Installation, Operation and Maintenance Bulletin OM37 Revision C Type ES37( ) 3.7-Meter ESA 3.7-Meter Earth Station Antenna Andrew Corporation 10500 West 153rd Street Orland Park, IL U.S.A. 60462 Telephone: 708-349-3300 FAX (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 Printed in U.S.A.
Table of Contents Introduction How to Use This Manual Getting Started Installation Procedures Operation Preventive Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Proprietary Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Information and Assistance . . . . . . . . . . . . . . . . . . . .
.7-Meter Earth Station Antenna Introduction Like all Andrew earth station antennas, the 3.7-Meter Earth Station Antenna provides high gain and exceptional pattern characteristics. The electrical performance and exceptional versatility provides the ability to configure the antenna with your choice of linearlypolarized 2-port or 4-port combining network. That versatility is provided at the time of initial purchase, as well as in the future, as your satellite communication requirements evolve.
Proprietary Data 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 Corporation. Information and Assistance Andrew Corporation provides a world-wide technical support network. Refer to the technical assistance portion of this this manual for the contact numbers appropriate to your location.
How to Use This Manual Overview The scope of this manual is intended to provide station personnel with the base installation, operation, and maintenance requirements necessary for a 3.7-Meter C- or Ku-Band Earth Station Antenna. This manual provides a convenient reference for authorized operator/service personnel requiring technical information on general system or specific subsystem equipment.
Getting Started Overview The installation, operation, and maintenance of the 3.7-Meter Earth Station Antenna requires qualified and experienced personnel. Andrew 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.
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 results of improper or unsafe installation, operation, or maintenance practices.
Parts Verification 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 thoroughly inspects and carefully packs all equipment before shipment. If you find that there are missing components, please refer to page 9 for step-bystep instructions on how to properly report the equipment loss.
Returning Equipment Andrew Corporation tries to ensure that all items arrive safe and in working order. Occasionally, despite these efforts, equipment is received which is not in working condition.
Installation Sequence Checklist The 3.7-Meter Earth Station Antenna requires the installation team to perform the assembly in the sequence presented below. Moreover, this sequence should be reviewed to ensure a smooth installation. Use the following checklist to verify and/or determine the installation sequence. Site Preparation Refer to Foundation Section for guidance in preparing location and installation of the 3.7-Meter Earth Station Antenna foundation.
For MPJK Types Only Mount azimuth pivot assembly to ground mount assembly Bolt one jack to azimuth pivot assembly Unscrew jack Tighten galvanized hardware using A-325 tensioning procedure Lubricate jackscrews Pull protective boot over jackscrew Bolt elevation pivot assembly brackets to ground mount assembly Bolt second jack to elevation pivot assembly Unscrew jack Tighten galvanized hardware using A-325 tensioning procedure Lubricate jackscrews Pull boot over jackscrew Main Reflect
Add reflector-mounting ring Mount front and back hub-mounting rings Apply sealant to outside of reflector-mounting ring Perform recommended string test Enclosure Assembly Remove rear and side covers from enclosure assembly Attach enclosure to mounting ring Apply sealant backing rod around enclosure/mounting ring mating surfaces Apply RTV sealant Reflector-ToMount Assembly Route sling through upper holes of torsion box assembly Route two rope tag lines through torsion box assembly to b
Subreflector Preassemble subreflector weldment Attach subreflector-mounting ring to strut assembly Attach angle clips Attach subreflector to reflector Adjust subreflector Tighten adjustment hardware Feed System Refer to installation instructions packaged with the individual feed systems 13 Getting Started
Installation Procedures Overview This section provides installation procedures for the 3.7-Meter Andrew Earth Station Antenna.
A-325 Tensioning During the installation process, there are 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, causing antenna misalignment. When designated, the A-325 hardware should be tightened according to the following tensioning procedure. NOTE: Tensioned bolts are for final connections only and should not be loosened for reuse.
