Transcript
RTU TOWER I N S TA L L AT I O N P R O C E D U R E
October 3, 2007
N OT ICE D ata F low Sy stems , Inc . as sume s no res p ons ibility for any err or s t hat may appe ar in this d ocume nt, nor d oe s it ma ke a ny c omm itme nt t o u pda te t he inf orm at ion c onta i ned here in. Howe ver, que st ions r egard ing t he inf orma tio n c o nta in ed in t h is do cume nt are w e lco m e d . D ata F lo w Sy stems a ls o re ser ves t he r ig ht t o ma ke c h an ges to the RTU t ow er i ns ta l lati o n p r oc e d u r e a n d t o t he inf or m a t i on c o n t a i ned i n t h is d oc umen t at any t ime w it h out n o ti ce. ©Data Flow Systems, Inc. 6 0 5 N . J o h n R od e s B lvd. , Me l bo u r ne , F L 3 2 93 4 P h o ne 3 21 - 25 9 - 5 0 09 • F a x 32 1 - 25 9 -4 0 0 6
Table of Contents Purpose................................................................................................................................ 1 Overview............................................................................................................................. 1 Step 1: Choosing and Preparing the Site............................................................................. 2 Step 2: Excavation .............................................................................................................. 2 Step 3: Install Conduit ........................................................................................................ 2 Step 4: Erect Tower (Stage 1)............................................................................................. 2 Step 5: Concrete pour.......................................................................................................... 3 Step 6: Affix Antenna ......................................................................................................... 3 Step 7: Assemble Coax ....................................................................................................... 4 Step 8: Erecting Tower (Stage 2)........................................................................................ 5 Step 9: Grounding ............................................................................................................... 6 Appendix A: Required Materials ........................................................................................ 8 Appendix B: Required Tools .............................................................................................. 9 Appendix C: 21’ 1-14” Mast 150MPH Wind Rated DFS Radio Tower ............................ 9
Purpose This manual is a reference guide for installing one of the many radio tower designs available from Data Flow Systems. The materials, tools, components and procedures necessary for constructing and installing the 21’ 1-14” Mast 150MPH Wind Rated Data Flow Systems (DFS) radio tower are provided, but the information can easily be adapted to any of DFS’ radio tower designs. Drawings for other DFS’ radio towers can be found on the DFS website (http://www.dataflowsys.com/products/antenna-hardware.php). The drawing for the 21’ 1-14” Mast 150MPH Wind Rated Data Flow Systems (DFS) radio tower can be found in Appendix C.
Overview The following paragraphs provide a brief synopsis of the procedure for constructing a DFS radio tower. Familiarize yourself with the drawing for the type of radio tower being installed before beginning the installation. The drawing for the 21’ 1-14” Mast 150MPH Wind Rated Data Flow Systems (DFS) radio tower can be found in Appendix C. Drawings for other DFS’ radio towers can be found on the DFS website (http://www.dataflowsys.com/products/antenna-hardware.php). • •
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A variety of Yagi and Omni antennas are affixed to a 21' X 1-1/2” SCH40 galvanized pole. This pole is inserted into a top tower section; the top tower section is attached to a mid tower section. RTC400 or RTC600 coax that has been terminated with a male connector and sealed with heat shrink is affixed to the antenna. The coax is secured to the pole and tower section with EVA-coated, stainless-steel cable ties. The other end of the coax is terminated to a DFS enclosure or polyphaser-mounted ground lug located near ground level. These enclosures are either attached to the base of the tower two feet above ground level or in close proximity. A hole that is four feet deep and two feet square is excavated. The entire antenna structure is stabbed into the hole at a depth of six inches into the ground. The hole is filled with concrete after the antenna structure is set. A concrete slab that is two-feet square and extends six inches above ground level is built using forms. A #6 solid-copper wire installed between a 10' X 5/8” copper ground rod and the tower itself provides temporary grounding for the tower. Permanent grounding, completed at the time the DFS enclosure is affixed to the tower base, is provided by a #6 solid-copper wire making a continuous connection between a 10' X 5/8” tower ground rod, the tower itself, the local utility grounding rod, and the DFS control enclosure.
