threaded rod on elevation and azimuth struts.

CAUTION

Never loosen strut set screws and fine 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
temporary reflector support while third installer loosens two U-bolts on each end of ele­vation pivot assembly (P/N 49635) and removes 3/4 x 4-1/2 inch (114 mm) bolt, lock­washer and nut connecting elevation strut to bottom of main triangle assembly. Carefully
lower reflector to vertical position.

Determine required length of elevation strut to nearest degree increment of desired ele­vation setting. Adjust coarse elevation setting by withdrawing secondary and, if neces­sary, 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 tertiary strut sections into red warning areas.

Carefully raise reflector and attach elevation strut to bottom of main triangle assembly
using previously removed 3/4 x 4-1/2 inch (114 mm) bolt, lockwasher and nut. Note:
Mechanical means or fine adjustment assembly may be used to achieve elevation
angles greater than 30°.

Coarse Azimuth Adjustment. Loosen to U-bolts on both upper (P/N 49630) and lower
(P/N 49629)azimuth axis joints. Remove 3/4 x 4-1/2 inch (114 mm) bolt, lockwasher and
nut connecting azimuth strut to U-bracket (P/N 49704).

ES45T-T Reflector Assembly

Step 6

Step 7

Step 8

Step 9

64

Installation Procedures

Determine required length of azimuth strut to nearest degree increment of desired
azimuth setting. Adjust coarse azimuth setting by withdrawing secondary strut section
from primary strut to achieve desired strut length. Install four 1/2 inch (13 mm) set
screws in holes provided and securely tighten. Note: Do not extend secondary strut
section into red warning area.

Carefully pivot reflector as required and attach azimuth strut to U-bracket using previ­ously removed 3/4 x 4-1/2 inch (114 mm) bolt, lockwasher and nut. Note: Apply grease
(P/N 49208) around bottom area 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 76 using appropriate brackets, U-bolts, brass hex nuts, flat­washers and threaded rod. Securely tighten all adjustment assembly hardware. Note:
Adjustment assembly may also be attached in alternate position shown depending on
required elevation angle.

Figure 76

Attach fine adjustment assembly between adjacent azimuth strut sections as shown in
Figure 77 using appropriate brackets, U-bolts, brass hex nuts, flatwashers and threaded
rod. Securely tighten all adjustment assembly hardware. Note: Fine adjustment assem­bly on azimuth strut should be positioned away from ground mount angles.

Figure 77

ES45T-T Reflector Assembly

Step 10

Step 11

Step 12

Step 13

Step 14

Feed

Support/Strut

Assembly

Step 1

Step 2

65

Installation Procedures

Set fine elevation and azimuth strut positions by loosening strut set screws and selected
out fine adjustment hex nut. Turn corresponding inner hex nut in appropriate direction
until required strut length is achieved. Securely tighten strut set screws and correspond­ing outer hex nut.

During final electrical tuning, adjust elevation and azimuth struts appropriately to length­en or shorten struts for optimal signal strength.

After fine adjustments are complete, ensure strut set screws are securely tightened and
spray with zinc-rich paint. Securely tighten hex nuts and U-bolts on both elevation and
azimuth 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 location for
future use.

You have now finished aiming your antenna at the desired satellite. Proceed to the Feed
Installation instructions packaged with the feed assembly for information on assembling
and attaching the feed assembly to the reflector.

By now, you can see that your installation of the 4.5-Meter Earth Station Antenna is
almost complete. The feed system is the last phase of the base installation 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 to 222930 feed support as shown in Figure 78.

Figure 78

Securely tighten all feed support strut mounting hardware.

Polarization

Adjustment

Step 1

Step 2

Step 3

Step 4

66

Connect receive LNA output to spectrum analyzer and fine adjust elevation and azimuth
strut lengths to achieve maximum signal strength from desired satellite.

Loosen four 3/8 x ½ in. set screws in feed support until feed assembly is free to rotate
and adjust feed for maximum receive signal strength on desire polarization.

Note: Do not loosen collar hardware (P/N 49795). Collar will maintain 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 direction through maximum signal until signal level again drops
1 dB. Mark this position.

Adjust feed assembly to midpoint of 1 dB marks and securely tighten four 3/8 x ½ in. set
screws in feed support making sure feed support is firmly seated against collar.

