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