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4.5m Earth Station
Antenna
Assembly, Installation, Operations, &
Maintenance Manual
Document# OM45T – Revision N
Kratos Defense & Security Solutions, Inc.
Kratos Defense & Security Solutions, Inc.
1120 Jupiter Road Suite 102
Plano, Texas 75074
USA
www.KratosDefense.com
Tel: 214-291-7654
Fax: 214-291-7655
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Summary of Contents for KRATOS ES45T-HW-1
- Page 1 4.5m Earth Station Antenna Assembly, Installation, Operations, & Maintenance Manual Document# OM45T – Revision N Kratos Defense & Security Solutions, Inc. Kratos Defense & Security Solutions, Inc. 1120 Jupiter Road Suite 102 Plano, Texas 75074 www.KratosDefense.com Tel: 214-291-7654 Fax: 214-291-7655...
- Page 2 Kratos Defense & Security, Inc. Kratos Defense & Security, Inc. reserves the right to change details in this publication without notice. Trademark Notices Any and all products and companies named herein are the trademarks of their respective creators and/or owners.
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Page 3: Table Of Contents
Table of Contents INTRODUCTION: HOW TO USE THIS MANUAL Purpose & Overview I.II Description I.III Miscellaneous Notices I.IV Warning Symbols Safety Terms Summary I.VI Summary of Safety Precautions I.VII Things to Never Do I.VIII Parts Verification 1.0 Recommended Tools & Foundation Preparation 1.1 Recommended Tools 1.2 A-325 Tensioning Procedure 1.3 Foundation Preparation... - Page 4 5.2.4 Prepping & Painting Galvanized Surfaces 5.2.5 Priming & Painting Cleaned Jack Surfaces 5.3 Removing Backlash via Jack Adjustment 5.4 Maintenance Kits APPENDIX: Equipment Issues & Technical Support List of Figures Figure 1-1a: Bolts Shorter than 4 Diameters Figure 1-1b: Bolts Longer than 4 Diameters Figure 1-2: Scraping Foundation Pads Figure 3-1: Pure Noise Signal on Spectrum Analyzer Figure 3-2: Minimum Transponder Signal on Spectrum Analyzer...
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Page 5: Introduction: How To Use This Manual
Maintenance. basic equipment and accessories are either manufactured or design controlled by Kratos Defense & Security Solutions, Inc.. The prerequisite information necessary for the 4.5m ESA 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. -
Page 6: I.iii Miscellaneous Notices
Kratos 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 Kratos and can be utilized as an installation tool for multiple installation purposes. -
Page 7: Safety Terms Summary
I.V Safety Terms Summary The following safety terms may appear on the product: Les termes de sécurité suivants peuvent apparaître sur le produit: DANGER—Indicates an immediately accessible injury hazard is present as you read the marking, and failure to take precautions could result in loss of life DANGER—Cette indication signale un risque de blessure immédiat et qui peut être mortel. -
Page 8: I.vii Things To Never Do
• NEVER ignore warning symbols or fail to read safety signs • NEVER skip steps in a sequence, unless specifically instructed to do so by the manual, software, and/or authorized Kratos Tech Support Personnel. Aside from risking harm to yourself, you risk doing permanent damage to the equipment •... -
Page 9: Recommended Tools & Foundation Preparation
All actual tools necessary for the installation of the supplied hardware/parts, however, should be provided by the installation crew. Kratos recommends the following tools, as shown in Table 1.1, be used for a proper installation of the 4.5m Earth Station Antenna: NOTE: the tools listed in the below table are subject to change without notice. -
Page 10: A-325 Tensioning Procedure
1.2 A-325 Tensioning Procedure Throughout the installation instructions, there will be 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 or slip, resulting in antenna misalignment. Use of A-325 hardware eliminates slippage between mating surfaces under high loading conditions as well as the need for future retightening. -
Page 11: Foundation Preparation
Before beginning the installation process on the ground mount assembly, ensure that the foundation has been prepared. Foundation specifications are provided by Kratos 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 or your Account Manager. -
Page 12: Mount & Antenna Assembly Procedures
Refer to the drawings, instructions, and schematics for the specific system being installed, per the information provided in Table 1.2. 2.1 Assembly Sequence & Helpful Tips Kratos recommends following these helpful tips regarding the sequence of assembly: • Always use the correct provided hardware and use the appropriate sequence for tightening/torque, as per the instructions provided with the part or kit being assembled and/or installed (as listed in Table 1.2). -
Page 13: Operation
Azimuth strut length through the Fine Adjustment Assembly until the satellite signal is spotted. There are a number of possible procedures for acquiring a satellite. Kratos recommends that a Spectrum Analyzer of some type be used, regardless of your chosen procedure. The following procedures provide explanations as to how a Spectrum Analyzer is used. -
Page 14: Figure 3-1: Pure Noise Signal On Spectrum Analyzer
Figure 3-1: Pure Noise Signal on Spectrum Analyzer Figure 3-2: Minimum Transponder Signal on Spectrum Analyzer Use the following steps in order to acquire a satellite: Step 1 of 9: Manually move the antenna in the Azimuth direction (scanning back-and-forth) to achieve a maximum transponder signal with the greatest amplitude •... -
Page 15: Figure 3-3: Antenna Radiation Pattern Topographical Diagram W/ Plan View
