Andrew ES73 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 15 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 7.3-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 cont ained 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 Corporati[...]

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 7.3-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 7.3-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 Andrew Corporation thoroughly inspects and carefully p acks all equipment before ship- ment. If you find that there are missing components, please notify Andrew Corporation immediately by cont[...]

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 7.3-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 • 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 5 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 nut s for each connection Installation Procedures Figure 5 Attach 200088A joint assembly to 201313A beam assembly as show[...]

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 nut s • Insert bolts from 201327A joint assembly to supports • Supports should be inst alled back-to-back with the flat of angle facing upwards • T ighten suppor[...]

Ste p 5 Ste p 6 15 Attach 201314 support s to 201301/201302 rear pad assemblies and 201273 joint assembly as shown in Figures 9 and 10. • Use 7/8 x 2-1/4 in (57 mm) bolts and nut s • Insert bolt from inside of joint assembly to outside of support • Supports should be inst alled back-to-back with the edges forward and the flats of angles facin[...]

Panning F rame Assembly Ste p 1 16 Attach 201487 p anning frame to 221384 azimuth pivot assembly as shown in Figures 1 1 and 12. Note: Ensure pivot assembly resolver/limit switch mounting holes are downward. • Use 7/8 x 2-1/4 in (57 mm) hardware and apply supplied RTV to flange surfaces as indicated • Bolts should connect from p anning frame to[...]

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

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

Ste p 5 Ste p 6 19 Attach 201770 plate connecting 201484/201484-2 extension assembly to 201487 p an- ning frame as pictured in Figure 17. • Use 7/8 x 2-1/4 in (57 mm) hardware • Insert bolts from inside p anning frame assembly Installation Procedures Figure 17 Attach 201488 outrigger plate to opposite end of 201487 p anning assembly . Attach 20[...]

Ste p 7 Ste p 8 20 Attach second 201488 outrigger plate to 201487 p anning frame assembly as shown in Figure 19. • Use 7/8 x 2-1/4 in (57 mm) hardware • Insert bolts 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 right tripod joint bracket and 301742 lef t 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 bolts from elevation axis assembly to tripod joint bracket s Figure 22 30174[...]

Ste p 10 Ste p 11 22 Installation Procedures Attach 300026 tripod channel legs to tripod joint bracket s as shown in Figure 23. • Use 7/8 x 2-1/4 in (57 mm) bolt, flatwasher and nut • Insert bolts from channel leg to joint bracket Figure 24 Figure 23 Attach 301772 tripod tube weldment to 300026 tripod channel legs as shown in Figure 24. • Use[...]

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. T ighten connection. • Use 7/8 x 2-1/2 bolts and nut s Figure 25 Loosen rubber boot from end of jackscrew . T urn elevation drive screw to extend jack to dimension 67.7 in (1[...]

Ste p 3 Ste p 4 24 Installation Procedures Figure 27 Attach 301771/301736 elevation jackscrew to 301772 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 p ad 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. T ighten supports to beam assembly per A-325 tensioning procedure. 201313A 201327A[...]

Ste p 5 Ste p 6 27 Installation Procedures Figure 32B Apply RTV to flange surfaces and att ach 221384 azimuth pivot assembly to 201327A joint assembly with 7/8 x 2-1/4 hardware from pivot assembly to joint assembly as shown in Figure 32C. Note: Use one 7/8 by 2-3/4 inch (70 mm) bolt, flat washer and nut for later attachment of grounding cable. Figu[...]

Ste p 7 Ste p 8 Ste p 9 28 Installation Procedures Figure 34 Raise 221923/223180 azimuth jackscrew and attach 221738 pivot assembly to 201273 joint assembly with 1 x 2-1/2 in (63 mm) hardware. Note: Mounting position of azimuth pivot jackscrew assembly is dependent upon azimuth range requirements and corre- sponds with mounting position of 201488 o[...]

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

R eflector/ Subreflector/ Feed Assembly Feed/W a v e guide Assembly Ste p 1 Ste p 2 30 Installation Procedures T ype A-325 hardware is utilized during the reflector attachment to the ground mount. Use of A-325 hardware eliminates slippage between mating surfaces under high loading conditions as well as the need for future retightening. Refer to the[...]

