Installation Instructions

Type 49640-( )

Bulletin 37675B
Revision A

Ground Mount Assembly

for 4.5-Meter Earth Station Antennas
1.0 Description 1.1 Type 49640-( ) Ground Mount Assembly includes a 49636 support angle kit, a 49634 azimuth axis support, a 49635 support and elevation pivot assembly, a 49639 hardware kit, a 49767 azimuth strut, and a 49766 elevation strut or 49779 high-look elevation strut. 1.2 The three-point ground mount is an elevation-overazimuth 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. 1.3 The antenna ground mount is assembled using A-325 friction-type hardware. This construction eliminates slippage under load conditions and the need for future retightening. 1.4 An optional earth station hoisting kit is available from Andrew which eliminates the use of a crane for installation. READ THE INSTRUCTIONS THOROUGHLY BEFORE ASSEMBLY 2.0 Foundation Layout 2.1 Refer to Figure 1 for foundation pad dimensions and anchor plate orientation. Studs extend 3 inches (76 mm) above pads and are 3/4 in (19 mm) in diameter. Foundation design should be reviewed with local civil engineer for local soil condition. 2.2 Antenna can be used for two or more satellites if azimuth degree separation between satellites is within azimuth adjustment range of antenna. Foundation should be installed at an azimuth angle which will accommodate viewing satellites of interest. Calculations for determining how to point the antenna are found in Section 6.

Figure 1
Andrew Corporation
10500 West 153rd Street Orland Park, IL U.S. A. 60462 Telephone: 708/349-3300 FAX (U.S.A.): 1-800/349-5444 TELEX: 25-3897 Customer Service, 24 hours: U.S.A. Canada Mexico: 1-800/255-1479 U.K.: 0800 250055 Republic of Ireland: 1 800 535358 Printed in U.S.A. 11/99 Other Europe: +44 592 782 612 Copyright 1999 by Andrew Corporation

3.0 Ground Mount Assembly 3.1 Note: All references to left or right are as viewed from rear of mount assembly.

3.2 Refer to Figure 2. Loosely attach 49634 azimuth axis support and 300747 rear anchor pads to foundation pads using 3/4-10 hex nuts and flat washers supplied with 47429 anchor bolt kit.

300747

300747

Figure 2 3.3 Refer to Figure 3. Attach 49624 support angles backto-back with 46560-2 spacers at mid-point between azimuth axis support and each corresponding rear anchor pad using 1/2 in. bolts and nuts. Securely tighten foundation pad hex nuts and add corresponding jam nuts. Note: Angles are attached edge down with flat of angle facing upward.

300747 REAR ANCHOR PAD

300747

Figure 3

3.4 Refer to Figure 4. Liberally apply 49208 grease to bottom of 300746 lower azimuth axis joint assembly.

3.5 Loosely attach 300746 lower azimuth axis joint assembly to bottom portion of azimuth axis support using two U-bolts and 1/2 in (13 mm) lockwashers and nuts.

300746

Figure 4 3.6 Refer to Figure 5. Remove temporary 1/2 in (13 mm) hex head bolts from elevation strut. Note required elevation range (refer to Section 6) and set coarse strut length based on procedure performed in paragraph 5.3. Attach fine adjustment assembly based on procedure performed in paragraph 5.8. Note: Mechanical means or fine adjustment assembly may be utilized to achieve elevation angles greater than 30. 3.7 Remove temporary 1/2 in (13 mm) hex bolt from azimuth strut. Note required azimuth range (refer to Section 6) and set coarse strut length based on procedure performed in paragraph 5.6. Attach fine adjustment assembly based on procedure performed in paragraph 5.9.

