KRATOS ES45T-HW-1 User manual

4.5mEarthStation
Antenna
Assembly,Installation,Operations,&
Maintenance Manual
Document# OM45T – RevisionN
Kratos Defense & Security Solutions, Inc.
Kratos Defense & Security Solutions, Inc.
1120 Jupiter Road Suite 102
Plano, Texas 75074
USA
www.KratosDefense.com
Tel: [phone]
Fax: [phone]

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©2020 Kratos Defense & Security, Inc.
All Rights Reserved. No part ofthis document may be photocopied, reproduced, stored in a retrieval system, or
transmitted, in any form or by any means whether electronic, mechanical, or otherwise without the prior written
permission of 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 oftheir respective creators and/or
owners.
Open Source Software Notice
This product makes extensive use of Open Source Software (OSS), including butnotlimited to the operating
system, network agents, user interface shells, and tools used to develop the software. This software gives you,
the customer, the benefit ofa large base ofwell-tested and feature-rich system software while lowering the
expense of providing these features to you. It also carries certain obligations.
Some of this software is licensed by the GNU General Public License (GPL), which requires that all
modifications or additions tothe source code be kept public, and that the licensee continues tomake the
source code covered public. None of this source code has been modified for use in this product. Ifyou are a
user ofthis product who desires a copy ofany source code covered by the GPL, contact ourtechnical support
and we will provide this free of charge through an agreeable medium. We expect allsource code archives will
be posted topublic FTP servers. Atthe time ofthis writing the exact address isnotknown. Beadvised that this
is a large archive. We may recommend you obtain it from the source we obtained it from, as the source may be
using more recent versions. We will always supply itourselves ifyou prefer.
Some of this software is licensed by the GNU Lesser General Public License (LGPL), which requires that
modifications be kept public but does not require proprietary source code linked to LGPL'ed libraries be made
public. None of this code has been modified for use in this product. All ofthe required source code will be
conveyed along with the code covered by the GPL above.
Some of this software is licensed by variations ofthe Berkeley Software Distribution (BSD) license, which do
not require us to pass on source code. Some of this software has been modified for use in this product.
However, in the spirit ofopen source, the original code will be supplied in the same manner as the code
covered by the GPL on request.
Please be advised that you will incur the same responsibilities we have incurred ifyou choose to redistribute
any or allofthe source codes obtained through this method. Please read the included license documents
carefully.
If you have any questions about our interpretation of our obligations under OSS licenses, do not hesitate to
contact us.Our intent isto comply fully with all licensing obligations.
©Kratos Defense & Security, Inc.
www.KratosDefense.com

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Table of Contents
INTRODUCTION: HOW TO USE THIS MANUAL 4
I.I Purpose & Overview 4
I.II Description 4
I.III Miscellaneous Notices 5
I.IV Warning Symbols 5
I.V Safety Terms Summary 6
I.VI Summary of Safety Precautions 6
I.VII Things to Never Do 7
I.VIII Parts Verification 7
1.0 Recommended Tools & Foundation Preparation 8
1.1 Recommended Tools 8
1.2 A-325 Tensioning Procedure 9
1.3 Foundation Preparation 10
1.4 4.5m Assembly & Installation Reference Documents/Drawings 10
2.0 Mount & Antenna Assembly Procedures 11
2.1 Assembly Sequence & Helpful Tips 11
3.0 Operation 12
3.1 Acquiring a Satellite 12
3.2 Removal of the Manual Actuator Assembly 16
4.0 Preventive Maintenance 17
4.1 General Cleaning 17
4.1.1 Electrical Parts 17
4.1.2 Mechanical parts 17
4.2 Inspections 18
4.2.1 Local Control/Motor Drive Controller Inspection 18
4.2.2 Antenna Inspection 19
4.2.3 Drive System Voltage & Current Checks 20
4.3 Pedestal Mount Bearing Pad Adjustment 21
4.4 Site Acceptance Test Procedure 21
4.5 Preservation & Lubrication of Component Parts 21
4.5.1 Preservation of Component Parts 21
4.5.2 Aluminum Parts 21
4.5.3 Galvanized Surfaces 22
4.5.4 Lubrication 22
4.5.5 Jackscrews/Motors 23
4.5.6 Gear Motor/Housing Fill Drain Requirements 23
5.0 Corrective Maintenance & Troubleshooting 24
5.1 Top 5 ESA Maintenance & Troubleshooting FAQ 24
5.2 Corrective Painting Instructions 24
5.2.1 Preparatory Cleaning of Aluminum Surfaces 24
5.2.2 Priming Cleaned Aluminum Surfaces 24
5.2.3 Painting Primed Aluminum Surfaces 24

