Instruction/ maintenance manual of the product ES45T Andrew
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Andrew Cor poration 10500 West 153rd S treet Orland Park, IL U.S.A. 60462 T elephone: 708-349-3300 F AX (U.S.A.): 1-800-349-5444 Internet: http://www .
Introduction How to Use This Manual Getting Star ted Installation Procedures Operation Prev entive T able of Contents 2 T a ble of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Like all Andrew earth station antennas, the 4.5-meter earth station antenna provides high gain and exceptional pattern characteristics. The electrical performance and excep- tional versatility provide.
Proprietar y Data Infor mation and Assistance Notice T echnical Assistance The technical data cont ained herein is proprietary to Andrew Corporation. It is intended for use in installation, operation, and maintenance of Andrew equipment.
Ov er view Content The scope of this manual is intended to provide station personnel with the base inst alla- tion (ie: mount, reflector and enclosure), operation and maintenance requirements nec- essary for a 4.5-Meter Earth S tation Antenna. Note: All antenna option instructions are included in the individual kit shipped with the part.
Ov er view Warnings The installation, operation and maintenance of the 4.5-Meter Earth S tation Antenna requires qualified personnel. Andrew installation, operation and maintenance instructions are illustrated for such personnel.
R ecommended T ools 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.
Par ts V erification R e por ting Equipment Loss or Damage R e por ting Visible Loss or Damage R e por ting Concealed Damage Inv entor y Equipment R eceiv ed R etur ning Equipment Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Upon receipt of your order , the shipment should be verified to ensure that all parts have reached your site.
Installation Sequence Checklist Site Pre paration T ripod Gr ound Mount Assembly ES45T -R Main R eflector Assembly ES45T -R Back Structure Assembly ES45T R eflector- to-Mount Assembly (With Cr ane) Feed Installa tion The 4.5-Meter Earth S tation Antenna requires the installation team to perform the assembly in the sequence presented below .
T ripod Gr ound Mount Assembly ES45T -T Main R eflector Assembly ES45T -T Back Structur e Assembly ES45T R eflector- to-Mount Assembly (With Cr ane) Feed Installa tion Wa veguide/Flex Section Assembly.
Ov er view Founda tion Pre paration 11 Installation Procedures This section provides installation procedures for the 4.5-Meter Andrew Earth S tation Antenna.
A-325 T ensioning Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 12 During the installation process there are several references to the A-325 hardware ten- sioning procedure. The A-325 hardware must be properly tensioned to avoid slippage between bolted surfaces under high loads.
T ripod Mount Ste p 1 13 The three-point mount in an elevation-over-azimuth configuration optimized for geosta- tionary satellite applications. The mount enables st andard elevation ranges from 2°-62°, and 33°-90° with high-look strut configuration.
Ste p 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.
Ste p 3 Ste p 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.
Ste p 5 Ste p 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.
Ste p 7 Ste p 8 Ste p 9 17 T ightly knot 40 ft. rope to azimuth axis joint (P/N 300748) for hoisting to azimuth axis support (P/N 49634). Installation Procedures Figure 10 S tation one inst aller 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.
Ste p 10 Ste p 11 Ste p 12 18 Use a carpenter ’s level to level support assembly as indicated in Figure 12. Loosen U- bolts to move support assembly up or down as needed to achieve level surface. Installation Procedures Figure 13 Figure 12 T ighten anchor bolts on rear p ads and azimuth axis support base plate down using A- 325 procedure.
Ste p 13 19 Installation Procedures Figure 14 Determine required length of elevation strut to nearest degree increment of desired ele- vation setting as specified in the Elevation and Azimuth Adjustments Section. Adjust coarse setting by extending secondary and, if necessary , tertiary sections to length.
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.
Ste p 16 Ste p 17 Ste p 18 Ste p 19 21 Connect U-bracket (P/N 49704) to appropriate connection plate. • Use A-325 ½ x 1-½ in. bolts, flatwashers and nuts.
ES45T -R R eflector Ste p 1 Ste p 2 22 The ES45T -R-1 reflector is composed of six precision-formed panels designed for accu- racy and strength and ensure reliable surface contour which provides exceptional oper- ating characteristics in C- or Ku-frequency band.
Ste p 3 23 Note: All six reflector segments are identified individually by a two letter designation (A- B, D-E, etc). Locate the markings on the reflector segments in order to assemble the reflector in the proper sequence.
Ste p 4 Ste p 5 24 Installation Procedures Raise segments and hold while loosely att aching mounting ring hub (P/N 49965) to con- vex side of center opening.
Ste p 6 Ste p 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.
Ste p 8 Ste p 9 26 Installation Procedures Loosely attach segment E-F to mounting ring hub, diameter setting bands and segment s 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.
Ste p 10 Ste p 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, lif t reflector and return temporary supports to initial measuring posi- tion.
28 Installation Procedures Ste p 12 Ste p 13 Ste p 14 Install last reflector p anel ( C-D ) by loosely attaching to diameter setting bands and mounting ring hub. Loosely attach p anel seam hardware as installer inside moves reflector segment to enable segment union.
