Andrew ES76PK-1 manual

Andrew Cor poration 10500 West 153rd S treet Orland Park, IL U.S.A. 60462 T elephone: 708-349-3300 F AX (U.S.A.): 1-800-349-5444 Internet: http://www .andrew .com Customer Service, 24 hours: U.S.A. • Canada • Mexico: 1-800-255-1479 U.K.: 0800 250055 • Republic of Ireland: 1 800 535358 Other Europe: +44 1592 782612 16 August, 2005 Copyright ©[...]

Introduction How to Use This Manual Getting Star ted Installation Procedures Operation Prev entive Maintenance T able of Contents 2 T a ble of Contents Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Proprietary Data . . . . . . . . . . . .[...]

Introduction Like all Andrew earth station antennas, the 7.6-Meter Earth S tation Antenna provides high gain and exceptional pattern characteristics. The electrical performance and excep- tional versatility provides the ability to configure the antenna with your choice of linearly- or circularly-polarized 2-port or 4-port combining network. That ve[...]

24-hour T echnical Assist ance For technical assistance, call the following numbers at anytime. Call From Call T o T elephone Fax North America (toll free) U. S. A. 1-(800)-255-1479 (800)-349-5444 Any Location U. S. A. (708)-349-3300 (708)-349-5410 (International) Customer Service Center The Andrew Customer Service Center gives you direct access to[...]

Ov er view Content The scope of this manual is intended to provide station personnel with the base inst alla- tion, operation, and maintenance requirements necessary for a 7.6-Meter C-, X- or Ku- Band Earth S tation Antenna. This manual provides a convenient reference for autho- rized operator/service personnel requiring technical information on ge[...]

Ov er view Warnings The installation, operation, and maintenance of the 7.6-Meter Earth S tation Antenna requires qualified and experienced personnel. Andrew installation, operation, and main- tenance instructions are illustrated for such personnel. Additionally , the antenna should be inspected by qualified personnel to verify proper installation,[...]

R ecommended T ools NOTE: Failure to follow an installation procedure could result in damage to equipment or personal injury . Additional warnings will be displayed throughout this manual for your awareness. These warnings can be identified in warning boxes as shown in the following sample. Andrew disclaims any liability or responsibility for the r[...]

Par ts V erification R e por ting Equipment Loss or Damage R e por ting Visible Loss or Damage R e por ting Concealed Damage Inv entor y Equipment R eceiv ed Upon receipt of your order , the shipment should be verified to ensure that all parts have reached your site. This process should occur before the inst allation process begins. Andrew Corporat[...]

R etur ning Equipment Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Andrew Corporation tries to ensure that all items arrive safe and in working order . Occasionally , despite these effort s, equipment is received which is not in working condi- tion. When this occurs, and it is necessary to return the equipment to Andrew Corporation for either repair or [...]

Ov er view Founda tion Pre paration 10 Installation Procedures This section provides installation procedures for the 7.6-Meter Andrew Earth S tation Antenna. The inst allation procedures include instructions on the following antenna com- ponents: • Mount • Reflector-to-Mount Assembly • Reflector • Subreflector • Enclosure Before beginning[...]

A-325 T ensioning Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 11 During the installation process, there are several references to the A-325 hardware ten- sioning procedure. The A-325 hardware must be properly tensioned to avoid slippage between bolted surfaces under high loads. Slippage can cause the corresponding assembly to move, causing ante[...]

P edestal Ground Mount Assembly P edestal Installation Ste p 1 Ste p 2 12 The Pedestal Mount is an elevation-over-azimuth mount optimized for geost ationary satellite applications. The mount enables continuous elevation adjustment from 0 to 90 degree. The azimuth axis has over 180 degrees of travel with 120 degrees (+/-60 deg.) of continuous travel[...]

Ste p 3 13 Using the 1-1/4 in. foundation hardware supplied, level the pedestal to within +/-0.1 degrees. T ighten each anchor bolt to 912 lb/ft (126 kg/m) as shown in Figure 4. Note: T ighten each bolt using no more than 300 lb/ft (41.5 kg/m) at a time in tightening sequence shown. • Use 1-1/4 in. flatwashers and hex nuts. Installation Procedure[...]

Ste p 4 Ste p 5 Ste p 6 Azimuth J ack Ar m Installation Ste p 1 14 Place Anchor Plates (17531 1) over the corresponding anchor bolts as shown in Figure 3. Note: Ensure anchor plates are oriented on the foundation bolt s as shown, level and on same datum as the pedestal assembly . Using the foundation supplied hardware, tighten each anchor bolt to 9[...]