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Step 1: Choosing and Preparing the Site Locates Locates for buried utility wiring and plumbing, i.e., liquid gas, natural gas, power, telephone, water, data, etc. must be completed before construction begins. Obstructions Visually survey they site for obstructions such as overhead phone lines, power lines, trees or cable before beginning the installation. Ensure that there is a minimum distance of 10 feet between the antenna structure and any aerial power lines. If other utility boxes are present, verify that there is adequate clearance for access to all existing panels (ensure that the tower or tower pad doesn’t block and panel doors).
Step 2: Excavation In the designated location, excavate a hole that is four-feet deep and two-feet square.
Step 3: Install Conduit Run 1” conduit between the DFS enclosure (most likely attached to the base of the tower), and an adjacent panel. Set the conduit 1-1/2” directly in front of the left RTU/CTU tower leg (see RTU Mounting or Conduit Detail on site drawings for further description) and a minimum of four feet above the finished concrete, unless otherwise specified. Position the panel end of the conduit so that it rises in an appropriate fashion to facilitate future connection and has an initial height of four feet above the finished concrete. Bury the conduit at a depth consistent with N.E.C. and local code. Place a line suitable as a wire fish in the conduit. Seal both ends of the conduit ensuring that the fish line extends outside the conduit on both ends. If analog wires are to be run, install a 3/4” conduit in a similar manner. Install the 3/4” conduit approximately 4 inches to the right of the 1” conduit. Refer to site drawings for further clarification.
Step 4: Erect Tower (Stage 1) Tower construction is accomplished in two stages. In the first stage, the bottom section is placed in the excavated hole. It is then embedded in concrete. After the concrete has cured, the upper section, pole, antenna and coax is installed. Stage 1: Place the tower bottom section into the hole excavated in step 2, above. Stab the legs 6 inches into the ground.
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Step 5: Concrete pour 1. Mix sufficient concrete to fill the hole approximately two feet deep to ground level. Check the tower for plumb; adjust if necessary. 2. Center the two-foot square concrete form around the base of the tower. 3. Mix the remaining concrete. Pour the concrete into the hole until it is level with the top of form. Check the tower for plumb; adjust if necessary. 4. Use a trowel to give the concrete a professional finish. 5. Before the concrete starts to harden, place a six-inch piece of 1” PVC nipple in the concrete. Line up the nipple with the center of pole leaving three inches above the surface of the concrete. Periodically check the nipple as you clean up the site to ensure that the nipple does not shift as the concrete hardens.
Step 6: Affix Antenna Yagi Antenna 1. Mount the Yagi antenna so that the elements are parallel to the galvanized pole and the first element is even with the top of the pole. Orient the antenna so that the coax connector is above the antenna shaft. Tighten the bolts on the bracket until the antenna bracket begins to flex. Alternately tighten the four nuts to achieve a parallel alignment. 2. Securely attach the 1-1/4” galvanized pipe cap to the top of the 21-foot galvanized pole. Spray the pipe cap and pipe threads with Zinc-It. 3. Proceed to Step 7: Assemble Coax. Omni Antenna 1. Mount the Omni antenna using the two DB375 mounting brackets that come with the antenna. Affix the antenna mast to the 1-1/4” pole so that the uppermost mounting bracket is 2 inches below the top of the pole. Mount the lower bracket one foot below the upper bracket. Approximately 2 inches of the antenna mast will protrude below the lower mounting bracket. Mount the coax connector in the face down position. 2. Securely attach the 1-1/4” galvanized pipe cap to the top of the 21-foot galvanized pole. Spray the pipe cap and pipe threads with Zinc-It. 3. Proceed to Step 7: Assemble Coax.