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5.2.4 Prepping & Painting Galvanized Surfaces 25
5.2.5 Priming & Painting Cleaned Jack Surfaces 25
5.3 Removing Backlash via Jack Adjustment 25
5.4 Maintenance Kits 26
APPENDIX: Equipment Issues & Technical Support 27
List of Figures
Figure 1-1a: Bolts Shorter
than 4 Diameters 9
Figure 1-1b: Bolts Longer than 4 Diameters 9
Figure 1-2: Scraping Foundation Pads 10
Figure 3-1: Pure Noise Signal on Spectrum Analyzer 13
Figure 3-2: Minimum Transponder Signal on Spectrum Analyzer 13
Figure 3-3: Antenna Radiation Pattern Topographical Diagram w/ Plan View 14
Figure 3-4: Polarization at 45 Degrees from Optimum Setting 15
Figure 3-5: Maximizing Odd Transponders 15
Figure 3-6: Optimum Polarization Settings 16
Figure 5-1: Jac/Jack Anti-Backlash Procedure 26
List of Tables
Table 1.1: Recommended Tools 8
Table 1.2: 7.6m Assembly & Installation Drawings 10
Table 4.1: Lubrication Chart 23
Table 5.1: Cure Times 25
Table 5.2: Maintenance Kits 26

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INTRODUCTION: How to Use This Manual
I.I Purpose & Overview
PURPOSE
The scope of this manual is intended to provide station personnel with the base installation, operation, and
maintenance requirements necessary for a 4.5-Meter Earth Station Antenna (4.5m ESA). This manual provides
a convenient reference for authorized operator/service personnel requiring technical information on general
system or specific subsystem equipment.
NOTE: All antenna option instructions are included in the individual kit shipped with that part.
Top Level Assembly Numbers are as follows:
ES45T-HW-1: 4.5m Tripod High Wind ESA
ES45MP-1: 4.5m C-, Ku-, or X-Band Prime Focus Transmit/Receive ESA. Motorizable Pedestal Mount with
Az/El manually adjustable struts
ES45MPJ-1: 4.5m C-, Ku-, or X-Band Prime Focus Transmit/Receive ESA. Motorizable Pedestal Mount with
Az/El Jackscrews
ES45P-1: 4.5m C-, Ku-, or X-Band Transmit/Receive ESA. Manual Pedestal Mount with Az/El manually
adjustable struts
ES45T-R-1: 4.5m C-, Ku-, or X-Band Receive Only Prime Focus ESA. Manual Low Look Tripod
ES45T-T-1: 4.5m C-, Ku-, or X-Band Prime Focus Transmit/Receive ESA. Manual Low Look Tripod
--------------
OVERVIEW
The installation, operation, and maintenance of the 4.5m ESA requiresqualified and experienced
personnel. Kratos 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 Preventive Maintenance. The 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.
I.II Description
The 4.5m ESA 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-
Ban, or X-Band operation. Both pedestal and tripod mounts are available (motorization available for pedestal
only). The versatility is provided at the time of initial purchase, as well as in the future, as your satellite
communication requirements evolve.
NOTE: The scope of this manual covers the Manual Tripod Mount 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 the need for reflector realignment.
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 enables
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 ability to be upgraded for motorized operation,
including step-tracking or SmarTrack®applications. The motorizable mount type is indicated within the antenna
type number as ES45MP or ES45MPJ. 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