You have now completed the feed installation for your Earth Station Antenna. Refer to
the appropriate section for the calculations necessary for antenna pointing.

Installation Procedures

Medium Modular

Mount

Refer to bulletin 237151C, for Installation Instructions.

67

Overview

Acquiring A

Satellite

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

68

Operation

Operation

After you have completed the assembly of your antenna, you are now ready for it to
become operational. In order to operate the earth station antenna, you will need to
direct it to the desired satellite adjusting both the elevation and azimuth angles
appropriately. The following procedures provide details on how to correctly position
your antenna on the desired satellite.

Follow the procedures listed below when acquiring the desired satellite:

Note: Ensure that the feed system and all electronics are installed properly before
proceeding.

Evaluate and determine the required elevation and azimuth angles for the satellite of
interest.

Steps 2 through 6 are for Pedestal Mounted Antenna Only

Loosely attach the manual actuator assembly (P/N 207882) to the elevation strut as
shown in Figure 100b using the appropriate hardware.

Note: The drain hole should be positioned downward for proper water drainage.

Ensure that the locking strut-support setscrew is firmly tightened on the strut assem­bly as shown in Figure 100b.

Remove the two indicated strut-support setscrews, and attach the base angle to the
corresponding strut support using the supplied 1/2 inch clamping nuts and the previ­ously removed strut-support setscrews as shown in Figure 100b.

Securely tighten the remaining mounting hardware to achieve sufficient clamping
force.

Repeat the entire process for the remaining strut assembly. Note: DO NOT loosen
the azimuth drive bearings.

If you have a pedestal mounted antenna, move the antenna to the desired azimuth
angle by adjusting the manual actuator until the satellite signal has been spotted. If
your antenna is mounted upon a tripod, adjust the azimuth strut length through the
fine adjustment assembly until the satellite signal has been spotted.

There are several procedures that may be used to properly acquire the satellite.
Andrew recommends that a spectrum analyzer be used. The following procedures
provide explanations as to how to use the spectrum analyzer.

Step 1

69

While viewing the spectrum analyzer screen, a pure noise signal as shown in Figure 1
will probably be observed. Additionally, some transponder signals may be observed
above the noise signal as shown in Figure 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) transponder signals.

• Scan in one direction until the amplitude continues to diminish and then scan in the

opposite direction until the same condition occurs.

•

Return to the position yielding the greatest amplitude.

Operation

Step 2

Step 3

Step 4

Step 5

70

Operation

The maximum azimuth excursion from the original setting should not exceed ±1.5° or
the antenna may begin to access a different satellite.

With the antenna positioned in azimuth such that the transponder signals are maxi­mized, follow the same procedure manually moving the antenna in elevation (scanning
up-and-down) to further maximize the transponder signals.

Repeat this procedure alternating between the azimuth and elevation excursions of the
antenna to peak the transponder signal amplitude.

A transponder signal amplitude of 30 dB or greater from peak to average noise signal
indicates the antenna is receiving the signal on the main beam. A transponder signal
amplitude less than 30 dB indicates the antenna is receiving the signal on the side lobe
of the main beam.

With the antenna peaked 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 increase (position B) to the level noted
when the antenna was peaked on the side lobe, the antenna is moving away from the
main beam; reverse the direction of the antenna movement.

From the original side lobe position (position A), the signal amplitude should now dimin­ish to a null point at position C (minimum amplitude showing only signal noise) and then
symmetrically increase again to the same level at position D as noted at position A. At
the null point (position C), the antenna is aligned with the alternate (elevation) axis. If
the antenna was peaked on a side lobe in the azimuth, it was appropriately aligned with
the elevation axis; proceed with Step 6. If the antenna was peaked on a side lobe in ele­vation, it was appropriately aligned with the azimuth axis; proceed with Step 6 moving
the antenna in azimuth rather than elevation.

Step 6

Step 7

Step 8

Step 9

71

Operation

Move the antenna in elevation while observing the spectrum analyzer screen. If the sig­nal amplitude increases, decreases and then increases again but to a lesser value, the
antenna is moving in the wrong direction; reverse the direction of the antenna move­ment. From the original null point, the signal level should decrease and increase alter­nately, but with an increasing amplitude until the transponder signal increases to a level
of at least 30 dB. Continue to manually peak the signal to a maximum level using the
azimuth and elevation adjustments.