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Step 7: Assemble Coax 1. On the antenna end of the coax, make a clean square cut on the coax cable. Our installation department uses a stripper that has two ends that are marked 1 and 2. This stripper is to be used first with the end marked 1 and then with the end marked 2. 2. There are three pieces in the coax connector kit: an aluminum collar or sleeve, the main body of connector (the threaded end) and a brass ferule shaped like a needle. Place the collar on the coax, and slide it back at least six inches. Insert the cable in the stripper side marked 1 and twist. 3. Insert the coax into the stripper side marked 2 and twist. Using a fine pair of wire strippers (tiny wire cutters), remove excess shielding from the center copper wire. Take care not to scratch the copper center conductor - the frequency travels on the outside of the copper center conductor. 4. To crimp the coax, place the copper ferule on the center conductor. Using the proper crimper, crimp the ferule to the center conductor. Only one side of the crimper will crimp correctly, so make sure to use the side that has a hexagon (six sided) shape to it and the correct size for RTC400 or RTC600 coax. 5. Spread the aluminum wire away from the center conductor. Using the fine cutters, trim the excess aluminum wire to about 3/8-inch. Slide the main body of the connector over the coax small end first. Slide the collar up until it fits squarely on the shoulder of the small end of the main body of the connector. This should bring the aluminum wire between the main body and the collar. Trim any excess wire protruding from the collar. 6. Crimp the collar using the large hexagonal end on the crimper. Rub an index finger across the large end of the coax connector. You should be able to feel the copper ferule in the middle, and it should be in the center of the connector. Grasp the connector with one hand and the coax in the other. With a medium amount of force, try to pull the connector off. If the connector comes loose or you can’t feel the copper ferule, repeat the coax connector assembly with a new connector kit. 7. To attach the coax, slide a one inch shrink tube over the antenna coax end, attach the coax to the antenna, and tighten until snug by hand. Slide heat shrink up to antenna connector and shrink to fit with a propane torch or heat gun. 8. Run coax along width of antenna back to pole. In between the two U-bolts that hold the antenna to the 1¼-inch pole, tie strap the coax to the antenna bracket using a bandit (steel vinyl coated tie strap). Route the coax about eight inches away from the assembly to form a service loop. Route the coax along the length of the pole and tie off with bandit every 18 inches to within 18 inches of the end of the pole.
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Step 8: Erecting Tower (Stage 2) Before proceeding, ensure that sufficient time has passed to allow the concrete to properly cure. 1. Remove the galvanized dip seal from the neck of the top tower section. The best method for removing the dip seals is to loosen it with a hammer and then pry it out with a pipe wrench. Liberally spray the area with Zinc It. 2. Climb the tower and attach the gin pole near the top of the tower. Extend the pole. Have personnel on the ground secure the gin pole line to the upper portion of the upper tower section and hoist upward. Align and mate the three legs of the top tower section to the middle tower section using three 5/16” and three 1/4” stainless steel nuts and bolts. 3. Move the gin pole to the top of the tower and extend the pole. Have personnel on the ground attach the line to the antenna and pole assembly and hoist upward. Align a 11/4” antenna pole into the neck of the upper tower section. Have the ground personnel gradually lower the pole until the bottom of the pole sits on the 1” conduit in the concrete base. 4. Obtain the azmyth. Aim the antenna towards that direction. 5. Insert a 3/8"-16 S.S. square nut into the nut sleeve on the neck of the top tower section. 6. Thread a 3/8"-16 X 1-1/2” S.S. bolt into the square nut and firmly tighten to keep the galvanized pipe from moving. Do not over-tighten and dislodge the nut sleeve. 7. While descending the tower, affix the coax to the rear leg of the tower every 18 inches. Loop an adequate amount to complete the coax run to the DFS enclosure or the contractor installed equipment. Tie off the excess coax using electrical tape or a wire tie. Tape the exposed end of the coax with electrical tape. Remove the concrete pad forms.