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systems.
A Manual Pedestal Mount is also available. It provides the same strong and versatile combination of mechanical
features as the motorizable version; except the Elevation and Azimuth axes are locking types, instead of bearing
mounted types. This mount type is always equipped with manuals 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 maintain pointing accuracy and ensure
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 in moderate coastal/industrial areas.
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.
I.III MiscellaneousNotices
Proprietary Information
The technical data contained herein is proprietary to Kratos Defense & Security Solutions, Inc..It is
intended for use in the installation, operation, and maintenance of Kratos equipment. This data shall not be
disclosed or duplicated, in whole or in part, without the expressed written consent of Kratos Defense & Security
Solutions, Inc.
Installation Notice
Installation, maintenance, or removal of the hardware described in this manual requires qualified and
experienced personnel. Kratos installation instructions are written for such personnel. Qualified personnel
MUST perform proper installation and maintenance of the equipment, and MUST verify the condition of the
equipment at initial installation and periodically thereafter.
NOTE: Kratos is NOT liable or responsible for results of improper or unsafe installation and maintenance practices. All
designs, specifications, and availability of products are subject to change without notice.
--------------
IMPORTANT: What to Know When You See
OPTION:
Any time you see OPTION: this means that the information following it is related to an optional element (in either
hardware or software) that may or may not apply to the arrangement of your particular NGC Unit. Please
note that if you see an option that you do not have but would like to purchase, please contact Kratos.
I.IV Warning Symbols
Various components of this System may display safety symbols. Be sure to use extreme caution when
operating components with any of the following safety symbols:
Certains éléments du système montreront peut-être des symboles de sécurité. Faites très attention à faire
marcher tous les éléments qui tiennent les symboles de sécurité suivants:
OR WARNING! HAZARDOUS MOVING PARTS! KEEP FINGERS AND OTHER BODY PARTS AWAY!
AVERTISSEMENT! PIÈCES MOBILES DANGEREUSES! GARDEZ LES DOIGTS ET LES AUTRES PARTIES DU
CORPS HORS D’ATTEINTE!
WARNING! RISK OF ELECTRIC SHOCK!
AVERTISSEMENT! RISQUE D’ÉLECTROCUTION!
WARNING! REFER TO MANUAL
AVERTISSEMENT! SE RÉFÉRER AU MANUEL D’UTILISATION.

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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.
WARNING—Indicates a nearby injury hazard that is not immediately accessible as you read the markings, and failure to
take precautions could result in personal injury and/or loss of life
AVERTISSEMENT—Cette indication signale un risque de blessure non immédiat mais qui peut être mortel.
CAUTION—Indicates a potential hazard to property, including the product
PRUDENCE—Indique un risque pour l’environ du produit, le produit inclus.
The following safety symbols and terms may be used in this manual:
Les symbols et les termes suivants de sûreté peuvant être employés en ce manuel:
WARNING! Statements identify conditions & practices that could result in injury or loss of life.
AVERTISSEMENT! Les rapports d’avertissement identifient les conditions ou les pratiques qui pourraient avoir comme
conséquence les dommages ou la perte de la vie.
RISK OF ELECTRIC SHOCK!
RISQUE DE DÉCHARGE ÉLECTRIQUE!
I.VI Summary of Safety Precautions
The following safety precautions are not related to any specific procedure, and so will not appear elsewhere in this manual.
Ensure all personnel understand & apply these precautions in all phases of installation, operation, & maintenance. Failure
to do so may result in loss of life.
KEEP AWAY FROM LIVE CIRCUITS: Personnel must observe all applicable safety regulations at all times. Ensure
power is disconnected or removed from the unit BEFORE replacing any components. Potential hazards may exist even
though the power control switch is in OFF position. Capacitors retain electrical charges. Always REMOVE POWER & use
test equipment to confirm a circuit is at ground potential BEFORE touching it. NEVER reach into or enter an enclosure to
service or adjust the equipment until the absence of power has been confirmed.
DO NOT SERVICE OR ADJUST ALONE: Under NO circumstances should ANY person reach into or enter the
enclosure for the purpose of servicing or adjusting the equipment except in the presence of someone who is capable
of rendering aid in case of an accident/emergency.
RESUSCITATION: Personnel working with or near high voltage should be familiar with resuscitation methods (CPR
and/or AED). CPR info may be obtained from medical personnel. For AED (Automated External Defibrillator) information,
contact supervisor or hosting administration for details on the availability and/or location of an AED unit at your worksite.
ELECTROSTATIC DISCHARGE PRECAUTION
This equipment contains electrostatic discharge (ESD) sensitive devices. ESD sensitive equipment handling methods
must be used to prevent equipment damage during handling and servicing.
ESSENTIAL HEALTH AND SAFETY REQUIREMENT
Refer to document “P/N 240117—Essential Health and Safety Requirements”.