Azimuth J ackscrew Assembly Ste p 1 16 Raise the Azimuth Jack assembly into place and attach it to the pedestal assembly as shown in Figure 7. NOTE: The bolts att aching the trunnion to the jack are supplied loose, this hardware must be torqued once the jack is installed and aligned (see Figure 7). • Install Azimuth T runnion Pin (302164). • Us[...]

Ste p 2 17 Attach Azimuth Jack rod end assembly to the Azimuth Jack Arm as shown in Figure 8. • Use Azimuth Pin (302168) and 3/8 x 1 in. capscrew , washer and lock washer . Installation Procedures Figure 8 (AZ Jack Pin, 302168) 1-1/4” W asher, 9997-188 (2) (AZ Jack, 302281) AZ Jack Pin, 302168) (302383) 3/8”x1.0 Bolt, 9963-632 Lockwasher , 99[...]

Ele v ation J ackscrew Assembly Ste p 1 19 Installation Procedures Raise and attach the Elevation Jack assembly to the pedest al assembly as shown in Figure 10. Fully retract the Elevation Jack to it’s minimum length. NOTE: The bolt s attaching the trunnion to the jack are supplied loose, this hardware must be torqued once the jack is installed a[...]

R eflector/ Backstructure Assembly Ste p 1 20 Installation Procedures Figure 1 1 W ARNING Assembly and installation of Reflector/Backstructure should only t ake place when winds are less than 15 mph (24 km/h) to prevent damage to reflector panels and ease the assembly process. Follow special instructions stenciled on crate relative to crate opening[...]

Ste p 2 Ste p 3 21 Installation Procedures Once all 16 Short S truts are inst alled and securely fastened, re-install Rear Enclosure Panel. Carefully rotate the enclosure right-side-up as shown in Figure 12. Place tempo- rary wood blocks under each of the enclosure’s three support p ads with the additional block positioned in between. Install Rib[...]

Ste p 4 22 Installation Procedures Install Outer S trut to assembly as shown in Figure 13. Leave hardware loose. Figure 13 V iew A-A Eccentric Bolt, 300084A W asher, 9997-101 1/2” Locknut, 9979-54 (Outer S trut, 300079) Outer S trut, 300079 V iew B-B 1/2”x1/2 Shoulder Bolt, 9858-19 1/2” W asher, 9997-101 3/8” W asher, 9997-89 3/8” Lockwas[...]

Ste p 5 23 Installation Procedures Lift truss/rib assembly and inst all Long S trut as shown in Figure 14. Note: the Long S trut is installed on the opposite side of the T russ Plate. Refer to Figure 12, View D-D for pre- viously installed hardware for Inner S trut to T russ Plate connection. Leave hardware loose. Figure 14 Long S trut, 300076 (Inn[...]

Ste p 7 24 Installation Procedures Attach stretch-formed Skirt s (222765-2), S trip S pacer (300040) and Inboard Skirt (300082-2) to Reflector Panels (222677) before attaching p anels to ribs. Refer to Figure 15, Section A-A & View B-B. Do not inst all outer-most screw on each side of skirt at this time. NOTE: Do not overtighten skirt panel scr[...]

Ste p 8 Ste p 9 Ste p 10 25 Installation Procedures Attach the reflector p anels by placing them on the ribs and sliding them inward, carefully guiding the rib flange between the skirt and panel. Place seam hardware (209236 & 9974-17) in the fourth hole from the outboard edge on both sides of the panel first, fin- ger tight only . Then place al[...]

Ste p 11 26 Installation Procedures After all 16 reflector p anels are fastened to ribs. Attach the Cross S truts (300078) by placing them in-between the Inner S truts (300080) and snug tight the hardware. Refer to Figure 16. After all 16 Cross S truts are attached, tighten all hardware. NOTE: The Cross S truts are the last item to be assembled to [...]

Customer-Supplied Theodolite Wild Heerbrugg T2 or T opCon Digital DT -05 or 05A X-Y Dual Axis Translation S tage Rotary Precision Lift (Rotate to Adjust Height) 18.050” (458.47mm) Support Assembly , 223712 R eflector Alignment T heodolite Installation Ste p 1 Notice T emperature change during calibration or alignment of this reflector will advers[...]