Figure 5 4

3.8 Refer to Figure 6. Loosely attach elevation strut between plates on 300746 azimuth axis joint using 3/4 x 3-1/2 in (89 mm) bolt, lockwasher and nut. 3.9 Refer to Figure 7. Loosely attach azimuth strut end bracket to 49705 universal block using two 3/4 x 1-1/4 in

(32 mm) bolts, flatwashers and lockwashers. Loosely attach universal block to appropriate rear anchor pad based on calculations performed in Section 6 to determine mounting configuration of azimuth strut. Use 3/4 x 5-1/2 in (140 mm) bolt, lockwasher and nut.

300746 AZIMUTH AXIS JOINT

Figure 6

Figure 7

3.10 Refer to Figure 8. Loosely attach 300748 upper azimuth axis joint to top portion of azimuth axis support

using two U-bolts and 1/2 in (13 mm) lockwashers and nuts.

300748 AZIMUTH AXIS JOINT

300746 AZIMUTH AXIS JOINT

300747 REAR ANCHOR PAD

300747 REAR ANCHOR PAD

Figure 8

3.11 Refer to Figure 9. Loosely attach 49622 support angIes to right and Ieft tabs on upper azimuth axis joint assembly using 1/2 in bolts, flatwashers and nuts. Note: Angles are attached edge down with flat of angle facing upward.

3.12 Attach 49635 support and elevation pivot assembly between previously installed 49622 support angles using 1/2 in bolts, flatwashers, and nuts.

300748 AZIMUTH AXIS JOINT

300747 AZIMUTH AXIS JOINT

300747 AZIMUTH AXIS JOINT

Figure 9

3.13 Refer to Figure 10. Loosely attach 49623 support angles back-to-back with 46560-2 spacers at mid-points between right and left connection plates on 49635 support/elevation pivot assembly and 300746 azimuth axis joint using 1/2 in bolts and nuts. Note: Angles are attached edge in with flat of angle facing downward. 3.14 Loosely attach 49704 U-bracket to appropriate connection plate on 49635 support/elevation pivot

assembly based on mounting configuration of azimuth strut using 1/2 in bolt, flatwasher, and nut. 3.15 Loosely attach remaining end of azimuth strut assembly to previously mounted U-bracket using 3/4 x 41/2 in (114 mm) bolt, lockwasher and nut. Securely tighten all ground mount hardware per hardware tensioning procedure.

Figure 10 8

TENSIONING PROCEDURE A-325 HARDWARE A-325 hardware must be properly tensioned to avoid slippage between bolted surfaces under high loads. Slippage can cause the mount assembly to move slightly and cause antenna misalignment. Make sure all bolts are tensioned per procedure below and replace any bolts that break. Proper Tensioning: 1. Insert bolt. 2. Lubricate bolt threads with stick wax to reduce friction. 3. Add nut and finger tighten. 4. After connections are completed, tighten bolts until surfaces are joined and nuts are snug, i.e., full effort of person using ordinary spud wrench.

5. Mark nuts and ends of bolts with straight line. See A. 6. Tighten nuts further with extra long wrench or power wrench until nuts are moved 1/3 turn (120 30). See B.

4.0 Reflector/Backstructure To Ground Mount Assembly 4.1 Note: Optional 49080 hoist kit must be assembled prior to reflector/backstructure assembly hoisting. Hoist assembly should not be used for antenna elevation angle adjustment. If hoisting kit is not utilized, reflector/ backstructure assembly must be raised using crane or some other mechanical means and continuing assembly procedure at paragraph 4.11. 4.2 Refer to Figure 11. Install 49067 support tab assembly into top of 49634 azimuth axis support. 4.3 Loosely attach corresponding 49071 and 49072 support assemblies using 49059 spacers and 45980-6 hardware. Note: Angles are installed edge down with flat of angles facing upward. 4.4 Install 49087 sheaves at each end between support assemblies using 39527 pins with 9958-6 cotter pins. Securely tighten support assembly hardware.