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I.VII Things to Never Do
•NEVER touch circuits orreach into an enclosure until the disconnection of power and absence ofcharge has
been confirmed
•NEVER service or adjust equipment alone. Electric shock can lead tocardiac arrest. Presence ofimmediate
aid gives you a 90% chance of survival, but this drops by 10% with every passing minute. After 5
minutes resuscitation without permanent heartand/or brain damage is nearly impossible.Consider
this: Without the immediate aidof CPR or an AED, what are the odds you will be found and
successfully revived in under 5minutes?
•NEVER ignore warning symbols or fail toread 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
•NEVER touch or stand near any potentially moving parts (even if they are not in motion at the time) when the
unit isin operation or powered on, as they may move without warning
•NEVER stand underneath any object while it isbeing lifted
•NEVER remove, disable, or exceed the unit’s safety, software, security, or movement limits, unless
specifically instructed to do so by the manual, software, and/or authorized Kratos Tech Support Personnel.
The careless disabling of such safeguards isone of the most common causes of serious equipment damage
during installation and operation
I.VIII Parts Verification
STOP! READ BEFORE BEGINNING ASSEMBLY OR INSTALLATION!
Upon receipt ofyour order, the shipment should be verified to ensure that allparts have reached your site. This
process should occur before the installation process begins. Kratos Defense & Security Solutions, Inc.
thoroughly inspects and carefully packs allequipment before shipment. Ifyou find that there are missing or
damaged components, please refer to the step-by-step instructions (located in back ofthis manual) on how to
properly report equipment loss or damage. When you have received your order, verify that allparts contained in
the shipment correspond to the parts listed on your packing slip/inventory.

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1.0 Recommended Tools & Foundation Preparation
The following sections offer information related to preparing for assembly and installation of the 4.5m Earth
Station Antenna, such as recommended tools and foundation preparation. The details of the A-325 tensioning
procedure, required for the tightening of all A-325 hardware will also be explained.
1.1 Recommended Tools
Kratos supplies allappropriate hardware/parts required for the installation of the 4.5m Earth Station Antenna.
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 tochange without notice. Consult assembly instruction documents,
drawings, and/or Kratos Tech Support if confirmation is needed.
Table 1.1: Recommended Tools
Tool
Size
Qty
Open End Wrench
1/4 Inch
3/8 Inch
1/2 Inch
9/16 Inch
5/8 Inch
3/4 Inch
7/8 Inch
1-¼ Inch
2
2
2
2
2
2
2
1
Drive Sockets
7/16 Inch
9/16 Inch
3/4 Inch
7/8 Inch
1-1/16 Inch
1-¼ Inch
2
1
1
1
1
1
Spud Wrench
1-1/16 Inch
1
Breaker Bar
1/2 Inch
1
Screwdriver
Standard
Philips
1
1
Allen Wrench
1/2 Inch
1
Tape Measure
Standard
1
Felt Tip Marker (or equivalent)
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 (2000lb breaking strength)
50 ft (15.24m)
1
Shackles
5/8 Inch
2
Ladder
10 Foot Extension
1
Nylon Web Sling
3 Inch x 3 Feet
2
Construction Level/Transit with Tripod
20
1

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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.
NOTE: A-325 tensioning is for final connections ONLY. NEVER LOOSEN OR REUSE A-325 HARDWARE.
Points to Keep in Mind:
•“Snug tight” is defined as tightness when plies of joint are in firm contact
•Do not proceed with felt-tip marker or tightening unless connection is final and will not be loosened again
•If after tensioning procedure the bolts are loose, discard them and replace with new hardware
•Do NOT use A-325 tensioning UNLESS SPECIFICALLY CALLED FOR BY INSTALLATION
INSTRUCTIONS
Figure 1-1a: Figure 1-1b:
Bolts Shorter
than 4 Diameters Bolts Longer than 4 Diameters
A-325 hardware should be tightened according to the following tensioning procedure:
Step 1. LUBRICATE the bolts with PROVIDED WAX STICK to reduce friction
Step 2. INSERT THE BOLT and ADD FLAT WASHER (if required). DO NOT allow wax to get under flat
washer
Step 3. ADD THE NUT, and TIGHTEN WITH YOUR FINGERS
Step 4. After all connections are complete, TIGHTEN THE BOLTS until surfaces are joined and nuts are
snug (for example, as achieved by the full effort of a SINGLE person using a standard spud
wrench)
NOTE: If A-325 bolts are loosened AFTER STEPS 5 and/or 6, DISCARD & REPLACE with NEW hardware
Step 5. Using a FELT-TIP MARKER, mark the nuts and ends of the bolts with a straight line as shown above
in Figures 1-1a (Bolts shorter than 4 diameters) and 1-1b (Bolts longer than 4 diameters)
Step 6. TIGHTEN NUTS EVEN FURTHER, using an EXTRA-LONG-HANDLED WRENCH, until the nuts are:
•MOVED 1/3 TURN (120°) as shown in Figure 1-1a, for bolts shorter than 4 diameters (“After
Tensioning”)
Or
•1/2 TURN (180°) as shown in Figure 1-1b, for bolts longer than 4 diameters (“After Tensioning”)