1.3 Install Brass Rod Holders: Install brass rod holders in seam hole #1 1 on rib #2, 7, & 10 in Figures 19 and 20. Reflector seam screws must first be removed in these locations. Make sure the bottom of the rod holders are sitting flush on the reflector panels and they are pointed toward the theodolite assembly . Attach the alignment stick to [...]

Ste p 2 1.5 “Clock" the Theodolite Assembly: Refer to Figure 20. The theodolite support assembly must be 'clocked' to the brass rod holders such that two of the tribrach leveling screws run parallel with ribs 2 and 10 (see enlarged view in Figure 20). This can be accomplished by rot ating the top flange of the torque tube which wil[...]

30 Installation Procedures Relocate stick to rib #7. Rotate theodolite, focus and adjust elevation to the scribe line and record this reading as R2. Relocate stick to rib #10. Rotate theodolite, focus and adjust elevation to the scribe line and record this reading as R3. Calculate an average angle by adding R1, R2, & R3 together and dividing by[...]

31 Installation Procedures Repeat the above procedure for the other axis of the X-Y translation st age 90 degrees to the first one. After centering, adjust the theodolite height as indicated below . 2.4 Adjust Height: The height adjustment of the theodolite is accomplished with the precision lift (refer to Figure 18). This device can lower or raise[...]

32 Installation Procedures Ste p 3 R eflector Alignment Relocate the stick to rib #7. Focus and adjust the elevation to align to stick scribe line. Reord as H3. The specification for height requires that H1, H2 & H3 be within +/-15 seconds (0.0042 degrees) of 90 degrees. This can only be achieved through successive leveling/center- ing sequence[...]

33 Installation Procedures 3.3 Rough Outboard Alignment: Adjust theodolite elevation angle to the ‘EL1’ value indicated in Figure 19. Point and focus the scope of the theodolite to target EL1 (do not move elevation) located on the rib #1, which is to the right of the top panel (top center of antenna with Andrew `Flash’ logo). While still focu[...]

3.5.3 Repeat all 16 adjustments again. This time, after each individual adjustment, fully tighten seam hardware #24 and 25 on the rib being adjusted. The outer ring of the reflector is now `locked’ in place. 3.6 Fine Inboard Alignment: NOTE: During seam hardware tightening as described in `Fine Inbard Alignment’ t ake extra pre- caution not to [...]

R eflector to Ground Mount Assembly Ste p 1 35 Installation Procedures Attach 16f t. (5m) chokers with corresponding 5/8” shackles to the Lifting T abs (206278). Attach 30f t. (9m) tag lines of suitable rope equally sp aced about reflector (refer to Figure 22). Note: Ensure ground mount pedestal assembly has elevation jack in the fully retracted [...]

Subreflector Installation Ste p 1 Ste p 2 36 Installation Procedures NOTE: Ensure that the Feed System is installed prior to inst allation of Subreflector and S truts. Place the reflector in the zenith (EL = 90 deg.) position. Refer to Figure 23. Loosely assemble Subreflector S trut Assembly (300092) as shown using supplied Angles (300088), Subrefl[...]

Ste p 3 Ste p 4 37 Installation Procedures Refer to Figure 23, View A-A and Figure 24. Loosely att ach Subreflector S trut Supports (300089) to panel segement s 8-16, 3-1 1, 7-15 and 4-12 as shown. Replace screws, washers, lockwashers and nuts previously inst alled during reflector assembly . NOTE: Subreflector S trut Supports should be positioned [...]

Ste p 5 Ste p 6 38 Installation Procedures Carefully raise and attach pre-assembled subreflector/strut assembly to corresponding subreflector strut supports as shown in V iew A-A (Figure 23) and Figure 25 using sup- plied hardware. Securely tighten all subreflector/strut assembly mounting hardware except for floating ring hardware shown in Figure 2[...]

Subreflector Centering Ste p 7 Subreflector Focusing Ste p 8 Ste p 9 39 Installation Procedures Measure and note the distance between outermost subreflector strut support bolt head and the subreflector rim as shown in Figure 25. Obtain corresponding measurement s from remaining subreflector struts. These measurements should have a maximum differ- e[...]

Ov er view Acquiring A Satellite 40 Operation After you have completed the assembly of your antenna, you are now ready to become operational. In order to operate the earth station antenna, you will need to direct it to the desired satellite adjusting both the elevation and azimuth angles appropriately . The fol- lowing procedures provide details on[...]