Ste p 3 31 Installation Procedures Align tabs on 77639 feed rot ating tube assembly with corresponding tabs on drum assembly . Attach rotating tube to center of drum assembly using 3/8 x 1-3/4 in (44 mm) bolts, lockwashers and nut s as shown in Figure 38. Do not tighten. Figure 38[...]

Ste p 4 Ste p 5 Ste p 6 32 Installation Procedures Attach 77874 feed support s between rotating tube tabs and corresponding drum t abs as shown in Figure 38. Fully tighten. • Use 1/2 x 1-1/8 (29 mm) shoulder bolts, lockwashers and nut s Note: Ensure shoulder bolts are fully seated and feed support angles are inst alled edge down with flats of ang[...]

Ste p 7 33 Installation Procedures Attach 77646-2 feed horn mounting pipe to 201606/301808 feed horn assembly as shown in Figure 40. • Use 1/2 x 2-1/2 in (63 mm) hex screws, lockwashers and nuts • Insert bolts from feed horn to mounting pipe Figure 40[...]

Ste p 8 34 Installation Procedures Install circular waveguide assembly through 77639 rot ating tube assembly and attach feed horn/mounting pipe assembly to rotating tube as shown in Figure 41A. Inst all 201065A circular waveguide support assembly as shown in Figure 41B. • Use 1/2 x 2 in (51 mm) bolts, lockwashers and nut s • Insert bolts from m[...]

Ste p 9 35 Installation Procedures Figure 42 Rotate drum assembly into upright position. Level drum with shims until no side can bounce, as shown in Figure 42.[...]

R eflector/ Backstructure Assembly Ste p 1 36 Installation Procedures Attach back strut assemblies to lower drum ring bracket s as shown in Figures 43 and 44. • Use 1/2 x 1-1/2 in (38 mm) bolts, lockwashers and nut s Figure 43 Figure 44[...]

Ste p 2 Ste p 3 Ste p 4 37 Installation Procedures Remove entire end of panel crate to allow easy access and careful removal of reflector panels. • When transporting panels, support p anel on side as packaged T ie assembly down by knotting rope between lifting t abs and three 3 ft stakes as shown in Figure 45. This will prevent an unbalanced cond[...]

38 Installation Procedures Figure 47 Center portion of Andrew “flash” logo[...]

39 Installation Procedures Ste p 5 Install back strut members to reflector segment tee section as shown in Figure 48. Use minimum torque to tighten hardware connecting back strut to reflector segment, reflector segment to upper drum ring assembly and back strut to lower ring drum assembly . • Use 1/2 x 1-1/2 in (38 mm) bolt, lockwasher and nut No[...]

Ste p 6 40 Installation Procedures Repeat S teps 4 and 5 to inst all second panel adjacent to panel segment 1 as shown in Figures 49. Install p anel seam hardware connecting panel segments 1 and 2 with step ladder . Do not tighten. • Use 5/16 x 3/4 in (19 mm) special bolts, 3/8 in flatwasher , 5/16 in lockwasher , and 5/16 in nut as shown in Figu[...]

Ste p 7 Ste p 8 41 Installation Procedures Install third p anel segment (adjacent to first panel segment) according to S teps 4 thru 6 and Figure 51. Figure 51 Continue installing p anel segments as described in S teps 4 thru 7 in counter-clockwise direction as shown in Figure 52. Note: Panels are numbered and should be installed in proper sequence[...]

Ste p 9 Ste p 10 Ste p 11 Ste p 12 Ste p 13 Ste p 14 42 Installation Procedures Prior to installing p anels 15 and 16 station a man on top of the drum assembly enclo- sure to install p anel seam hardware. Care must be taken not to apply heavy weight to surface of panel segment s. Note that there are 16 panel segment s each with 21 bolt holes number[...]

Beginning with panel seam 1, fully tighten hardware att aching panels to upper drum assembly ring, reflector tee segment to back strut assembly , back strut assembly to lower drum assembly ring and back strut assembly pairs. Continue tightening att aching hardware on all reflector segments. Install 170147 quadrapod plates at positions indicated in [...]

44 Installation Procedures Subreflector Str ut Assembly Ste p 1 Attach subreflector strut assemblies to 170147 quadrapod plates as shown in Figures 56 and 57. T ighten hardware until snug only . • Use 1/2 x 1-1/2 in (38 mm) bolts, lockwashers and nut s Figure 56[...]