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Step 9: Grounding
Wear high voltage gloves (1000 VAC protection) when performing this procedure Note: Underground locates must be complete prior to proceeding. Grounding for the tower and DFS equipment is provided by a #6 solid bare-copper wire having a continuous connection (no splices) between a 10' X 5/8”tower ground rod , the tower, the local utility grounding rod and the DFS polyphaser mounted ground lug. Refer to the illustrations below and on the next page. 1. At a position adjacent to the concrete pad nearest to the back of the tower's rear leg, drive the 5/8” X 10' ground rod into ground until it is just below the concrete pad. 2. Grounding: Determine if the site work has been completed. • Temporary Ground (site work not complete): Run a #6 bare copper wire between the copper grounding rod and the tower base. Attach the wire to the ground rod with a 5/8” tear drop ground lug. Use a 1-1/4” ground clamp with copper screw to attach the temporary ground to the tower leg. • Permanent Ground (site work complete): Install a continuous run of #6 barecopper wire between the grounding rod, the tower, the local utility grounding rod, and the DFS enclosure or polyphaser-mounted ground lug. Use a 1-1/4” ground clamp with copper screw on the tower leg adjacent to the concrete. Grounding to the ground rods should be done with a 5/8” tear drop ground lug. Illustration – Ground wire connected to RTU Polyphaser
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Illustration – Ground wire connected to Tower
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Appendix A: Required Materials 21-Foot 1-1/4” Mast 150 MPH Wind Rating Assembly - Drawing # DFS-00355-008-01 (see Appendix C) Part Number
Description
Quantity
003-0125
1-1/4" SCH40 Galvanized Pipe Cap
1
004-0118
21' X 1-1/4" SCH40 Galvanized Pole (Antenna Pole)
1
005-0048
9' Top Tower Section
1
005-0034
10' Middle Tower Section
1
003-0053
3/8"-16 S.S. Square Nut (Tower )
1
003-0052
3/8"-16 X 1-1/2 S.S. Bolt ( Tower )
1
003-0062
5/16"-24 X 1-1/2" S.S. Bolt ( Tower )
3
003-0061
5/16"-24 S.S. Nut ( Tower )
3
003-0038
1/4" -20 X 1-1/2" S.S. Bolt
3
003-0037
1/4” -20 S.S. Nut
3
020-0001
1” Shrink Tubing
1 foot
003-0082
Zinc It (Zinc-Rich Cold Galvanizing Spray Can)
1
020-0016
Band-It Stainless Steel E.V.A. Coated Cable Tie
12
004-0017
1” PVC Male Adapter
2
004-0002
1” Locknut For PVC Male Adapter
2
004-0011
1” PVC 90-Degree Elbow
2
004-0018
1” PVC SCH 80
20 feet
004-0060
5/8” x 10' Grounding Rod
1
003-0019
# 6 Bare Copper Wire
25 feet
004-0059
5/8” Tear Drop Ground Lug
2
004-0070
1-5/8” Ground Clamp With Copper Screw
1
019-0063
RTC400 Coax Cable
25 feet
016-0058
RTC400 Coax Cable Male Connector
1
Appropriate Antenna Assembly with bracket
1
Concrete Mix (Dry) (30-31 60lbs bags)
1,800 lbs.
Concrete Form, 2-feet square, 2 piece
1
Water
30 gallons
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Appendix B: Required Tools 1. Digging tools: pick-ax, shovel, post hole digger 2. Wheel BARROW, INDUSTRIAL 3. Concrete mud hoe 4. Water bucket, 5 gallon 5. 4-foot level 6. Pipe wrench, minimum 2” jaws 7. PVC cutters 8. Large flat blade screwdriver 9. Heavy-duty portable battery-powered drill 10. 24” X 24” X 6” concrete form 11. Stripper – RTC400 or RTC600 cable 12. Crimper - RTC400 or RTC600 cable 13. Magnetic compass 14. High voltage gloves 15. Portable torch/heat gun 16. Wrenches: 1/2”, 9/16”, 5/8” 17. Lineman's pliers 18. Ground rod driver 19. 1” metal hole saw 20. Erection fixture (gin pole) EF2545
Appendix C: 21’ 1-14” Mast 150MPH Wind Rated DFS Radio Tower Note: Drawings for other DFS’ radio towers can be found on the DFS website (http://www.dataflowsys.com/products/antenna-hardware.php). The drawing on the next page is provided in an 11”x17” size for readability.
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©Data Flow Systems, Inc. 6 0 5 N . J o h n R od e s B lvd. , Me l bo u r ne , F L 3 2 93 4 P h o ne 3 21 - 25 9 - 5 0 09 • F a x 32 1 - 25 9 -4 0 0 6 w w w. d a t a f low s y s . c om