29 Installation Procedures R eflector Le v eling Procedure Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 Ste p 7 Ste p 8 Position (6) temporary supports near p anel seams exactly as shown in Figure 29.
Ste p 9 Ste p 10 Ste p 11 Ste p 12 Ste p 13 Feed Strut Assembly Ste p 1 Ste p 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 mea- sured.
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 maint ains the parabolic accuracy of the dish. An example of the assembled back structure is presented in Figure 33.
Ste p 1 32 Installation Procedures Refer to back structure Figure 34 for positioning and orientation det ails. • Apply stick wax (P/N 200852) to A-325 bolt threads before installation to reduce fric- tion.
Ste p 2 Ste p 3 33 Installation Procedures Loosely attach tee plates (P/N 202447) to point s B , F and D on convex side of reflector as shown in Figure 35.
Ste p 4 Ste p 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 bolt s from concave side of reflector • Angles should be installed with edge in and flat side away from reflector as shown.
Ste p 6 Ste p 7 Ste p 8 Ste p 9 Ste p 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).
R eflector-to-Mount Assembly (With Cr ane) Ste p 1 Ste p 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 inst alling the reflector to the mount using a crane.
Ste p 3 Ste p 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 bracket s to support and elevation pivot assembly with U-bolts (P/N 9956- 65), ½ in.
Ste p 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.
R eflector-to-Mount Assembly (With Hoist Kit) Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 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.
Ste p 7 Ste p 8 Ste p 9 Ste p 10 40 Installation Procedures Loosely attach support (P/N 49060) and remaining ends of support s (P/N 49061) to cor- responding pick-up assemblies (P/N 49064) using appropriate hardware (P/N 45980-1). Securely tighten all mounting hardware.
Ste p 11 Ste p 12 Ste p 13 41 Installation Procedures Remove small portion of foam padding from reflector p acking crate and install under bottom portion of reflector assembly to prevent reflector damage during hoisting proce- dure. Position man at bottom of reflector/backstructure to guide assembly during hoist- ing procedure.
Ste p 14 Ste p 15 Ste p 16 Ste p 17 42 Installation Procedures Raise lower portion of reflector/backstructure assembly and attach remaining end of ele- vation strut to elevation axis bracket of main triangle assembly .
Ele v ation and Azimuth Adjustments Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 Ste p 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 .
Ste p 8 Ste p 9 Ste p 10 Ste p 11 Ste p 12 Ste p 13 Ste p 14 44 Installation Procedures Attach fine adjustment assembly between adjacent azimuth strut sections as shown in Figure 51 using appropriate brackets, U-bolt s, brass hex nuts, flatwashers and threaded rod.
Feed Suppor t Assembly Ste p 1 Ste p 2 45 Installation Procedures By now , you can see that your installation of the 4.5-Meter Earth S tation Antenna is almost complete. The feed system is the last phase of the base inst allation described in this manual.
ES45T -T -1 R eflector Ste p 1 Ste p 2 46 Installation Procedures The ES45T -T -1 reflector is composed of six precision-formed panels designed for accu- rate strength, and ensures a reliable surface contour that provides exceptional operating characteristics in C-, X- or Ku-frequency bands.
Ste p 3 Ste p 4 47 Installation Procedures Note: All six reflector segments are identified individually by a two letter designation ( A- B , D-E , etc). Locate the markings on the reflector segment s in order to assemble the reflector in the proper sequence.
Ste p 5 Ste p 6 48 Installation Procedures Loosely attach reflector segment s 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.
Ste p 7 Ste p 8 49 Installation Procedures Figure 58 Loosely attach segment E-F to mounting ring hub, diameter setting bands, and seg- ments 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 .
Ste p 9 Ste p 10 Ste p 11 50 Installation Procedures S tation an inst aller inside reflector to finger-tighten seam hardware and attach final pan- els as shown in Figure 59. Figure 59 Loosely attach reflector segment B-C to mounting ring hub and diameter setting bands.
Ste p 12 Ste p 13 Ste p 14 Ste p 15 Ste p 16 R eflector Le v eling Procedure Ste p 1 51 Installation Procedures Install final reflector p anel (C-D) by loosely attaching to diameter setting bands and mounting ring hub. Loosely attach p anel seam hardware as installer inside moves reflector segment to enable segment union.
Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 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) S teel Rule 0.03-0.06 Inch Increment (0.
Ste p 7 Ste p 8 Ste p 9 Ste p 10 Ste p 11 Ste p 12 Ste p 13 R eflector Center Plate Assembly Ste p 1 53 Installation Procedures Position measuring rod point down over temporary supports and on the fla.
Ste p 2 Feed Strut Assembly Ste p 1 Ste p 2 54 Installation Procedures Figure 65 Pass feed struts (P/N 221491-1) to inst aller underneath for attachment to feed strut brackets.
ES45T -T -1 Back Structure Ste p 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 maint ains the parabolic accuracy of the dish. Before assembling the back structure, verify that the appropriate part s are present.
Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 Ste p 7 Ste p 8 Ste p 9 Ste p 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.
