Andrew 7.6-Meter ESA manual

Andrew Cor poration 10500 West 153rd Street 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 26 September, 2006 Copyright ?[...]

Introduction How to Use T his 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[...]

Proprietar y Data Infor mation and Assistance Notice T echnical Assistance The technical data contained herein is proprietary to Andrew Corporation. It is intended for use in operation and maintenance of Andrew supplied equipment. This data shall not be disclosed or duplicated in whole or in part without express written consent of Andrew Corporatio[...]

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

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 epor ting Equipment Loss or Damage R epor ting Visible Loss or Damage R epor 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 installation process begins. Andrew Corporation [...]

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 installation procedures include instructions on the following antenna com- ponents: • Mount • Reflector-to-Mount Assembly • Reflector • Subreflector • Enclosure • Feed System ([...]

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[...]

T ripod Gr ound Mount Assembly Azimuth Beam Assembly Ste p 1 Ste p 2 Ste p 3 12 The three-point mount is an elevation-over-azimuth mount optimized for geostationary satellite applications. The mount enables continuous elevation adjustment from 0 to 90°. Azimuth adjustment is ±90° and divided into three 120° ranges with 30° overlap. Follow the [...]

Suppor t Le gs Assembly Ste p 1 Ste p 2 13 Attach 201327A joint assembly to 201313A beam assembly as shown in Figure 5. Attach 200083 angles to 201313A beam assembly as shown in Figure 5. • Use 7/8 x 2-1/4 in (57 mm) bolts and nuts for each connection Installation Procedures Figure 5 Attach 200088A joint assembly to 201313A beam assembly as shown[...]

Ste p 3 Ste p 4 14 Raise 201313A beam assembly to upright position and attach 201315 supports to 201327A joint assembly as shown in Figure 7. • Use 7/8 x 2-1/4 in. (57 mm) bolts and nuts. • Insert bolt s from 201327A joint assembly to supports. • Supports should be installed back-to-back with the flat of angle facing upwards. • T ighten sup[...]

Ste p 5 Ste p 6 15 Attach 201314 supports to 201301/201302 rear pad assemblies and 200884 joint assembly as shown in Figure 9. • Use 7/8 x 2-1/4 in. (57 mm) bolts and nuts • Insert bolt from inside of joint assembly to outside of support • Supports should be installed back-to-back with the edges forward and the flats of angles facing rear Ins[...]

Panning Frame Assembly Ste p 1 16 Attach 201487 panning frame to 221384 azimuth pivot assembly as shown in Figures 1 1 and 12. • Use 7/8 x 2-1/4 in. (57 mm) hardware • Bolts should connect from panning frame to pivot assembly Installation Procedures Figure 1 1 Figure 12[...]

Ste p 2 17 Attach 221608 joint assemblies to panning frame as shown in Figures 13 and 14. • Use 7/8 x 2-1/4 in (57 mm) hardware • Insert bolt s from panning frame to joint assembly Installation Procedures Figure 13 Figure 14[...]

Ste p 3 Ste p 4 18 Attach 201316 support pairs to 221608 joint assemblies as shown in Figure 15. • Place support s back-to-back with edges out and flat of angle inward • Install 45967 spacer at midpoints of support pairs • Use 7/8 x 2-1/4 in (57 mm) hardware for each connection Installation Procedures Figure 15 Attach 221345 azimuth pivot ass[...]

Ste p 5 Ste p 6 19 Attach 201770 plate connecting 201484/201484-2 extension assembly to 201487 pan- ning frame as pictured in Figure 17. • Use 7/8 x 2-1/4 in (57 mm) hardware • Insert bolt s from inside panning frame assembly Installation Procedures Figure 17 Attach 201488 outrigger plate to opposite end of 201487 panning assembly . Att ach 201[...]

Ste p 7 Ste p 8 20 Attach second 201488 outrigger plate to 201487 panning frame assembly as shown in Figure 19. • Use 7/8 x 2-1/4 in (57 mm) hardware • Insert bolt s from inside assembly to outrigger plate Installation Procedures Figure 19 Attach 221721 elevation axis assembly to 201487 p anning frame assembly and 221608 joint assemblies as sho[...]

Ste p 9 21 Installation Procedures Figure 21 Attach 301741/301742 tripod joint bracket to 221721 elevation axis assembly as shown in Figure 22. • Use 7/8 x 2-1/4 in (57 mm) bolt, flatwasher under bolt and under nut, and nut • Insert bolt s from elevation axis assembly to tripod joint bracket Figure 22[...]

Ste p 10 Ste p 11 22 Installation Procedures Attach 300026 tripod channel legs to 301741/301742 tripod joint bracket as shown in Figure 23. • Use 7/8 x 2-1/4 in (57 mm) bolt, flatwasher and nut • Insert bolt s from channel leg to joint bracket Figure 24 Figure 23 Attach 301725 tripod tube weldment to 300026 tripod channel legs as shown in Figur[...]

Ele v ation J ackscrew Assembly Ste p 1 Ste p 2 23 Installation Procedures Attach 301771/301736 elevation jackscrew assembly to 201596 mounting plates as shown in Figure 25. Tighten connection. • Use 7/8 x 2-1/2 bolts and nuts Figure 25 Loosen rubber boot from end of jackscrew . T urn elevation drive screw to extend jack to dimension 67.7 in (171[...]

Ste p 3 Ste p 4 24 Installation Procedures Figure 27 Attach 301771/301736 elevation jackscrew to 301725 tripod tube weldment as shown in Figure 28. • Use 7/8 x 5-1/4 (133 mm) bolt. Fasten with heavy hex nut and flatwasher according to A-325 procedure with the exception of tightening the nut 1/2 turn from snug condition. T ighten jam nut in accord[...]