Mount The elevation/azimuth mount design simplifies installation, minimizes foundation requirements, and enables horizon-to-horizon coverage from any worldwide location. The ground mount assembly enables 180 degree positioning for selected azimuth viewing. Azimuth range coverage is plus or minus 90 degrees, divided into three 120 degree continuous ranges with a 30 degree overlap. Elevation adjustment is continuous from 0 degrees to 90 degrees.
Step 1 Carefully remove the ground mount assembly (P/N 208800 - motorizable or P/N 202680-2 manual) from the packing crate. Leave the steel strapping intact to avoid disengagement of the panning frame from the square-tube weldment during the ground mount installation. Step 2 Securely attach the crane to the ground mount assembly using a sling, and carefully raise the entire ground mount as shown in Figure 3-3.
Step 5 Attach the ground mount assembly to the eight corresponding anchor bolts using a 3/4 inch flat washer and 2-3/4 inch hex nuts as shown in Figure 3-4a. One 3/4 inch hex nut is supplied with the anchor bolt kit and the second 3/4 inch hex nut is supplied with the antenna. Figure 3-4a: Ground Mount Assembly Base Hardware Step 6 Remove the steel strapping from the ground mount assembly. Step 7 Tighten the foundation hardware using the A-325 tensioning procedure.
Assembly (Without a Crane) As stated earlier, Andrew recommends the use of a crane during this installation process; however, we recognize that a crane may not always be available. If a crane is not available, the following steps provide the procedure for installing the ground mount assembly without a crane. Step 1 Carefully remove the ground mount assembly (P/N 208800-motorizable or P/N 2026802- manual) from the packing crate.
Step 3 Lift the ground mount assembly into an upright position. In the absence of a crane, it is recommended that a minimum of two people assist in the lifting of the mount assembly as shown in Figure 3-6a and Figure 3-6b.
Figure 3-7: Mount Alignment/Adjustment NOTE: You may need to adjust the mount when lifting it to ensure that the anchor bolts are aligned directly underneath the base of the ground mount assembly as shown in Figure 3-7. Step 4 Attach the ground mount assembly to the eight corresponding anchor bolts using a 3/4 inch flat washer and 2-3/4 inch hex nuts as shown in Figure 3-3a. NOTE: Ground mount positioning on the foundation is dependent upon predetermined azimuth viewing requirements.
Motorizable Pedestal Ground Mount Assembly The ground mount assembly enables 180° positioning for selected azimuth viewing. Azimuth range coverage is ±90° divided into three 120° continuous ranges with 30° overlap. Elevation adjustment is continuous from 0 to 90°. Step 1 Position and mount 204737 azimuth tiller arm weldment to ground mount assembly as shown using 0.75 x 1.75 in. A-325 bolts and nuts. Tighten hardware per A-325 tensioning procedure.
1/2” Flat Washer 1/2 x 1-3/4” Bolt and Nut Universal Terminal 5/16 x 3/4” Hex Head Screw and Lock Washer Grounding Cable Figure 3-8d: Ground Mount Assembly Tiller Arm Hardware Left Position -90° To +30° Center Position -60° To +60° Right Position -30° To +90° Figure 3-8e: Ground Mount Assembly Tiller Arm Hardware 23 Installation Procedures
Manual Pedestal Ground Mount Assembly Step 1 Prepare the ground mount hardware in the mount hardware kit by sorting all bolts, nuts, and flat washers into separate sections as shown in Figure 3-9. Figure 3-9: Hardware Separation Step 2 Wax two sides of each galvanized bolt with the stick wax provided. This allows a smooth installation of each galvanized bolt as shown in Figure 3-10.
Step 3 Position and mount the azimuth tiller arm (P/N 203112) to the tiller-arm bracket on the left side (facing the satellite) of the ground mount assembly. This mounting position of the azimuth tiller arm is dependent upon pre-determined azimuth range requirements as shown in Figure 3-11. NOTE: The ground mount assembly enables 180 degrees positioning for selected azimuth viewing.
An illustration of the final azimuth tiller arm is shown in Figure 3-12. Figure 3-12: Azimuth Tiller Arm - Final Assembly Step 5 Locate the elevation and azimuth struts (P/N 202951-2-manual) as shown in Figure 3-13. NOTE: The azimuth strut is the strut on the right and the elevation strut is on the left.