If the antenna is aligned in azimuth and elevation (signal maximized) and 24 transpon­der 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 polarized signals. Therefore 24 transponder signals must be visually
noted in order to determine the proper polarization setting.

Rotate the feed assembly clockwise until 24 transponder signals are noted and of
approximately equal amplitude. Note: It is more accurate and visually easier to minimize
the alternate set of transponder signals rather than maximizing the transponder of inter­est.

Figure 4

With all 24 transponder signals of approximately equal amplitude appearing on the
spectrum analyzer screen determine the specific antenna system and satellite parame­ters. Rotate the feed assembly as required until the appropriate (odd or even) transpon­der signals are maximized.

Manual Actuator

Assembly Removal

Step 1

Step 2

Step 3

72

Operation

Figure 6

After you have successfully acquired the satellite and all adjustments have been made,
the manual actuator should be removed. The following steps provide the procedure for
the proper removal of the manual actuator 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 adjusted. Store the manual actuator assembly and the corre­sponding hardware in a dry area for future use.

Remove the remaining clamp segments with the corresponding hardware.

After the antenna is pointed at the satellite, tighten all azimuth and elevation setscrews
to 35 foot-pounds.

Figure 5

Overview

General Cleaning

Electrical Parts

73

Preventive Maintenance

This section contains periodic preventative maintenance instructions for the 4.5-Meter
Earth Station Antenna. Included in this section are inspection and preventative mainte­nance procedures including cleaning and lubrication, painting and an operational volt­age/current checkout procedure deemed within the capabilities of the average station
technician. Refer to applicable vendor manuals for any repair procedures not included in
this section yet designated as capable of being performed in the “field” rather than
requiring specialized facilities, tools and/or test equipment as well as technically trained
personnel.

An operational checkout procedure provides an accurate indication of the overall earth
station performance and should be performed at intervals of approximately three
months. This procedure is essentially performed during the various modes of normal
operation of the earth station. In addition, the operational checkout procedure should be
performed after any repairs or adjustments have been made, or whenever the earth sta­tion is suspected of degraded operation. If any discrepancy in performance exists and
the condition cannot be readily remedied to return the earth station to a proper operating
condition, the appropriate troubleshooting procedures should be referenced to locate the
fault. After the trouble is determined and the repairs effected, a final operational check­out procedure should be performed to verify that all discrepancies have been corrected.

The following paragraphs describe the inspection and preventative maintenance proce­dures for the earth station. These instructions include general cleaning and inspection,
the preservation of metal parts and the lubrication of moving parts. Periodic replacement
of assemblies or components as a preventative measure is not required. Malfunctions of
the earth station can be traced to components, assemblies and parts through the use of
applicable troubleshooting procedures.

To prevent the excessive accumulation of dust and dirt as well as the removal of such
contaminants, thoroughly clean the equipment whenever visually inspecting the earth
station components. No special cleaning procedures are required. However, a thorough
cleaning in accordance with the following procedures is required to assure continued
trouble-free operation.

Minor cleaning, such as the removal of dust and loose foreign particles can be accom­plished by one of the following:

•

Vacuuming

• Using a soft brush or lint-free cloth

• Blowing out the dust and dirt with low pressure (5 to 25 psi), dry compressed air

When using air to blow off the contaminants, either avoid or be careful when directing
the air stream on delicate parts. To remove imbedded dirt, grease or oil from electrical
parts: use a 50% solution of isopropyl (rubbing) alcohol and apply with a soft bristle
brush. It may be necessary to brush some parts vigorously with a stiff bristle brush to
remove imbedded and hardened dirt particles. If possible, avoid excessive use of clean­ing solvent on electrical insulation. After cleaning, allow the cleaned parts to dry for 10 to
15 minutes before placing the equipment into operation.
Clean mechanical parts by first removing dust, dirt and other loose contaminants with a

Preventive Maintenance

Mechanical Parts

Inspection

Local

Control/Motor

Drive Controller

74

scraper, stiff brush (bristle, or wire in the case of rust or corrosion), or cloth or com­pressed air at 25 to 40 psi. Any accumulated imbedded dirt, corrosion, grease or oil
deposits that require further cleaning may be removed with a bristle or wire brush and a
cleaning solvent such as trichlorethylene or equal. After cleaning, allow cleaned parts to
dry for 10 to 15 minutes before placing the equipment into operation.