Ste p 1 Ste p 2 Ste p 3 Ste p 4 41 The following steps provide the procedure for acquiring a satellite. Manually move the antenna in the azimuth (scanning back-and-forth) to achieve the maximum (greatest amplitude) transponder signals. • Scan in one direction until the amplitude continues to diminish and then scan in the opposite direction until [...]

Ste p 5 Ste p 6 Ste p 7 Ste p 8 42 If the signal amplitude diminishes and does not increase (position B) to the level noted when the antenna was peaked on the side lobe, the antenna is moving away from the main beam; reverse the direction of the antenna movement. From the original side lobe position (position A), the signal amplitude should now dim[...]

Ste p 9 43 With all 24 transponder signals of approximately equal amplitude appearing on the spectrum analyzer screen determine the specific antenna system and satellite parame- ters. Rotate the feed assembly as required until the appropriate (odd or even) transpon- der signals are maximized. Figure 4-5: Maximizing Odd T ransponders Figure 4-6: Opt[...]

Subreflector Adjustment Sur viv al Struts 44 Operation After the satellite has been acquired and testing has t aken place with the spectrum analyzer , the subreflector may need to be adjusted to maximize optimum performance of your anten- na. The following procedures should be followed if a subreflector adjustment is required to maximize optimum pe[...]

Ov er view General Cleaning Electrical Par ts 45 Prev entiv e Maintenance This section contains periodic preventive maintenance instructions for the 7.6-Meter Earth S tation Antenna. Included in this section are inspection and preventive mainte- nance procedures including cleaning and lubrication, painting, and an operational volt- age/current chec[...]

Mechanical P ar ts Machined Surfaces (Not Galv anized) Inspection Local Control/Motor Driv e Controller 46 Clean mechanical part s by first removing dust, dirt, and other loose contaminants with a scraper , stiff brush (bristle or wire in the case of rust or other corrosion), or cloth or com- pressed air at 25 to 40 psi. Any accumulated imbedded di[...]

Antenna 47 • Check all electrical components for dirt, cracks, chip s, breaks, discoloration and other signs of deterioration and damage. A discolored, blistered, or burnt condition is evidence of overload. Measure actual value of suspect electrical components and comp are against specified value. • Check transformer for an excessive wax deposi[...]

48 • Check all electrical component for dirt, cracks, chips, breaks, discoloration, and other signs of deterioration and damage. A discolored, blistered, or burnt condition is evidence of overload. • Operate the azimuth and elevation drives as well as the feed rotation in both the plus and minus direction from the local control/motor drive cont[...]

Driv e System V olta g e and Cur rent Checks Ste p 1 Ste p 2 Ste p 3 49 • Visually inspect all mechanical p arts for freedom of operation with no misalignment, binding or interference. Check all cabling for sufficient slack to prevent cable strain as well as adequate restraint to prevent abrasion or chaffing during antenna and feed movement. • [...]

Ste p 4 Ste p 5 Ste p 6 Ste p 7 Ste p 8 Ste p 9 50 the installation/accept ance check off. If the readings differ by more than five percent, refer to appropriate troubleshooting information and perform applicable corrective action. Then take volt age readings off each of the three conductors; the readings should agree with each other within two per[...]

Preser v ation of Component Par ts Aluminum P ar ts Galv anized Surfaces Lubrication 51 When preserving the component part s, refer to the following paragraphs in this section. Remove all loose paint and corrosion by scraping, wire brushing, or using steel wool. If using steel wool near the feed window , make sure that none remains on the feed horn[...]

J ackscrews/Motors Gear Motor/Housing Fill Drain R equirements 52 and remove any old lubricant to prevent an excessive build-up. Remove indicated access plugs from square tube weldment and apply lubricant to panning frame tube assembly and corresponding thrust pads. Securely replace access plugs in square tube weldment. Be certain to remove any pro[...]

53 Prev entiv e Maintenance Lube Components Frequency T ype T ype No. of Lube Point to be (Months) of of Points or No. Lubricated 1361 2 Service Lube Quantity 1. Azimuth/Elevation Jackscrew Housing X Pressure Fitting SHC32 1 2. 1 Azimuth/Elevation Jackscrew Gear I* C** Pipe Plugs SHC624 10 Oz Housing Fill and Drain 3. Polarization Drive Gear X Brus[...]

Antenna Lubrication Points 3 4 1 2 Local Motor Control 54 Prev entiv e Maintenance Gearbox Drain Gearbox Level Pressure Fitting 5 Pressure Fitting 5 Pressure Fitting 6[...]