Step 6 Insert pivot blocks (P/N 205876) onto the end of the azimuth strut using lubricated 1/2 inch bolt, flatwasher and hex nut as shown in Figure 3-14. A 3/4 inch flat washer should be inserted between the strut and the spacer block. Tighten hardware according to the A-325 tensioning procedure.
Figure 3-16: Azimuth Pivot Assembly Step 9 Mount the azimuth strut to each bracket on the ground mount assembly as shown in Figure 3-17a and Figure 3-17b. The front and rear brackets should be aligned as shown in Figure 3-18.
Figure 3-17b: Azimuth Strut Assembly - Rear Figure 3-18 illustrates a final azimuth strut assembly mounted to the ground mount assembly.
Step 10 The next step is to install the elevation strut assembly. Begin by bolting the elevation strut tube assembly (P/N 205872) to the ground mount assembly as shown in Figure 3-19. Figure 3-19: Elevation Strut Pick Up Assembly (Top View) Step 11 Bolt the elevation bracket-support plates (P/N 205873) to the elevation strut tube assembly using 5/8 inch hardware (hex bolt, flatwasher and nut)as shown in Figure 3-20.
Step 12 The elevation strut tube assembly should now be bolted to the elevation strut bracket as shown in Figure 3-21a and Figure 3-21b.
Manual Actuator Assembly Step 1 The manual actuator assembly (P/N 207882) is used to adjust the elevation and azimuth angles of the 3.7 meter antenna. The following steps provide the procedure used to assemble and install the manual actuator assembly. Loosely attach the manual actuator assembly (P/N 207882) to the elevation strut as shown in Figure 3-22 using clamp segments, 1/4 inch screw, lockwasher and hex nut in each of the 12 connections.
Step 4 Remove the two indicated strut-support setscrews, and attach the base angle to the corresponding strut support using the supplied 1/2 inch clamping nuts and the previously removed strut-support setscrews as shown in Figure 3-22b. Step 5 Securely tighten the remaining mounting hardware to achieve the clamping force. Step 6 Follow directions for “Acquiring a Satellite”. Step 7 Repeat the entire procedure for the remaining strut assembly.
Step 2 Bolt one jack to the azimuth pivot assembly using 5/8 inch hardware (hex bolt, flatwasher and hex nut) as shown in Figure 3-24. Figure 3-24: Jack Attachment Step 3 Unscrew the jack using a spud wrench until it meets with the front azimuth strut weldment as shown in Figure 3-25a.
Step 4 Place pivot blocks (P/N 205876) on both sides of the jackscrew ends, bolting with lubricated 1/2 inch hex bolt, flatwasher and hex nut as shown in Figure 3-25b. Figure 3-25b: Azimuth Jack Attachment Step 5 Tighten the hardware using the A-325 tensioning procedure. Step 6 Lubricate the jackscrews according to the maintenance instructions. Step 7 Pull the protective boot over the jackscrew, and clamp at the end as shown in Figure 3-26. Note: Position condensation drain holes downward.
Step 8 Bolt the elevation pivot assembly brackets (P/N 208370 - left and P/N 208371 - right) to the inside of the ground mount assembly as shown in Figure 3-27. Figure 3-27: Elevation Pivot Bracket Assembly Step 9 Bolt the jack to the elevation pivot assembly using 5/8 inch hardware (hex bolts, flatwashers and nuts) as shown in Figures 3-28a and 3-28b.
Figure 3-28b: Elevation Jack Step 10 Loosen the clamp on the jack boot. Step 11 Unscrew the jack by using a spud wrench until the jack connects to the back of the enclosure as shown in Figure 3-28c. Figure 3-28c: Elevation Jack Extension Step 12 Tighten the hardware using the A-325 tensioning procedure. Step 13 Lubricate the jackscrews using the maintenance procedures. Step 14 Pull the protective boot over the jackscrew, and clamp it at the end as was performed with the azimuth jackscrew.