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1.3 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.
•Sweep foundation clear of any dirt or debris
•To ensure smooth surface for mount, scrape foundation pads as shown in Figure 1-2
•To ensure level and smooth surface for mount, remove any excess concrete form the shear caps.
•Apply stick wax to stud threads to ease later connections.
Figure 1-2: Scraping Foundation Pads
1.4 4.5m Assembly &Installation Reference Documents/Drawings
This section provides the Kratos document numbers ofall necessary instructions, drawings, and schematics for
assembly ofthe 4.5m ESA. As these procedures are performed, itisimportant torefer to the appropriate
drawing.
NOTE: It isimportant to match up the appropriate drawings listed inthe below table tothe specific antenna type. Refer to
the Introduction,Section I.I, inthis manual for Top Level Assembly Numbers ifnecessary.
Table 1.2: 4.5m Assembly &Installation Drawings/Instructions
Document/Drawing
ES45T-HW-1
ES45MP-1
ES45MPJ-1
ES45P-1
ES45T-R-1
ES45T-T-1
Med. Modular Mount Install.
237151C
HW Foundation Install.
237746
HW Reflector Install.
239485
4.5m Tripod Feed Support
240385
240385
240385
Motorized Mount Install.
239106
239106
Manual Jack Install.
239318
239318
Manual Actuator Install.
239049
239049
El Jack Adaptor Kit Install.
239381
239381
4.5m Pedestal Foundation
Specs.
37846C
37846C
37846C
Az Bearing Lube Instructions
239495
239495
Handwheel Kit Install.
239365
239365
Lightning Rod Kit Install.
239150
239150
239150
239150
4.5m Manual Pol Interface
240844
240844
240844
4.5m Motorized Pol Interface
240845
240845
240845
Motorizable Mount w/
Jackscrews
240868
Ground Mount Assembly
37852A
37852A
4.5m Tripod Foundation Specs
37690B
37690B
4.5m Tripod Back Structure
Assembly
237106A
237106A
4.5m Tripod Ground Mount
Assembly
37675B
37675B

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2.0 Mount & Antenna Assembly Procedures
These sections provide the basic sequence and tips for the assembly of various elements of the 4.5m ESA.
Appropriate drawings and schematics references for assembly of the antenna are also provided, when
applicable. 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).
•As a rule, never fully tighten A-325 type hardware (see Section 1.2) unless instructed to do so by
instructions. Once tightened, A-325 cannot be loosened. If loosened, it must be replaced with new A-325
hardware.
•The Mount should be assembled at ground level before beginning any hoisting with crane.
•The Reflector & Back Structure should be assembled at ground level before beginning any hoisting with
crane.
•During assembly of the Azimuth Jackscrew, ensure that the Azimuth Jackscrew assembly is in the fully
retracted position.
•During hoisting (with crane) of the Motor/Jack Assembly, do NOT attach any ropes to the Small Motor.
•Always attach hoisting ropes in such a way that moving parts will not drop/rotate when lifted.
•Realignment of the Panning Frame/Pivot Assembly may be necessary to ensure proper alignment of the
Azimuth Jackscrew pin. Make snug the Panning Frame/Pivot Assembly hardware and fully extend the
Azimuth Jackscrew so that binding does not occur along the full range of the Azimuth Pivot.
The following steps represent the recommended (but not required) basic sequence of assembly for this
antenna:
NOTE: More steps may be required, in addition to those listed below, depending on the antenna type and/or the presence
of particular options. Refer to Table 1.2 to locate document numbers for the system being installed. Such documents will
be provided in the shipment of each part, kit, and/or option.
1. Foundation Installation: Refer to instructions per document specified in Table 1.2
2. Mount Assembly: Refer to instructions per document specified in Table 1.2
3. Reflector & Back Structure Assembly: Refer to instructions per document specified in Table 1.2
4. Feed Support Installation: Refer to instructions per document specified in Table 1.2