Ste p 11 Ste p 12 Ste p 13 R eflector-T o- Mount Assembly (With Cr ane) Ste p 1 Ste p 2 57 Installation Procedures Check diameter setting bands to ensure they are uniformly taut. If not, check leveling of temporary supports and make necessary adjustment s by adding or subtracting shims until bands are uniformly taut.
Ste p 3 Ste p 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 bracket s to support and elevation pivot assembly with U-bolts (P/N 9956- 65), ½ in.
Ste p 5 59 Installation Procedures Attach remaining end of elevation strut to elevation axis bracket of main triangle assem- bly as shown in Figures 71 and 72. • Use ¾ x 4-½ in. bolt, lockwasher and nut Figure 71 Figure 70 Figure 72 Y ou have now completed the attachment of the reflector to the tripod ground mount assembly .
R eflector-T o- Mount Assembly (With Hoist Kit) Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 Ste p 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.
Ste p 8 Ste p 9 Ste p 10 Ste p 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 nut s as shown in Figure 74. • Keep winch cable aligned with sheaves Figure 74 Begin releasing winch cable.
Ste p 12 Ste p 13 Ste p 14 62 Installation Procedures Hoist reflector/backstructure assembly to vertical position until upper joints of main trian- gle assembly contact pipe and straddle two locator bars on support and elevation assembly (P/N 49635) as shown in Figure 75.
Ste p 15 Ste p 16 Ste p 17 Ele v ation and Azimuth Adjustments Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 63 Installation Procedures Set fine elevation and azimuth strut positions based on the procedure performed in the Elevation and Azimuth Adjustment section.
Ste p 6 Ste p 7 Ste p 8 Ste p 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.
Ste p 10 Ste p 11 Ste p 12 Ste p 13 Ste p 14 Feed Suppor t/Str ut Assembly Ste p 1 Ste p 2 65 Installation Procedures Set fine elevation and azimuth strut positions by loosening strut set screws and selected out fine adjustment hex nut. T urn corresponding inner hex nut in appropriate direction until required strut length is achieved.
P olarization Adjustment Ste p 1 Ste p 2 Ste p 3 Ste p 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.
Medium Modular Mount Refer to bulletin 237151C, for Installation Instructions. 67.
Ov er view Acquiring A Satellite Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 Ste p 7 68 Operation Oper a tion After you have completed the assembly of your antenna, you are now ready for it to become operational.
Ste p 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.
Ste p 2 Ste p 3 Ste p 4 Ste p 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.
Ste p 6 Ste p 7 Ste p 8 Ste p 9 71 Operation Move the antenna in elevation while observing the spectrum analyzer screen. If the sig- nal 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 move- ment.
Manual Actua tor Assembly R emo val Ste p 1 Ste p 2 Ste p 3 72 Operation Figure 6 After you have successfully acquired the satellite and all adjustment s have been made, the manual actuator should be removed. The following step s provide the procedure for the proper removal of the manual actuator assembly .
Ov er view General Cleaning Electrical Par ts 73 Prev entiv e Maintenance This section contains periodic prevent ative maintenance instructions for the 4.
Mechanical P ar ts Inspection Local Control/Motor Driv e Controller 74 scraper , stiff brush (bristle, or wire in the case of rust or corrosion), or cloth or com- pressed air at 25 to 40 psi.
Antenna 75 • Check all electrical components for dirt, chip s, 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 comp are against specified value where applicable.
76 • Check all electrical components for dirt, cracks, chip s, breaks, discoloration and other signs of deterioration and damage. A discolored, blistered or burnt condition is evidence of overload.
Driv e System V olta g e and Cur rent Checks Ste p 1 Ste p 2 Ste p 3 Ste p 4 77 • Check security of antenna mounting and interconnecting assembly hardware. Be cer- tain all electrical grounding connections (including cross-axis grounding strap s) and intact and secure, not corroded or broken.
Ste p 5 Ste p 6 Ste p 7 Ste p 8 P edestal Mount Bearing Pad Adjustment Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 78 T urn the ELEV A TION DOWN/UP switch to either position and while the antenna is rot a.
Preser v ation of Component Par ts Aluminum P ar ts Galv anized Surfaces Lubrication 79 When preserving component part s, refer to the following paragraphs in this section. Remove all loose paint and corrosion by scraping, wire brushing or using steel wool.
J ackscrews/Motors Gear Motor/Housing Fill Drain R equirements 80 the application of lubricant to any part s, 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.
81 T able 1. Antenna Lubrication Chart Lube Parts to be Lubricated Action Frequency Service Lube Quantity/ Andrew Point T ype T ype Points Number 1 Elevation jackscrew Lubricate Every 3 Pressure SHC32.
An important point after buying a device Andrew ES45T (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Andrew ES45T yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Andrew ES45T - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Andrew ES45T you will learn all the available features of the product, as well as information on its operation. The information that you get Andrew ES45T will certainly help you make a decision on the purchase.
If you already are a holder of Andrew ES45T, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Andrew ES45T.
However, one of the most important roles played by the user manual is to help in solving problems with Andrew ES45T. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Andrew ES45T along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