Embedded Pipe Ground Mount Assembly Refer to Figure 3-29a for an overall view of the assembled embedded pipe ground mount assembly, reflector and subreflector assemblies. Subreflector Assembly Ground Mount Assembly Reflector Assembly Figure 3-29a: Typical Embedded Pipe Mount Earth Station Antenna Step 1 Attach the 104320 left side frame, to the 168 tube using four 104326 U-bolts, 100526-51 M16 nuts and 100522-51 lockwashers.
Step 2 Attach the 104319 front frame to the left side frame as shown in Figure 3-29c. Attach the 104325 braces to the left side by means of the U-bolts. Attach the right side frame and braces to the front frame and the right side frame to the left side frame, also shown. For all of these joints, use 100532-21 M16x40 long bolts, 100526-51 nuts and 10052251 lockwashers. When assembly is in place, tighten to 95 N-m. (70 lbs-ft).
Step 4 Attach the elevation strut to the top of the rear frame assembly as shown in Figure 3-29e using the 100537-15 M20 x 50 bolt, 100526-57 nut and 100521-57 flatwasher. Tighten bolts to 185 N•m. (136 lbs-ft). M20 x 50 Bolt, Flatwasher Lockwasher and Nut Figure 3-29e: Elevation Strut Attachment Attach 301917 elevation axis weldment to the front of the frame assembly in two places using 100537-15 M20 x 50 long bolt, 100526-57 nut and 100522-57 lockwasher as shown in Figure 3-29f.
Step 5 Attach the azimuth strut to the bottom rear of the frame assembly as shown in Figure 329g, using the 100537-15 M20 x 50 long bolt, 100526-57 nut, 100521-57 flatwasher and 100522-57 lockwasher. Attach the strut to the foundation anchor, as shown in Figure 3-29g. Step 6 Install 301931 pointer where shown in Figure 3-29g by removing the mount bolt at specified location then reinstalling with 100521-51 flatwasher and pointer.
Step 7 Install fine az. adjustment, attach 40188-3 thread rod to 49712-3 bracket with 9999-167 .75-10 nuts and 9997-166 flatwasher. Slide threaded rod through welded tab and fasten using 9999-167 .75-10 nuts and 9997-166 flatwasher. Note: It will be necessary to temporarily remove one square head bolt for fine adjusting the threaded rod. After fine adjustment it is recommended that the fine adjustment rod assembly remain in place. If the threaded rod is removed the square head bolt must be replaced.
The ground mount assembly is now completed with the necessary operational essentials. All ground mount options (such as motors) have separate instructional bulletins located in the parts kit that contains the option. The next step in the installation process is the reflector assembly. Proceed to the instructions on assembling the reflector.
Figure 3-30b: Export Pack Figure 3-30c: Unpacking Step 3 Pry the short ends of the crate off by using a pry bar and hammer as shown in Figure 3-30c. NOTE: Notice that the parts of your order are boxed and banded to your crate. Remove these boxes by snipping the banding with tin snips. Step 4 Take the front, long side of the crate off. Step 5 Unbolt the reflector halves from the bottom of the crate. DO NOT PRY. Step 6 Find a flat area for the reflector assembly.
Step 7 Lay the first half of the reflector (which has the flash located at twelve o’clock) face down on the blocks of wood. Step 8 Lay the second half of the reflector face down on the blocks of wood. Step 9 Unbolt the mounting ring from the crate, and set with the rest of the parts to be assembled. Step 10 Assembly Improve timeliness of clean up by discarding unneeded materials while unpacking the crate. You can place all wood and unneeded materials in one area away from the installation site.
Step 3 Insert all of the joint-plate bolts, except for the socket-head shoulder bolts. All bolts should be inserted from the same direction using a 5/16 inch hardware—flat washer under a lock washer and nut. DO NOT TIGHTEN. Note: DO NOT force bolts—manipulate reflector halves to allow free insertion. Step 4 At both antenna seams, loosely install three location bolts and nuts (5/16 inch hardware) adjacent to the center hole as shown in Figure 3-32.