4.5 Attach entire support assembly to previously installed 49067 support tab assembly using 45980-6 hardware. 4.6 Loosely attach 49064 pick-up assemblies to 49635 support and elevation pivot assembly as shown using supplied U-bolts with 1/2 inch (13 mm) lockwashers and nuts. Note: Pick-up assemblies are mounted with slanted tabs facing outward. 4.7 Loosely attach 49061 supports to corresponding tabs on 49071 and 49072 support assemblies using 45980-1 hardware. Note: Angles are installed edge down with flat of angles facing upward. 4.8 Loosely attach 49060 support and remaining ends of 49061 supports to corresponding 49064 pick-up assemblies using 45980-1 hardware. Securely tighten all mounting hardware. Note: Ensure entire hoist assembly is centered on 49635 support and elevation pivot assembly.

Figure 11

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4.9 Refer to Figure 12. Securely attach 39532 winch assembly to lower portion of 49634 azimuth axis support using supplied U-bolts, lockwashers and nuts. Note: Keep winch cable aligned with sheaves. 4.10 Begin releasing winch cable. Route cable through both 49087 sheaves allowing sufficient cable length to reach top of main triangle assembly on reflector backstructure. 4.11 Route 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. Note: Distance between choker/winch (or choker/crane) connection and top of main triangle assembly should be approximately 13inches (330 mm). 4.12 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.

Figure 12

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4.13 Refer to Figure 13. Hoist refIector/backstructure assembly to verticaI position untiI upper joints of main triangle assembly contact pipe and straddle two locator bars on 49635 support and elevation pivot assembly. 4.14 Install two U-bolts at each pivot bracket of main triangle assembly using 1/2-inch (13 mm) lockwashers and nuts. Note: Securely tighten U-bolts allowing for

some reflector movement. 4.15 Raise lower portion of reflector/backstructure assembly and attach remaining end of elevation strut to elevation axis bracket of main triangle assembly using 3/4 x 4-1/2 in (114 mm) bolt, lockwasher and nut. Note: Mechanical means or fine adjustment assembly may be utilized to achieve elevation angles greater than 30.

Figure 13 4.16 Set fine elevation and azimith strut positions based on procedure performed in paragraph 5.10. Note: If fine alignment is not performed at this time, continue assembly procedure at paragraph 4.17. 4.17 Securely tighten U-bolts and elevation strut mount12 ing hardware. 4.18 Remove both fine adjustment assemblies and store in weather protected location for future use. Continue with feed system and corresponding LNA installation.

5.0 Elevation and Azimuth Adjustments 5.1 Proper antenna pointing requires specific coarse and fine elevation and azimuth strut length adjustments which can be determined using the graphs provided in Section 6. Adjustable azimuth and elevation struts are initially set in coarse setting as near as possible to predetermined 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. 5.2 Coarse Elevation Adjustment. Station at least two men at reflector rim to provide temporary reflector support while third man loosens two U-bolts on each end of 49635 elevation pivot assembly and removes 3/4 x 41/2-inch (114 mm) bolt, lockwasher and nut connecting elevation strut to bottom of main triangle assembly. Carefully lower reflector to vertical position. 5.3 Refer to Figure 17. 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 in (13 mm) set screws in holes provided and securely tighten. Note: Do not extend

secondary or tertiary strut sections into red warning areas. 5.4 Carefully raise reflector and attach elevation strut to bottom of main triangle assembly using previously removed 3/4 x 4-1/2 in (114 mm) bolt, lockwasher and nut. Note: Mechanical means or fine adjustment assembly may be used to achieve elevation angles greater than 30. 5.5 Coarse Azimuth Adjustment. Loosen two U-bolts on both 49630 upper and 49629 lower azimuth axis joints. Remove 3/4 x 4-1/2-inch (114 mm) bolt, lockwasher and nut connecting azimuth strut to 49704 Ubracket. 5.6 Refer to Figure 18. 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 required strut length. Install four 1/2 in (13 mm) set screws in holes provided and securely tighten. Note: Do not extend secondary strut section into red warning area. 5.7 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 49208 grease around bottom area of 49629 lower azimuth axis joint assembly before changing azimuth position of antenna.