45 Installation Procedures Figure 57[...]

Ste p 2 46 Installation Procedures Attach subreflector strut assemblies to opposing sides of 77943 apex bracket as shown in Figures 58 and 59. • Use 1/2 x 1-1/4 in (32 mm) bolts, lockwashers and nut s Figure 58 Figure 59[...]

Ste p 3 Ste p 4 Ste p 5 47 Installation Procedures Attach subreflector ring to corresponding strut assembly plates as shown in Figure 60. Ensure subreflector ring assembly is installed with indicated adjustment stud hole at 3 o’clock position as shown. Do not tighten mounting hardware. • Use 1/2 x 1-1/4 in (32 mm) holts, flatwashers, lockwasher[...]

R eflector to Ground Mount Assembly Ste p 1 Ste p 2 48 Installation Procedures Attach 5/8 in (16 mm) shackles to three lif ting tabs as shown in Figure 62. Attach 15 ft (4.5 m) tag lines to opposing quadrapod plates. Figure 62 Raise reflector/backstructure assembly and align with corresponding mounting holes in drum and elevation axis assemblies us[...]

49 Installation Procedures Figure 63 Figure 64[...]

Subreflector Assembly and Adjustment Ste p 1 Ste p 2 50 Installation Procedures Install subreflector subassembly to subreflector ring by inserting studs on subassembly into adjustment stud mounting holes as shown in Figure 65. • Use 3/4 in (19 mm) flatwasher , nut and jam nut Figure 66 Figure 65 Refer to Figure 66. Measure and note the distance b[...]

Ste p 3 Ste p 4 Installation Procedures Figure 67 Repeat the adjustment procedure performed in S tep 2, until all areas of the subreflector are uniform. Adjust the jam nuts, and securely tighten the adjustment hardware. Adjust subreflector hardware to obtain appropriate setting from surface of reflector at seam bolt ring #1 to bottom of subreflecto[...]

Cross-Axis Grounding Kit Ste p 1 52 Installation Procedures Note: Thoroughly clean exposed portions of grounding cables, unplated portion of uni- versal terminals and cor-responding mounting surfaces using a wire brush. Liberally apply supplied 203233-2 conductive grease to all connection surfaces prior to and after inst al- lation. Thoroughly remo[...]

Refer to Figure 69. Attach lugs to universal terminals at each end of 46373 grounding cable as shown, using 5/16 by 1 inch (25 mm) bolts, flat washers and nut s. Attach cable to available hole in panning frame, using 7/8 by 2-1/4 inch (57 mm) bolt and nut. Attach other end of cable to existing 5/8 by 2 inch (51 mm) bolt on tripod as shown. Attach s[...]

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 Ste p 5 Ste p 6 55 The following steps provide the procedure for acquiring a satellite. Begin by obtaining the correct Az/El pointing data for the satellite of interest based on specific calculations for this particular site. Using an inclinometer placed on the enclosure drum surface, position the antenna to the spec[...]

Ste p 7 Ste p 8 Ste p 9 56 Move the antenna in azimuth to obtain a null, then move ± in elevation to obt ain a large peak signal. If not, move the antenna in the opposite azimuth direction through the peak and again move ± in elevation to obtain a large peak signal. If a larger peak is not found, you were on the main lobe. NOTE: The following exp[...]

Ste p 10 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. Rotate the feed assembly as required until the appropriate (odd or even) transpon- der signals are maximized. Figure 4-4: Maximizing Odd T ransponders Figure 4-5: Op[...]

Subreflector Adjustment 58 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 performance. NOTE: A[...]

Ov er view General Cleaning Electrical Par ts 59 Prev entiv e Maintenance This section contains periodic preventive maintenance instructions for the 7.3-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-af ter-break provision through the release of one push- button as the alternate pushbutton i[...]

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 the antenna and feed movement, and limit travel to prevent struc- tural interference and damage. Check the mechanical limit switches for corrosion and wat[...]

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 strap s) 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 u[...]

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 of f each of the three conductors (phases) connect- ed to the load side of the azimuth d[...]

Preser v ation of Component Par ts Aluminum P ar 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 g[...]

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

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-S peed 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 Pressu[...]

Medium-S peed 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[...]