The frequency of inspection is contingent upon the user’s individual standards and the
operational environment in which the earth station is located. However, a visual inspec­tion of the earth station components should be performed st least semi-annually. Where
there are no established wear limits, perform a visual inspection to locate worn or dam­aged parts which could cause improper functioning of the earth station. It is recommend­ed that the mechanical and electrical inspection be performed on the assembled or par­tially disassembled equipment to determine the extent of disassembly required prior to
completely disassembling a suspected malfunctioning component or module. In the
absence of any special inspection requirements, operational tests are the most effective
means in isolating parts and assemblies requiring further inspection. Any condition
noted during inspection that may preclude continued proper operation of the earth sta­tion prior to the next scheduled inspection should be noted. The discrepant condition
should be corrected (repaired or replaced) immediately or at the conclusion of the
inspection procedure.

Inspection of the local control/motor drive controller conforms generally to standard visu­al inspection procedures on electromechanical equipment. In addition to these standard
procedures, perform the following checks and visual inspections for the specific condi­tions noted:

WARNING

Care must be taken to avoid electrical shock. Failure to heed warning could result in
injury or death.

•

Check the main panel for illegible and indistinct panel markings.

•

Connect the detachable hand controller assembly (local control) for visible signs of

damage such as cracked housing, damaged connector/bent pins, cuts or damage to
cable jacket insulation, etc. Examine selector switches for damage and proper actuation
movement.

• Inspect all wiring and cables for discoloration and burned insulation, dirt, breaks,

security of connection and other signs of deterioration. Examine connections for dirt,
flux, corrosion and mechanical defects. Check for loose or broken lacing and cut, brittle,
abraded, frayed or cracked insulation.

• Examine connectors for corrosion, broken inserts and stripped threads. Check con-

nector shells for distortion and dents, and contact pins for bends, misalignment or other
deformities. Check connector inserts for carbon tracking indicating arc-over.

Preventive Maintenance

Antenna

75

• Check all electrical components for dirt, chips, cracks, breaks, discoloration or other

signs of deterioration and damage. A discolored, blistered or burnt condition is evidence
of overload. Measure actual value of suspect electrical components and compare
against specified value where applicable.

• Check transformer for an excessive wax deposit on the surface, discoloration or a

pungent odor indicative of burning varnish denoting overheating or a total breakdown.

• Check all terminal blocks for broken or missing terminals and stripped threads. Check

tightness of lead attaching hardware.

Caution

Make sure electrical power has been disconnected.

• Check the motor starters and circuit breakers for free operation. Check tightness of all

wire connections.

• Visually inspect printed circuit board for signs of debris that might short out compo-

nents. Verify that all LED indicators are functioning correctly. Check the terminal block
connectors for tightness of lead attracting hardware and signs of scorching or burning.

• Check for security of all hardware and stripped or otherwise damaged threads. Check

metallic parts for corrosion, dents, distortion 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) to
seal any exposed electrical fitting, bolt hole or other possible water entry into the
enclosed electrical components in order to maintain a water proof condition.

• Check or change vapor corrosion inhibitor unit.

Inspection of the antenna conforms generally to standard visual inspection procedures
performed on electromechanical equipment. In addition to these procedures, perform
the following checks and visual inspections for the specific conditions noted:

• Inspect all wiring and cables, particularly the network to enclosure and enclosure to

mount interfaces, for discoloration and burned insulation, moisture entry, corrosion, dirt,
breaks, security of connection, and other signs of deterioration. Examine connections for
dirt, corrosion and mechanical defects. Check for loose or broken lacing and cut, abrad­ed, frayed, brittle and cracked insulation.

• Examine connectors for corrosion, broken inserts and stripped threads. Check con-

nector shells for distortion and dents, and contact pins for bends, misalignment or other
deformities. Check connector inserts for cracks, carbon tracking, burns or charring indi­cating arc-over.

Preventive Maintenance

76

• Check all electrical components for dirt, cracks, chips, breaks, discoloration and other

signs of deterioration and damage. A discolored, blistered or burnt condition is evidence
of overload.