Step 5 VERY IMPORTANT Add the alignment hex bolts to the end holes of the joint plates as shown in Figure 333a (outside and inside of plate) to ensure that it is evenly aligned; and use hex bolts to fill the rest of the joint plates as shown in Figure 3-33b. THESE MUST NOT BE DRIVEN, BUT INSERTED BY HAND. NOTE: All bolts should be inserted from the same direction using a bolt, flatwasher under a lockwasher and nut on joint plate and a bolt and locknut on the seam.
Splice Strip and Mounting Ring Hardware Tapered M6 x 1.0 (25 mm) Location Bolts, Washers for Mounting Ring Attachment Only, and Lock Nuts Joint Plates Seal Seam All Around Ring Mounting Ring Tabs Red Line Match Marks Serial No. (On Joint Plates) Splice Strip Serial No. Joint Plate Hardware (2) 0.31 x 1.25 (32 mm) Socket Head Shoulder Bolts (7) 0.31 x 1.
Step 7 Add the reflector-mounting ring to the assembled reflector. Notice that the notches in the mounting ring fit over the reflector seam indicating where the mounting ring should be placed. There is also a red stripe placed on the mounting ring. This red stripe must be aligned with the red stripe on the reflector as shown in Figure 3-34a. When all bolts are inserted, tighten in a clockwise sequence, tabs on the mounting ring must be flush with the reflector as shown in Figure 3-34b.
Step 8 Mount the front (P/N 202790) and back hub-mounting ring (P/N 49965) to the reflector with the appropriate hardware as shown in Figures 3-35a and b. NOTE: These components are included as part of P/N 206319 Feed Hardware Kit. For K-Band Antennas, these components are included as part of P/N 301544 Feed Hardware Kit (2-Port) or P/N 301515 Feed Hardware Kit (4-Port).
Alignment Test As a final test of proper reflector alignment, Andrew recommends that a string test be performed. The following steps provide the procedure for the string test. Step 1 Attach a string at the twelve o’clock position of the reflector stretching to the six o’clock position of the reflector. Step 2 Attach a second string at the three o’clock position stretching to the nine o’clock position. Step 3 Verify its intersection to the first string as shown in Figure 3-37.
Enclosure (Pedestal Mount Only) The enclosure (P/N 202934A) assembly attaches to the rear of the reflector. The enclosure provides weather protection for RF equipment and can accommodate up to a 4port combiner network. An example of the assembled enclosure is presented in Figure 3-38a and Figure 3-38b. Figure 3-38a: Enclosure - Final Assembly Figure 3-38b: Enclosure - Final Assembly Before assembling the enclosure, verify that the appropriate parts are present.
Step 2 Raise the enclosure assembly, and attach to the mounting ring on the reflector using the appropriate hardware as shown in Figure 3-39a and Figure 3-39b.
Step 3 Install the supplied sealant backing rod material around entire circumference of the mounting ring/enclosure mating surfaces as shown in Figure 3-40. Figure 3-40: Backing Rod Assembly Step 4 Securely tighten the enclosure mounting hardware using the A-325 tensioning procedure. Step 5 Apply the supplied RTV sealant around the outer perimeter of the reflector-mounting ring/enclosure assembly junction as shown in Figure 3-41.
Reflector-to-Mount Assembly Using a Crane Step 1 The reflector can be installed on the mount manually or by using a crane. However, Andrew recommends that this procedure be performed using a crane. The following steps provide the procedure for installing the reflector to the mount using a crane. Route a sling through the upper holes in the reflector torsion box assembly, and connect the ends using a 5/8 inch shackle as shown in Figure 3-42.
Figure 3-44a: Crane Lift Step 3 Verify that all hoist assembly hardware is fully in tact before lifting the reflector to avoid personal injury or damage to the reflector. Step 4 Route the crane’s cable and hook from the hoist over the slings, and attach the shackle’s hook to the crane’s hook for raising the reflector. Step 5 Position a person at the end of each tag line to guide the reflector as it is being lifted, and position another person on the mount to crank the hoist.