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3.0 Operation
After assembly of the antenna has been completed, it is time for it to be made operational. It will be necessary
to first direct it to the desired satellite in order to begin operating the Earth Station Antenna, adjusting both the
Elevation and Azimuth angles appropriately. The procedures in the following sections provide details on how to
correctly position the antenna on the desired satellite.
NOTE: Ensure that the proper feed system and all electronics have been properly installed before proceeding.
3.1 Acquiring a Satellite
Steps 1 through 7 below are for initial satellite signal spotting:
Step 1 of 7:Evaluate and determine the required Elevation and Azimuth angles for the satellite of interest.
IMPORTANT NOTE: Steps 2 through 6 below are intended foruse with Pedestal Mounted Antenna systems ONLY
Step 2 of 7:Loosely attach the Manual Actuator Assembly (207882) tothe Elevation strut using appropriate
hardware, as shown in Figure 100b.
NOTE: The drain hole should be positioned downward for proper water drainage.
Step 3 of 7:Ensure that the locking strut support setscrew isfirmly tightened on the Strut Assembly, as shown
in Figure 100b.
Step 4 of 7:Remove the two indicated strut support setscrews, and attach base angle to corresponding strut
support using the supplied ½ Inch clamping nuts and previously removed strut support setscrews, as shown in
Figure 100b.
Step 5 of 7:Securely tighten the remaining mounting hardware to achieve sufficient clamping force.
Step 6 of 7:Repeat the entire process for the remaining Strut Assembly
IMPORTANT NOTE: DO NOT loosen theAzimuth drive bearings
Step 7 of 7:If the antenna is on a Pedestal Mount,move the antenna to the desired Azimuth angle by
adjusting the manual actuator until the satellite signal is spotted. If the antenna is on a Tripod Mount,adjust
the Azimuth strut length through the Fine Adjustment Assembly until the satellite signal isspotted.
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.
While viewing any Spectrum Analyzer screen, a pure noise signal will likely be observed, as shown below in
Figure 3-1.Additionally, some transponder signals may be observed above the noise signal, as shown below
in Figure 3-2.

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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
•Scan in one direction until the amplitude continues to diminish, and then scan in opposite direction until the
same occurs
•Return to the position yielding the greatest amplitude
•The maximum Azimuth excursion from the original setting should not exceed +/- 1.5 degrees, or the
antenna may begin to access a different satellite than the one desired.
Step 2 of 9: With the antenna positioned in Azimuth, with the transponder signal maximized, follow the same
procedure as in Step 1, only this time using the Elevation direction (scanning up-and-down). Once again, do
this until the transponder signal has been maximized.
Step 3 of 9: Repeat this procedure, alternating between the Azimuth and Elevation excursions of the antenna,
until you have peaked the antenna transponder amplitude.

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•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.
Step 4 of 9: If the antenna is peaked on a side lobe in Az or El, move the antenna Azimuth while observing the
Spectrum Analyzer screen, as illustrated below in Figure 3-3.
Figure 3-3: Antenna Radiation Pattern Topographical Diagram w/ Plan View
Step 5 of 9: If the signal amplitude diminishes and does not increase (position B) to the level that was noted
when the antenna was peaked on a side lobe, then this means that the antenna is moving away from the main
beam. Reverse the direction of antenna movement.
•From the original side lobe position (Position A), the signal amplitude should now diminish to a null point at
Position C (minimum amplitude showing only signal noise) and then symmetrically increase again to the
same level at Position D as noted at Position A
•At the null point (Position C), the antenna is aligned with the alternate (El) axis. If antenna was peaked on a
side lobe in Azimuth, it was appropriately aligned with the El axis (go to Step 6).
•If the antenna was peaked on a side lobe in Elevation, it was appropriately aligned with the Az axis (go to
Step 6, moving the antenna in Azimuth rather than Elevation).
Step 6 of 9: Move the antenna in Elevation while observing the Spectrum Analyzer screen. If the signal
amplitude increases, then decreases, and then increases again (but to a lesser value than the first increase),
this means the antenna is moving in the wrong direction. Reverse direction of antenna movement.
•From the original null point, the signal level should increase and decrease alternately, but with increasing
amplitude until transponder signal increases to a level of at least 30 dB, at which time it will be on the main
beam. Continue to manually peak signal to a maximum level, using Azimuth and Elevation adjustments.
Step 7 of 9: If the antenna is aligned in Azimuth and Elevation (signal maximized) and a total of 24
transponder signals of relatively equal amplitude are NOT noted (12 horizontal + 12 vertical = 24), the
Polarization adjustment is set incorrectly and must be modified. Is 12 transponder signals are noted, they may
or may not be the properly polarized signals. Therefore, 24 transponder signals must be visually noted in order
to determine the proper Polarization setting.