Azimuth J ackscrew Assembly Ste p 1 Ste p 2 Mount Assembly Ste p 1 Ste p 2 25 Installation Procedures Insert 221923/223180 azimuth jackscrew tube into 221738 azimuth pivot assembly as shown in Figure 29. Insert jack carefully to prevent scratching jackscrew tube. Note: Ensure jackscrew assembly remains fully retracted at this time. Figure 29 Apply [...]

Ste p 3 Ste p 4 26 Installation Procedures Attach rear pad assemblies to rear foundation pads as pictured in Figure 31. Figure 31 Connect beam assembly using 7/8 x 2-1/4 in (57 mm) hardware. Tighten supports to beam assembly per A-325 tensioning procedure. 201327A JOINT ASSEMBL Y 201313A BEAM ASSEMBL Y 221345 PIVOT ASSEMBL Y[...]

Ste p 5 Ste p 6 27 Installation Procedures Hoist elevation jackscrew assembly to mount. Attach 221384 azimuth pivot assembly to 221608 joint assembly with 7/8 x 2-1/4 hardware from pivot assembly to joint assembly as shown in Figure 32. Figure 32 Attach 221435 azimuth pivot assembly to 201408 beam assembly with a line of RTV around the plate and fo[...]

Ste p 7 Ste p 8 Ste p 9 28 Installation Procedures Figure 34 Refer to Figure 34. Position hoisting ropes on motor/jack assembly so jack will not roll when hoisted. Attach one rope to large motor frame next to gearbox to balance assem- bly; do not attach rope to small motor . Tie up loose conduit before lifting jack. Raise 221923/223180 azimuth jack[...]

Ste p 10 Ste p 11 29 Installation Procedures Extend jackscrew to meet outrigger assembly . Loosely re-attach outrigger plate to pin assembly in azimuth jackscrew as shown in Figure 35. Note: Realignment of panning frame/pivot assembly may be necessary to ensure proper alignment of azimuth jackscrew pin. Snug panning frame/pivot assembly hardware an[...]

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Ov er view Acquiring A Satellite 54 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 55 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 56 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 57 With all 24 transponder signals of approximately equal amplitude appearing on the spectrum analyzer screen determine the specific antenna system and satellite parame- ters. Rot ate the feed assembly as required until the appropriate (odd or even) transpon- der signals are maximized. Figure 4-5: Maximizing Odd Transponders Figure 4-6: Opt[...]

Subreflector Adjustment 58 Operation After the satellite has been acquired and testing has taken 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 performance. NOTE: Al[...]

Ov er view General Cleaning Electrical Par ts 59 Prev entiv e Maintenance This section contains periodic preventive maintenance instructions for the 5.6-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 Inspection Local Control/Motor Driv e Controller 60 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 dirt, corrosion, grease, or oil deposits that require further cleaning may be removed with a bristle or wire brush and a cleanin[...]

Antenna 61 pungent odor indicative of burning vanish denoting overheating or a total breakdown. • Check all terminal boards for broken or missing terminals and stripped threads. Check tightness of lead attaching hardware. • Check each starter for a make-after-break provision through the release of one push- button as the alternate pushbutton is[...]

62 and minus direction from the local control/motor drive controller at least once every three months during antenna down time. Check the mechanical limit switches provided at the end points stop antenna and feed movement, and limit travel to prevent structural interference and damage. Check the mechanical limit switches for corrosion and water ent[...]

Driv e System V olta g e and Cur rent Checks Ste p 1 Ste p 2 Ste p 3 63 tain all electrical grounding connections (including cross-axis grounding straps) are intact and secure, not corroded or broken. Thoroughly clean any noticeable corroded portions of grounding cables, unplated portion of universal terminals and corresponding mounting surfaces us[...]

Ste p 4 Ste p 5 Ste p 6 Ste p 7 Ste p 8 Ste p 9 64 T urn the AZIMUTH EAST/WEST switch to either position and while the antenna is rotat- ing, carefully use a clamp on ammeter in accordance with the ammeter manufacturer ’s instructions to take current readings off each of the three conductors (phases) connect- ed to the load side of the azimuth dr[...]

Preser v ation of Component Par ts Aluminum Par ts Galv anized Surfaces Lubrication 65 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 window . Edges of existing paint can be blended with the metal surface by using a fine gr[...]

J ackscrews/Motors Gear Motor/Housing Fill Drain R equirements 66 tube assembly and corresponding thrust pads. Securely replace access plugs in square tube weldment. Be certain to remove any protective caps and clean off each lubrication fitting prior to injecting fresh grease. The elevation and azimuth jackscrew assemblies are equipped with a grea[...]

67 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. Elevation Jackscrew Housing X Pressure Fitting SHC32 1 2. 1 Elevation Jackscrew Gear Housing I* C** Pipe Plugs SHC624 10 Oz Fill and Drain 3. 2 Elevation Drive Intermediate Gearbox I* C** [...]

High-Speed Antenna Lubrication Points 5 9 10 6 7 8 4 1 2 3 Local Motor Control Heater Control Pressure Fitting Pressure Fitting Gearbox Fill Gearbox V ent Gearbox Level Gearbox Fill Gearbox V ent Gearbox Level Polarization Drive Gear Worm Gear Pillow Blocks (2) Note Medium-speed motors shown for illustrative purposes only . Pressure Fitting Pressur[...]

Medium-Speed Antenna Lubrication Points 5 9 10 6 7 8 4 1 2 3 Local Motor Control Heater Control Pressure Fitting Pressure Fitting Gearbox Level Gearbox Drain Gearbox Level Gearbox Drain Polarization Drive Gear Worm Gear Pillow Blocks (2) Pressure Fitting Pressure Fitting 69 Prev entiv e Maintenance[...]