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5.8 Fine Adjustment. Refer to Figure 14. Attach fine adjustment assembly between adjacent elevation strut sections as shown 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.

5.9 Refer to Figure 15. Attach fine adjustment assembly between adjacent azimuth strut sections as shown 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 14 5.10 Set fine elevation and azimuth strut positions by loosening strut set screws and selected outer 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. 5.11 During final electrical tuning, adjust elevation and azimuth struts appropriately to lengthen or shorten struts for optimum signal strength.

Figure 15 5.12 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. 5.13 Securely tighten eight U-bolts on elevation pivot assembly and upper and lower azimuth axis joints.

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6.0 Calculations for Antenna Pointing 6.1 The earth station antenna mount permits the antenna to be pointed through an azimuth range of 82 with standard elevation ranges from 2 - 62 and 33 - 90 with high-look strut configuration. The foundation must be oriented properly at each site to permit the antenna to be pointed at any satellite in the desired orbital arc. The antenna has fine adjustment capability in both azimuth and elevation which provides strut adjustment from the coarse settings of the antenna. Refer to Figures 17 and 18. 6.2 This section contains formulas and graphs for determining the pointing capabilities of the antenna. Mount support pads permit attachment of azimuth strut in left elevation axis, right rear pad position, right elevation axis, right rear pad position, left elevation axis, left rear pad position, or right elevation axis, left rear pad position. Refer to Figure 18. Additional azimuth strut positions provide greater flexibility when repositioning antenna to view other satellites of interest. 6.3 Formulas. Formulas for calculating true azimuth (AZ), true elevation (EL), relative angle between true azimuth and mount pointing angle (dAZ), and strut lengths of Andrew earth station antennas are given below. Knowing earth station latitude, longitude, azimuth setting of mount (AZm) and satellite(s) longitude (over the equator), the following calculations should be performed: 6.4 AZ = 180 + tan-1 (tan /) = true azimuth with respect to earth. Note: This equation applies to earth stations north of the equator. For earth stations south of the equator: AZ = 360 - tan-1 (tan /sin ll where: = earth station latitude = relative longitude = satellite longitude minus earth station longitude

Note: Earth station latitude values are positive (+) for sites located north of the equator and negative (-) for sites located south of the equator. Earth station longitude values are positive (+) for sites west of Greenwich and negative (- ) for sites located east of Greenwich. 6.5 dAZ = AZ - AZm = relative angle between true azimuth angle and mount pointing direction. where: AZm = azimuth at which mount is set (nominal foundation pointing angle). Refer to paragraph 6.9. 6.6 EL = 90 - T - R = true elevation with respect to earth where: R = cos-1 (cos cos ) and T = tan-1 (sin R/6.6166 - cos R 6.7 18266.38 - 16064.52 cos (EL + 9.04) = elevation strut length 6.8 12774 - 65 + x2 + z2 = azimuth strut length For azimuth strut attached from left elevation axis pickup to right rear pad (as viewed from rear of antenna): X = 43.201 + 56.331 cos(23.927 + dAZ) and Z = 84.978 + 56.331 sin (23.927 + dAZ) For azimuth strut attached from right elevation axis pickup to right rear pad (as viewed from rear of antenna): X = 43.201 - 56.331 cos(23.927 - dAZ) and Z = 84.978 + 56.331 sin(23.927 - dAZ). For azimuth strut attached from left elevation axis pickup to left rear pad (as viewed from rear of antenna): X = 43.201 - 56.331 cos(23.927 + dAZ) and Z = 84.978 + 56.331 sin(23.927 + dAZ) For azimuth strut attached from right elevation axis pickup to left rear pad (as viewed from rear of antenna): X = 43.201 + 56.331 cos(23.927 - dAZ) and Z = 84.978 + 56.331 sin(23.927 - dAZ)