• Transponder signal amplitude of 30 dB or greater from peak to average noise signal indicates that the antenna is receiving the signal on the main beam. • Transponder signal amplitude of less than 30 dB indicates that the antenna is peaking on a side lobe of the main beam. -
Page 16: Figure 3-4: Polarization At 45 Degrees From Optimum Setting
Step 8 of 9: Rotate the feed assembly clockwise until 24 transponder signals are noted and of approximately equal amplitude. NOTE: it is more accurate and visually simple to minimize the alternate set of transponder signals rather than maximizing the transponder of interest. Figure 3-4: Polarization at 45 Degrees from Optimum Setting Step 9 of 9: With all 24 transponder signals of approximately equal amplitude appearing on the Spectrum Analyzer screen, determine the specific antenna system and satellite parameters. -
Page 17: Removal Of The Manual Actuator Assembly
Figure 3-6: Optimum Polarization Settings 3.2 Removal of the Manual Actuator Assembly After the satellite has been successfully acquired and all necessary adjustments are made, the manual actuator should be removed. The following steps provide the procedure for properly removing the Manual Actuator Assembly. -
Page 18: Preventive Maintenance
4.0 Preventive Maintenance The following sections contain periodic preventative maintenance instructions for the 4.5m ESA. Included in these sections are instructions for performing inspections, preventative maintenance procedures, and general cleaning. NOTE: Refer to applicable vendor manuals for any repair procedures that are not included in this manual. The following sections describe the cleaning, inspections, and preventative maintenance procedures. -
Page 19: Inspections
4.2 Inspections The frequency of inspection is contingent upon the user’s individual standards and the operational environment in which the earth station antenna is located. However, a visual inspection of the components should be performed at least semi-annually. Where there are no established wear limits, perform a visual inspection to locate worn or damaged parts that could result in a malfunction of the earth station antenna. -
Page 20: Antenna Inspection
• Visually inspect all mechanical parts for freedom of operation, with no binding or interference. Check for security of all hardware, and for stripped or otherwise damaged threads. Check metallic parts for corrosion, dents, distortion, and/or other deformations • Check for evidence of water within the enclosure. If there is evidence of any water, you will need to clean the area thoroughly and check to make sure all seals are intact. -
Page 21: Drive System Voltage & Current Checks
At the conclusion of the installation procedure 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 Kratos 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. -
Page 22: Pedestal Mount Bearing Pad Adjustment
Once the installation procedure has been completed, and prior to turning over the system to the station facility, some form of Site Acceptance Test procedure will need to be performed, checked off, and signed (such as the Kratos Site Acceptance & Proof of Performance Document). 4.5 Preservation & Lubrication 4.5.1 Preservation of Component Parts... -
Page 23: Galvanized Surfaces
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 surface to dry thoroughly before priming. Prime the cleaned surface by applying zinc chromate primer. -
Page 24: Jackscrews/Motors
The following is a list of the lubricant characteristics: • Lubrication Engineers (LE) 4622: LE4622 is Lithium complex grease. Operating temperature range is -40 degrees to 400+ degrees Fahrenheit (-40 degrees to 204+ degrees Celsius). • Mobil SHC624: low temperature synthetic oil for worm gear reducers. Operating temperature range is -40 degrees to 125+ degrees Fahrenheit (-40 degrees to 52+ degrees Celsius). -
Page 25: Corrective Maintenance & Troubleshooting
4. Are there any particular precautions that can be taken to avoid damaging the feed window? All Kratos ESA feed windows are rated at .5 psi. This means placing any pressure on the feed window of more than .5 psi is likely to cause permanent damage to feed window, which will require replacement. -
Page 26: Prepping & Painting Galvanized Surfaces
Thoroughly cover all previously primed areas with paint and blend the paint with any preexisting painted surfaces. 5.2.4 Prepping & Painting Galvanized Surfaces • Remove all loose paint or rust using a scraper, wire brush, or sanding. • Wipe clean the surface to be painted with a soft cloth rag and acetone. •... -
Page 27: Maintenance Kits
Over-tightening can also result in a destructive heat buildup and/or operational failure. Figure 5-1: Jac/Jack Anti-Backlash Procedure 5.4 Maintenance Kits The below table provides descriptions of and Kratos part numbers for commonly used maintenance kits: Table 5.2: Maintenance Kits Part # Description AE03K-D0149-001 4.5m Feed Window Kit... -
Page 28: Appendix: Equipment Issues & Technical Support
Kratos strives to ensure all items arrive safe and in working order. Despite these efforts, equipment is at times received with damage or faults. When this occurs, it may be necessary to return some items to Kratos for either repair or replacement. - Page 29 For technical support, contact information, and/or technical documentation: www.KratosDefense.com Kratos Corporate Website: (214) 291-7659 Kratos Tech Support Phone: Kratos Tech Support Email: Kratosspacesupport@kratosdefense.com Kratos Defense & Security Solutions, Inc. 1120 N Jupiter Road, Suite 102 Plano TX 75074 OM45T_Rev N Page 28...
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