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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. Rotate the feed assembly as
required until the appropriate (odd or even) transponder signals have been maximized.
Figure 3-5: Maximizing Odd Transponders

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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.
Step 1 of 3: Remove the Manual Actuator Assembly by first removing the hardware that secures the actuator
to the base angle. Store the manual actuator assembly and corresponding hardware in a dry area for future
use.
NOTE: The Adjustment Kit Assembly should be removed after the antenna has been adjusted.
Step 2 of 3: Remove the remaining clamp segments, along with the corresponding hardware.
Step 3 of 3: After the antenna is pointed at the satellite, tighten all Azimuth and Elevation setscrews to 35 foot
pounds.

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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. Regularly
replacing normally functioning assemblies or components as a preventative measure is not required.
Malfunctions of your Earth Station Antenna can normally be traced to components and/or parts through the use
of troubleshooting procedures.
4.1 General Cleaning
To prevent excessive accumulation of dust and dirt, as well as to ensure the removal of various contaminants,
the equipment needs to be thoroughly cleaned. It is recommended that you clean the antenna every time you
conduct a visual inspection of the components. No special cleaning procedures are required. However, to ensure
trouble-free operation, it will be necessary to clean in accordance with the following procedures (Sections 4.1.1
and 4.1.2).
--------------
4.1.1 Electrical Parts
CAUTION: Confirm ALL ELECTRICAL POWER IS REMOVED BEFORE proceeding.
Minor cleaning, such as the removal of dust and loose foreign particles, can be accomplished by one or all
of the following methods:
•Vacuuming
•Using a soft-bristle brush or lint-free cloth
•Using an air compressor, with dry air at a LOW PRESSURE (between 5 and 25 psi), to blow out dust
and dirt
NOTE: When using air to clear contaminants, take extreme care when blowing air stream on or near ANY delicate parts.
To remove imbedded dirt, grease, and/or oil from electrical parts:
•Use a 50% solution of Isopropyl “rubbing” alcohol
•Apply to surface with a soft-bristle brush
NOTE: At times, it may be necessary to brush some parts vigorously with a stiff bristle brush in order to remove imbedded
or hardened dirt particles.
NOTE: After cleaning, ALLOW CLEANED PARTS TO DRY FOR 10-15 MINUTES before restoring power and/or
returning equipment to operation.
--------------
4.1.2 Mechanical parts
Cleaning of mechanical parts starts by removing dust, dirt, and other loose contaminants by using a scraper,
stiff-bristle brush (or a wire brush is cases of rust or corrosion removal), lint-free cloth, or compressed air
(pressure between 25 and 40 psi). Any accumulation of imbedded dirt, corrosion, grease, or oil deposits
which require more cleaning may be remove with a stiff-bristle or wire brush, in concert with a cleaning
solvent such as acetone (or an equivalent).
NOTE: After cleaning, ALLOW CLEANED PARTS TO DRY FOR 10-15 MINUTES before restoring power and/or
returning equipment to operation.

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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. It is recommended
that the mechanical and electrical inspections be performed on the assembled or partially disassembled
equipment to determine the extent of disassembly required prior to completely disassembling a component or
module that is suspected of malfunctioning. In the absence of any special inspection requirements, operational
tests are the most effective means in isolating parts and assemblies requiring further inspection. During
inspection, any noted damage and/or problematic condition which could preclude the continuation of proper
operation (prior to the next scheduled inspection) should be recorded. These discrepancies should be
immediately corrected (either by repair or replacement, as required), or dealt with immediately after the
inspection procedure has been completed.
CAUTION: Allowing your antenna to continue to operate after damage or discrepancies have been noted during
inspection may result in property damage (especially to your earth station antenna), as well as increase the risk of
creating dangerous situations for personnel, causing personal injury and/or loss of life.
--------------
4.2.1 Local Control/Motor Drive Controller Inspection
Inspection of the Local Control/Motor Drive Controller generally conforms to standard visual inspection
procedures for electromechanical equipment. In addition to such standard procedures, you will need to
perform the following checks and visual inspections for the specific conditions as noted:
•Check the front panel for illegible signage and/or indistinct panel markings
•Check the three (3) position selector switches (Azimuth-Slow/Fast, Elevation-Slow/fast, and Polarization-
CCW/CW) for smooth operation. Note that there is an audible click during actuation (from Left to Center)
for each switch. Note that there is a spring return (from Right to Center). For each of the two Position
Selector Switches (Azimuth-East/West, Elevation-Up/Down, and Local/Remote), individually inspect both
for smooth operation and audible clicks for each actuation
•Inspect all wiring and cables for discoloration, burned insulation, dirt, breaks, secure connections, and
other signs of damage or deterioration. Examine connections for dirt, flux, corrosion, and mechanical
defects. Check for loose or broken lacing, as well as cuts, cracking, dry rot, braiding, or frays
•Inspect all connectors for corrosion, broken inserts, and stripped threads. Inspect connector shells,
checking for distortion and dents. Inspect contact pins for bends, misalignment, and/or other deformities.
Check connector inserts for carbon tracking, burns, or charring, indicating arc-over
•Check all electrical components for dirt, cracks, chips, breaks, discoloration, and any other signs of
damage or deterioration. Discoloration, blistering, or burns are evidence of overload(s). Measure the
actual value(s) of any suspect electrical components (as with a digital multimeter) and compare against
value(s) in the product’s specifications
•Inspect transformer for excessive wax deposits on the surface. Visually inspect for discoloration. Smell
the air around it to check for pungent odors (scents of ozone or burning), which is evidence of
overheating. Overheating may be a precursor to a total breakdown
•Inspect all terminal boards for broken or missing terminals and/or stripped threads. Check the tightness of
lead-attaching hardware
•Inspect each starter for a make-after-break provision, by releasing one pushbutton as the alternate
pushbutton is being simultaneously pressed
•Inspect the relays and contactors for free operation of the armatures and contact condition. The contacts
may still be usable even though pitted, burned, worn, or discolored. Contacts, contactors, or relay
assembly should only be replaced when the contact material has been completely torn away or worn off