• Operate the azimuth and elevation drives as well as the feed rotation in both the plus

and minus direction from the local control/motor drive controller at least once every
three months during antenna down time. Check the mechanical limit switches provided
at the end points stop antenna and feed movement, and limit travel to prevent structural
interference and damage. Check the mechanical limit switches for corrosion and water
entry and the arm on each feed limit switch for free movement without binding. Be cer­tain both feed rotation limit switch arms are not distorted and ride centrally on the actu­ating cam to open their corresponding limits switch.

• Inspect the azimuth and elevation jackscrew boots for security of attachment at both

ends, for abrasion, tears, cuts, brittleness and other damage that may expose the
jackscrew to the environment (water, dust, etc.). Minor repairs can be made with RTV­108 silicone rubber sealant.

• Visually inspect the feed window for dirt and the feed, feed supports, feed window and

reflector for distortion, foreign object damage and environmental deterioration due to ice
and snow, dust, rain, hail and high winds, etc. which may cause electrical component
and/or structural deformation.

• Check the cable attachment to the resolvers and to the LNA or LNBs and enclosure

mount 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 mechanical attachment. Ensure proper torquing of
polarization drive gear box setscrews and appropriate tensioning of corresponding drive
chain assembly, if applicable.

• Check (if applicable) that the drain holes in the bottom of the enclosure are not

obstructed and there is no evidence of water accumulation. Check the enclosure doors
for proper closure and that the door seals are intact, not torn, abraded or otherwise
damaged. Check that all other seals are intact and if not, use a coating of RTV-108 (sili­cone rubber sealant) to seal any exposed electrical fitting, bolt hole, or other possible
water entry to electrical components in order to maintain a weatherproof condition. If the
enclosure is provided with a vent fan, check for free operation of the fan blade. The fan
bearings are permanently lubricated; any binding, abnormal noise or vibration necessi­tates replacement of the fan assembly. Check and replace the fan filter element if it
appears dirty or obstructed with dust.

• Check for the appearance of surface lubricants that will cause the accumulation of dirt

and grime. Clean off all excess surface lubricants with a cloth and, if required, a cloth
dampened (not wetted) with trichlorethylene, or equal.

• Visually inspect all mechanical parts for freedom of operation with no misalignment,

binding or interference. Check all cabling for sufficient slack to prevent cable strain as
well as adequate restraint to prevent abrasion or chaffing during antenna and feed
movement.

Preventive Maintenance

Drive System

Voltage and

Current Checks

Step 1

Step 2

Step 3

Step 4

77

• Check security of antenna mounting and interconnecting assembly hardware. Be cer-

tain all electrical grounding connections (including cross-axis grounding straps) and
intact and secure, not corroded or broken. Thoroughly clean any noticeable corroded
portions of grounding cables, unplated portion of universal terminals and corresponding
mounting surfaces with a wire brush. Replace rather than tighten any loose A-325 struc­tural hardware. The hardware distorts at initial installation and once loosened will not
maintain the required high strength friction connection. All other assembly and installa­tion hardware should be tightened to its original torqued condition. When installing new
structural hardware, do not use a wrench with a lever arm longer than two feet.

• Examine painted aluminum and galvanized surfaces and touch-up where required.

At the conclusion of the installation procedure and prior to turning the system over to the
station facility, an installation acceptance check-off sheet was prepared and duly signed
off if installed by an Andrew crew. Part of this check-off included voltage readings retak­en to determine if proper voltage was available. Current readings were also taken as a
reference for future comparison to serve as a troubleshooting aid in determining possi­ble equipment degradation and shortened life. Any current reading taken during the fol­lowing procedure that significantly varies by more than five percent from the preestab­lished reference values necessitates trouble shooting the particular system involved to
determine the cause and required corrective action.

Approximately every three months and during a period of down time, disconnect as
applicable the RF transmitter and all power supplies. The main disconnect switch in the
main load center box at the antenna site must be in the ON position and the detachable
hand-held controller assembly must be plugged in.

Open the outer local control/motor drive controller door at the antenna site to gain
access to the conductors supplying power to the azimuth, elevation and polarization
drive motors. Turn the primary power disconnect switch to the ON position.

Turn the Az/El speed switch to the FAST position. Turn the AZIMUTH EAST/WEST
switch to either position and while the antenna is rotating, carefully use a clamp-on
ammeter in accordance with the ammeter manufacturer’s instructions to take current
readings off each of the power conductors (phases) connected to the main terminal
block at the bottom of the panel. Record the current draw in the equipment log and com­pare the readings to the reference values entered in the installation/acceptance check­off. If the readings differ significantly, refer to the appropriate troubleshooting information
and perform the applicable corrective action. Then take voltage readings off each of the
three conductors; the readings should agree with each other - within two percent. Turn
the AZIMUTH switch to OFF.