Figure 3-44c: Crane Lift Without a Crane The following steps provide the procedure for installing the reflector to the mount without the use of a crane. Step 1 Route one rope tag line through two consecutive holes at the top of the reflector in the torsion box assembly. Step 2 Place foam blocks (provided as packaging material) on the bottom lip of the reflector (between the ground mount and the reflector) to prevent the reflector from scraping the ground as it is lifted.
Step 3 Position three people at the top of the reflector to lift the reflector on its end, facing forward as shown in Figure 3-45. Figure 3-45: Manual Lift of the Reflector to the Mount Step 4 Position one person (of the three) on the mount to guide the reflector to the mount. Refer to Figure 3-46.
Step 5 Align the enclosure bracket to the ground mount assembly. The left bolt should be inserted to hold reflector in place using 3/4” A-325 hardware (hex bolt, flatwasher and nuts as shown in Figure 3-47 and Figure 3-48. Figure 3-47: Enclosure Bracket Step 6 Have the two people on the ground rotate the reflector to connect with the right bolt of the enclosure bracket against the ground mount angle bracket.
Step 7 Extend the elevation strut or elevation jackscrew, and attach it to the top rear of the enclosure assembly as shown in Figure 3-49. Figure 3-49: Elevation Jack/Enclosure Attachment Step 8 Tighten the hardware using the A-325 tensioning procedure. Step 9 Carefully raise the reflector/enclosure assembly to the zenith (elevation = 90 degrees) position, and securely tighten the strut-support setscrews to 40 foot-pounds. Step 10 Remove all hoisting apparatus.
The Reflector-to-Mount components can be verified and/or clarified in the following diagram.
Reflector-to-Mount Assembly Embedded Pipe Ground Mount Step 1 Lift the reflector carefully onto the mount as shown in Figure 3-50b. Secure the reflector to the mount using 100537-15 M20 x 50 long bolts, 100526-57 nuts and 100522-57 lockwashers in three places. Tighten these three to 38 N•m.
Subreflector Once the reflector has been assembled to the mount, the subreflector must be installed. Figure 3-51 presents a final subreflector assembly. Figure 3-51: Installed Subreflector The following steps provide the procedure for assembling the subreflector. Step 1 Loosely preassemble the subreflector strut weldment (P/N 202775) using the supplied strut angles (P/N 202776) and the 3/8 inch by 2-1/4 inch bolts, lock washers, and nuts as shown Figures 3-52a and 3-52b.
Figure 3-52b: Subreflector Strut Assembly Step 2 Position and attach the subreflector-mounting ring (part of 205929 subreflector assembly) to the corresponding mounting holes in the strut-support plates using 3/8 inch by 1 inch bolts, oversized flat washers, lock washers, and nuts as shown in Figure 3-53a and Figure 3-53b. NOTE: Ensure that one subreflector adjustment stud is located at the six o’clock position.
Figure 3-53b: Subreflector Assembly Step 3 Attach the angle clips (P/N 49187) around the reflector perimeter at the indicated positions using the appropriate hardware as noted in Figure 3-53c.
Step 4 Raise and attach the preassembled subreflector strut assemblies between the corresponding angle clips using a tag line as shown in Figure 3-54a. The angle clips should correspond with the holes in the reflector. NOTE: Ensure that one subreflector adjustment stud is located at the six o’clock position.
Subreflector Struts Embedded Pipe Ground Mount Assembly Step 1 Loosely preassemble the 300056 Subreflector Struts using supplied 222888 strut supports and the 9963-127 3/8 inch by 2 1/4 inch bolts, 9974-63 lockwashers, and 9999-60 nuts as shown in Figure 3-54b, View A. Note: At this time it is recommended (but not necessary) to install the Subreflector, for K- & Ku-Band, see Kit #301921; for C-Band, see Kit #301939.
Subreflector Adjustment After the subreflector assembly has been attached to the reflector, the subreflector must be adjusted to ensure correct alignment. The following steps provide the procedure for adjusting the subreflector. Step 1 Position the supplied setting bar (P/N 203896 Ku-band, P/N 203896-3 C-band) ) on the outer edge of the subreflector as well as on the outer edge of the front ring (P/N 202790) at the twelve o’clock (top) position.