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•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. If seals are NOT intact, use a coating of
RTV-108 (silicone rubber sealant) to seal any exposed electrical fittings, bolt holes, or other locations of
possible water entry into the enclosed electrical components in order to maintain a waterproof condition
•Check the humidity absorber and change if necessary
--------------
4.2.2 Antenna Inspection
Inspection of the antenna generally conforms to standard visual inspection procedures performed on
electromechanical equipment. In addition to these procedures, perform the following checks and visual
inspections for the specific conditions as noted:
•Inspect all wiring and cables, particularly the network-to-enclosure and enclosure-to-mount interfaces, for
discolored and/or burned insulation, entry of water/moisture, corrosion, dirt, breaks, secure connections,
and any other signs of damage or deterioration. Examine connections for dirt, corrosion, and mechanical
defects. Check for loose or broken lacing, as well as cuts, braiding, dry rot, or cracks in insulation
•Inspect all connectors for corrosion, broken inserts, and stripped threads. Inspect connector shells,
checking for distortion and dents. Inspect contact pins for bends, misalignment, and/or other deformities.
Check connector inserts for carbon tracking, burns, or charring, indicating arc-over
•Check all electrical components for dirt, cracks, chips, breaks, discoloration, and any other signs of
damage or deterioration. Discoloration, blistering, or burns are evidence of overload(s). Measure the
actual value(s) of any suspect electrical components (as with a digital multimeter) and compare against
value(s) in the product’s specifications
•Operate the Azimuth and Elevation drives, as well as the feed rotation (if applicable) in both the plus and
minus direction from the local control/motor drive controller at least once every three (3) months during
antenna down time. Check to make sure the mechanical Hard Limit switches stop the antenna and feed
movement, and limit travel to prevent structural interference and damage. Check the mechanical Hard
Limit switches for corrosion and water entry. Check the arm on the feed limit switch for free movement,
with no binding or interference. Be certain both of the feed rotation limit switch arms are not distorted and
ride centrally on the actuating cam to open their corresponding Hard Limit switch
•Inspect the Azimuth and Elevation Jackscrew boots for security of attachment at both ends, checking for
abrasions, tears, cuts, dry rot, and other damage that might expose the jackscrew to environmental
conditions (rain/water/ice, dust, etc.). Minor repairs can be made by resealing compromised areas with
RTV-108 silicone rubber sealant
•Visually inspect the feed window for dirt. Check the feed, feed supports, feed window, and reflector for
distortion, foreign object damage, and environmental deterioration (due to snow/ice, rain, hail, high winds,
etc.). Environmental deterioration can result in damage and/or deformation of both the electrical
components and the structure
•Check the cable attachment to the resolvers, to the LNA/LNB, and the enclosure-to-mount interface for
security. Check the cable routing for secure hanger attachment. Check cable insulation for cuts, cracks,
abrasions, and other signs of damage or deterioration. Check LNA/LNB and resolvers for secure
mechanical attachments. Ensure there is proper torque in setscrews of Polarization drive gear box, and
proper tensioning of corresponding drive chain assembly (if applicable)