Repeat preceding step (3) with the AZIMUTH EAST/WEST switch in the alternate oper­ating position.

Preventive Maintenance

Step 5

Step 6

Step 7

Step 8

Pedestal Mount

Bearing Pad

Adjustment

Step 1

Step 2

Step 3

Step 4

Step 5

78

Turn the ELEVATION DOWN/UP switch to either position and while the antenna is rotat­ing, carefully use a clamp-on ammeter in accordance with the ammeter manufacturer’s
instructions to take current readings off each of the power conductors (phases) connect­ed to the main terminal block at the bottom of the panel. Record the current draw in the
equipment log and compare the readings to the reference values entered in the installa­tion/acceptance check-off. If the readings differ significantly, refer to the appropriate
troubleshooting information and perform the applicable corrective action. Then take volt­age readings off each of the three conductors; the readings should agree with each
other - within two percent. Turn the ELEVATION switch 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 readings are within tolerance, turn the primary power discon­nect switch OFF. Then close and lock the outer local motor controller door. Disconnect
the hand held controller to return antenna control to studio.

The bearing pad (within the pedestal mount) adjustment rods/bolts require yearly adjust­ment and verification of torque value. With the antenna at zenith (90 degrees), follow
the procedures presented below:

Loosen jam nuts on all rods/bolts.

Torque the upper adjustment rod evenly to 40-45 foot-pounds. Then torque the lower
adjustment rod evenly to 40-45 foot-pounds.

Torque the upper adjustment bolt evenly to 40-45 foot-pounds. Then torque the lower
adjustment bolt evenly to 40-45 foot-pounds.

Repeat steps 2 and 3 verifying all adjustment rods/bolts are evenly torqued within the
limits specified.

Tighten the jam nuts.

Preventive Maintenance

Preservation of

Component Parts

Aluminum Parts

Galvanized

Surfaces

Lubrication

79

When preserving component parts, refer to the following paragraphs in this section.

Remove all loose paint and corrosion by scraping, wire brushing or using steel wool. If
using steel wool near the feed window, make sure that none remains on the feed horn
window. Edges of existing paint can be blended with a metal surface by using a fine grit
sandpaper. Wipe the surface to be painted with a soft rag dampened in trichlorethylene,
lacquer thinner or equal. Be certain to remove all loose paint, corrosion, imbedded dirt,
grease and oil deposits or the paint will not adhere to the surface. Lacquer thinner will
dissolve paint if applied heavily and rubbed vigorously. The reflector may be washed
with plain water if necessary. Do not use bleach, soap solutions or kerosene as it is diffi­cult to remove the residue. Allow the cleaned surfaces to dry thoroughly before priming.

Prime the cleaned surface by applying zinc chromate primer. The primer can be applied
with brush, roller or pressurized spray. If necessary, thin the primer with lacquer thinner
to the proper consistency. Feather primer onto adjacent painted surfaces. Allow primer
to thoroughly dry before applying the finish paint coat.

Paint all RF surfaces, such as the inside of the main reflector and subreflector with a
high-reflectance white paint. This type of paint disperses light rays, reducing the focus­ing effect of the sun’s radiation, thereby reducing heat build-up caused by the focused
sun’s rays on the feed system. Rear surfaces of the reflector and subreflector may be
painted with a flat white enamel paint. The paint can 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 existing paint­ed surfaces.

Remove all loose paint and corrosion by scraping, wire brushing or using steel wool.
Edges of existing paint can be blended with the metal surface by using a fine grit sand­paper. Wipe the surface to be painted with a soft rag dampened in trichlorethylene, lac­quer thinner, or equal. Be certain to remove all loose paint, corrosion, imbedded dirt,
grease, and oil deposits or the paint will not adhere to the surface. Lacquer thinner will
dissolve paint if applied heavily and rubbed vigorously. Do not use bleach, soap solu­tions or kerosene as it is difficult to remove these products’ residue. Allow the clean sur­face to dry thoroughly before painting.