Step 6 Repeat the entire procedure until all four noted positions indicate that the subreflector aperture is set parallel to the ring (P/N 202790) as shown in Figure 3-56. Step 7 Temporarily tighten the adjustment hardware until after step 10 has been completed. Figure 3-56: Subreflector Alignment Step 8 Measure and note the distance between either outermost angle clip bolt head and the subreflector rim.
Step 9 Obtain the corresponding measurements from the remaining subreflector struts, and adjust the subreflector mounting hardware (4 places) to achieve a maximum differential of 1/16 inch. Step 10 Repeat the adjustment procedure performed in Steps 1-4, until all areas of the subreflector are uniform. Step 11 Adjust the jam nuts, and securely tighten the adjustment hardware. 46.925” 47.2” Figure 3-57: Subreflector Alignment Feed System You have now completed the subreflector assembly.
Operation Overview 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 following procedures provide details on how to correctly position your antenna on the desired satellite. Acquiring A Satellite NOTE: Ensure that the feed system and all electronics are installed properly before proceeding.
Figure 4-1: Pure Noise Signal on Spectrum Analyzer Figure 4-2: Minimum transponder Signal on Spectrum Analyzer 72 Operation
The following steps provide the procedure for acquiring a satellite. Step 1 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 the same condition occurs. • Return to the position yielding the greatest amplitude. The maximum azimuth excursion from the original setting should not exceed plus or minus 1.
Step 5 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 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.
Step 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 are maximized.
Manual Actuator Assembly Removal After you have successfully acquired the satellite and all adjustments have been made, the manual actuator should be removed. The following steps provide the procedure for the proper removal of the manual actuator assembly. Step 1 Remove the manual actuator assembly by first removing the hardware securing the actuator to the base angle. NOTE: The adjustment kit assembly should be removed after the antenna has been adjusted.
Subreflector Adjustment 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 antenna. The following procedures should be followed if a subreflector adjustment is required to maximize optimum performance. NOTE: All INTELSAT Type Approved antennas do not require subreflector adjustment. Using the provided setting bar and procedures will correctly place the subreflector.
Preventive Maintenance Overview This section contains periodic preventive maintenance instructions for the 3.7-Meter Earth Station Antenna. Included in this section are inspection and preventive maintenance procedures including cleaning and lubrication, painting, and an operational voltage/current checkout procedure deemed within the capabilities of the average station technician.
Mechanical Parts Clean mechanical parts 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 compressed 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 cleaning solvent such as trichlorethylene or equal.
• Check transformer for an excessive wax deposit on the surface, discoloration, or a 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 pushbutton as the alternate pushbutton is pressed.
• 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 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 entry and the arm on each feed limit switch for free movement without binding.
• Check security of antenna mounting and interconnecting assembly hardware. Be certain 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 using a wire brush. Replace rather than tighten any loose A-325 structural hardware.
Step 4 Repeat preceding step (3) with the FEED CCW/OFF/CW switch in the alternate operating position. Step 5 Turn the AZIMUTH EAST/WEST switch to either position and while the antenna is rotating, 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) connected to the load side of the azimuth drive motor circuit breaker.
Preservation of Component Parts Aluminum Parts When preserving the component parts, 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 window. Edges of existing paint can be blended with the metal surface by using a fine grit sandpaper.
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 protective caps and clean off each lubrication fitting prior to injecting fresh grease.
Lube Point Parts to be Lubricated Action 1 Elevation jackscrew housing 2 Elevation gear motor housing Inspect fill and drain Change Frequency Lubricate Every 3 months Monthly Service Type Lube Type Pressure Fitting SHC32 Pipe Plugs SHC624 1 Andrew Number 49208 10 ounces 47497 Every 3 months 3 Azimuth jackscrew housing Lubricate Every 3 months Pressure Fitting 4 Azimuth jackscrew gear housing fill and drain Inspect Monthly Pipe Plugs SHC624 Change Every 3 months 5 Quantity /Point