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6.9 Foundation Orientation. Generally, the foundation is oriented on a true North-South line. In the Northern Hemisphere, the foundation would point due South, equivalent to the direction, AZ = 180. In the Southern Hemisphere, the foundation would point due North, equivalent to the direction, AZ = 0. Note: True North is not equivalent to magnetic North. 6.10 Pointing Considerations. Knowing the foundation orientation (AZm), it is necessary to determine the coarse and fine settings of the mount struts to see a particular satellite within that orbital arc. 6.11 Using formulas in paragraphs 6.4 thru 6.6, calculate AZ, dAZ and EL for the satellite of interest. Figure 16 shows these angles in relation to the antenna geometry. 6.12 Using Figure 17, determine elevation struth length knowing EL. 6.13 Using Figure 18, determine azimuth strut length knowing dAZ.

Figure 16 16

Figure 17 17

Figure 18

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Parts List Type No. 49636 49624 49623 49622 49639 300746 300748 300747 40188-3 49712 49712-2 9956-67 9956-65 9974-5 9999-157 9997-166 9999-122 9963-703 9963-452 9963-706 9974-10 9978-173 9963-795 49704 49705 9956-101 9974-4 9999-109 33489 46560-2 45980-9 9999-167 49208 9997-228 9903-15 49634 49635 Description Quantity Type No. 47429 47430 49080 49071 49072 49067 49087 49059 39527 49061 43909 49064 49060 9958-6 45980-6 45980-1 9956-101 9999-109 9974-4 39532 49208

Optional Items Description Quantity

Support Angle Kit, consists of: Support Angle, Back 4 Support Angle, Front 4 Support Angle, Top 2 Hardware Kit, consists of: Az. Axis Joint, Bottom Az. Axis Joint, Top Rear Pad 3/4 - 10 x 10 in. Threaded Rod Bracket Bracket U-Bolt U-Bolt 3/8-in. Lockwasher 3/8 - 16 Hex Nut 3/4-in. Flatwasher 3/4 - 10 Hex Nut 3/4 - 10 x 3-1/2-in. Bolt 3/4 - 10 x 4-1/2-in. Bolt 3/4 - 1 0 x 5-1/2 in. Bolt 3/4-in. Lockwasher 1/2 - 13 Set Screws 3/4 - 10 x 1-1 /4-in. Hex Bolt U-Bracket Universal Block U-Bolt 1/2-in. Lockwasher 1/2 - 13 Hex Nut Zinc Paint Spacer 1/2 - 13 Bolt and Nut Assy. 3/4 - 10 Hex Nut, Brass Grease 1/2-in. Flatwasher Set Screw Wrench Azimuth Axis Support

Anchor Bolt Kit, consists of: Anchor Bolt and Hardware Kit 12 Hoist Kit, consists of: Support Assembly Support Assembly Support Tab Assembly Sheave Spacer Pin Support Choker Cable Assembly Pick-Up Assembly Support Cotter Pin Bolt Assembly Bolt Assembly U-Bolt 1/2-13 Hex Nut 1/2-in. Lockwasher Winch Assembly Grease

1 1 2 2 1 2 1 2 6 6 10 5** 1 2 1 6 13 2 1 1 8 17** 17** 1 4 31* 8 1 10** 1 1

1 1 1 2 2 2 2 1 2 1 4 3 6 4 8 8 1 1

Notice The installation, maintenance or removal of antenna systems requires qualified, experienced personnel. Andrew installation instructions have been written for such installation 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 for the results of improper or unsafe installation practices.

Support and Elevation Pivot Assembly - TOP 1 Elevation Strut High-Look EL Strut Azimuth Strut 1 1 1

49766 49779 49767

*This is an A-325 112 x 1-1/2" (38 mm) bolt and nut assembly. **Includes spare(s).

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