Paint the cleaned surface with a zinc-rich paint. The paint can be applied with a brush,
roller or pressurized spray. If necessary, thin the paint with the appropriate thinner to the
proper consistency.

Thoroughly paint over the cleaned surface and blend with the existing painted surface.

For long life and trouble-free operation be certain no to extend the lubrication schedule
beyond the frequency recommended in Table 1. The frequency should be shortened if
the antenna is subjected to an adverse environment (e.g. high temperature, extended
periods of rainfall, high humidity, dust storms, etc.). Any component or part should be
immediately be lubricated if, during inspection or operation, rough, jarring or intermittent
motion is noted, or if squeaky or other unusual noises are heard. Lubrication is required
on all metal-to-metal rolling or sliding parts. Use the lubricants recommended. Do not
over lubricate. Over-lubrication can often be as damaging as under-lubrication. Prior to

Preventive Maintenance

Jackscrews/Motors

Gear

Motor/Housing Fill

Drain

Requirements

80

the application of lubricant to any parts, use a clean cloth and/or bristle brush and
remove any old lubricant to prevent an excessive build-up. Remove indicated access
plugs from square tube weldment and apply lubricant to panning frame tube assembly
and corresponding thrust pads. Securely replace access plugs in square tube weldment.
Be certain to remove any protective caps and clean off each lubrication fitting prior to
injecting fresh grease. The elevation and azimuth jackscrew assemblies are equipped
with a grease fitting and corresponding pipe plug on opposite sides of the jack housing.
Remove the appropriate pipe plug and fill it with grease until lubricant seeps from pipe
plug opening. Replace and securely tighten pipe plug.

The following is a list of the lubricant characteristics:

• Mobil Temp SHC32 A non-soap hydrocarbon fluid type grease. Operating tempera-

ture is -65 degrees to 350+ degrees Fahrenheit (-54 degrees to
177+ degrees Celsius).

• Mobil SHC624 A low temperature synthetic oil for worm gear reducers.

Operating temperature range is -40 degrees to 125+ degrees
Fahrenheit (-40 degrees to 52+ degrees Celsius).

• Moly Grease A grease lubricant containing molybdenum 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 adequate lubrica­tion. Loosen jackscrew boot clamps to expose the lifting screw assembly. Fully extend
jackscrew assembly, being careful not to exceed preset mechanical limits. Brush thin
coating of Mobil SHC32 grease on exposed lifting screw. Replace boot and attach corre­sponding boot clamps. If lifting screw is rusty, remove existing lubricant with solvent and
wire brush rusted area. Rinse with solvent and apply fresh grease.

Periodically inspect and remove dust and dirt deposits from the motor housings to avoid
hindering the thread exchange with the ambient air. Slight dirt accumulation on the air
vent screw through splash oil cannot be avoided, however, keep vent screw clean to
ensure proper pressure compensation.

Lube points 2 and 4, shown in Table 1, require removal of the indicated drain plugs and
collecting/measuring the amount of SHC624 drain oil using measuring cup. The speci­fied amount of oil must be added to the gear motor/hosing (after installing the drain
plug) via the fill/vent plug opening using supplied funnel. Addition of the oil requires use
of an appropriate filling utensil. Use of a modified level stick will not correctly gauge the
appropriate amount of oil in the gear housings.

Preventive Maintenance

81

Table 1. Antenna Lubrication Chart

Lube Parts to be Lubricated Action Frequency Service Lube Quantity/ Andrew
Point Type Type Points Number

1 Elevation jackscrew Lubricate Every 3 Pressure SHC32 1 49208

housing months Fitting

2 Elevation gear motor Inspect Monthly Pipe plugs SHC624 10 ounces 47497

housing fill and drain Change 3 months

3 Azimuth jackscrew Lubricate 3 months Pressure SHC32 2 49208

housing Fitting

4 Azimuth gear motor Inspect Monthly Pipe plugs SHC624 10 ounces 47497

housing 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 signs of oil leakage, draining, replacing and
adding oil to ensure appropriate oil level requirements. Excessively dirty oil will require
fresh replacement. If oil leakage is found to be excessive, refer to appropriate trou­bleshooting information and perform applicable corrective action. Periodic inspection
procedures can be less frequent after first or second scheduled inspections.

Initial oil change requirements include flushing gear boxes with a standard cleaning
agent.

Preventive Maintenance