Installation, Operation and Maintenance Bulletin OM73 Revision F Type ES73( ) 7.3-Meter ESA 7.3-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.
Table of Contents Introduction Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Proprietary Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Information and Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Notice . . . . . . . . . . . . . .
7.3-Meter Earth Station Antenna Introduction Like all Andrew earth station antennas, the 7.3-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 linearlyor circularly-polarized 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 7.3-Meter C-, X- or KuBand 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 7.3-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 Reporting Equipment Loss or Damage Reporting Visible Loss or Damage Andrew Corporation thoroughly inspects and carefully packs all equipment before shipment. If you find that there are missing components, please notify Andrew Corporation immediately by contacting the Customer Service Center (refer to page 4). If you find that there was damage caused to the equipment during the shipping process, a claim should be filed with the carrier.
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 Procedures Overview This section provides installation procedures for the 7.3-Meter Andrew Earth Station Antenna. The installation procedures include instructions on the following antenna components: • Mount • Reflector-to-Mount Assembly • Reflector • Enclosure Foundation Preparation • Subreflector • Feed System (C-, X- or Ku-band) Before beginning the installation process on the ground mount assembly, ensure that the foundation has been prepared.
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.
Tripod Ground Mount Assembly 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 subsequent procedures for proper installation of tripod ground mount assembly. Azimuth Beam Assembly Step 1 All ground mount hardware is type A-325. Lubricate all A325 bolt threads with supplied stick wax.
Support Legs Assembly Step 1 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 Figure 5 Step 2 Attach 200088A joint assembly to 201313A beam assembly as shown in Figure 6.
Step 3 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 bolts from 201327A joint assembly to supports • Supports should be installed back-to-back with the flat of angle facing upwards • Tighten supports until assembly can support itself 201315 Supports Figure 7 Step 4 Attach 201301/201302 rear pad assembly to 201315 supports as shown in Figures 8 thru 10.
Step 5 Attach 201314 supports 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 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 Figure 9 Step 6 Attach 201317 supports between angle pairs as shown in Figure 10.
Panning Frame Assembly Step 1 Attach 201487 panning frame to 221384 azimuth pivot assembly as shown in Figures 11 and 12. Note: Ensure pivot assembly resolver/limit switch mounting holes are downward.
Step 2 Attach 221608 joint assemblies to panning frame as shown in Figures 13 and 14.
Step 3 Attach 201316 support pairs to 221608 joint assemblies as shown in Figure 15. • Place supports 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 201316 Supports Figure 15 Step 4 Attach 221345 azimuth pivot assembly to 201316 support pairs. Attach 201596 mounting plates to 221345 azimuth pivot assembly tab as shown in Figure 16.
Step 5 Attach 201770 plate connecting 201484/201484-2 extension assembly to 201487 panning frame as pictured in Figure 17. • Use 7/8 x 2-1/4 in (57 mm) hardware • Insert bolts from inside panning frame assembly 201770 Plate 201487 Panning Frame 201484/201484-2 Extension Assembly Figure 17 Step 6 Attach 201488 outrigger plate to opposite end of 201487 panning assembly. Attach 201481/201482 supports to outrigger plate as shown in Figure 18.
Step 7 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 bolts from inside assembly to outrigger plate 201488 Outrigger Plate Figure 19 Step 8 Attach 221721 elevation axis assembly to 201487 panning frame assembly and 221608 joint assemblies as shown in Figures 20 and 21.
Figure 21 Step 9 Attach 301741 right tripod joint bracket and 301742 left tripod joint bracket to 221721 elevation axis assembly as shown in Figure 22.
Step 10 Attach 300026 tripod channel legs to tripod joint brackets 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 300026 Tripod Channel Legs 301741/301742 Tripod Joint Brackets Figure 23 Step 11 Attach 301772 tripod tube weldment to 300026 tripod channel legs as shown in Figure 24.
Elevation Jackscrew Assembly Step 1 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 Step 2 Loosen rubber boot from end of jackscrew. Turn elevation drive screw to extend jack to dimension 67.7 in (1719 mm) as shown in Figure 26. Apply grease to screw shaft. Reattach rubber boot. 67.
Step 3 Prop 301771/301736 elevation jackscrew up to align with 301772 tripod tube weldment as shown in Figure 27. 301771/301736 Elevation Jackscrew Figure 27 Step 4 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. Tighten jam nut in accordance with A-325 procedure.
Azimuth Jackscrew Assembly Step 1 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. 221738 221923/223180 Figure 29 Step 2 Apply RTV to flange surface as shown in Figure 29. Fasten jack to pivot using 7/8 x 23/4 in (70 mm) bolts and nuts. Mounting hardware is included with corresponding jack assembly hardware kit.
Step 3 Attach rear pad assemblies to rear foundation pads as pictured in Figure 31. 201327A 201313A Figure 31 Step 4 Connect beam assembly using 7/8 x 2-1/4 in (57 mm) hardware. Tighten supports to beam assembly per A-325 tensioning procedure.
Step 5 Hoist elevation jackscrew/panning frame assembly to mount as shown in Figures 32A/32B. Figure 32A Figure 32B Step 6 Apply RTV to flange surfaces and attach 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.
Step 7 Attach 221345 azimuth pivot assembly to 201408 beam assembly with a line of RTV around the plate and four 7/8 x 2-1/4 in (57 mm) holts inserted from pivot assembly to beam assembly as shown in Figure 33. Note: Use one 7/8 by 2-3/4 inch (70 mm) bolt, flat washer and nut for later attachment of grounding cable. 221345 7/8 x 2-1/4” (57 mm) Figure 33 Note: If optional motor drive system is included, install motors at this point. Refer to installation instructions provided with motor kits.
Step 10 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 fully extend azimuth jackscrew to ensure binding does not occur throughout entire azimuth pivot range. 221923/223180 221738 Figure 35A Step 11 Refer to Figures 35A/35B.
Reflector/ Subreflector/ Feed Assembly Feed/Waveguide Assembly Step 1 Type 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 A-325 tensioning procedure in preceding installation text. CAUTION: Adhere to any special instructions stenciled on crate relative to crate opening, contents removal and/or personnel safety.
Step 3 Align tabs on 77639 feed rotating 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 nuts as shown in Figure 38. Do not tighten.
Step 4 Attach 77874 feed supports between rotating tube tabs and corresponding drum tabs as shown in Figure 38. Fully tighten. • Use 1/2 x 1-1/8 (29 mm) shoulder bolts, lockwashers and nuts Note: Ensure shoulder bolts are fully seated and feed support angles are installed edge down with flats of angles facing upward. Step 5 Fully tighten flange to drum connection hardware. Step 6 Attach circular waveguide assembly to 201606 feed horn assembly as shown in Figure 39.
Step 7 Attach 77646-2 feed horn mounting pipe to 201606/301808 feed horn assembly as shown in Figure 40.
Step 8 Install circular waveguide assembly through 77639 rotating tube assembly and attach feed horn/mounting pipe assembly to rotating tube as shown in Figure 41A. Install 201065A circular waveguide support assembly as shown in Figure 41B.
Step 9 Rotate drum assembly into upright position. Level drum with shims until no side can bounce, as shown in Figure 42.
Reflector/ Backstructure Assembly Step 1 Attach back strut assemblies to lower drum ring brackets as shown in Figures 43 and 44.
Step 2 Remove entire end of panel crate to allow easy access and careful removal of reflector panels. • When transporting panels, support panel on side as packaged Step 3 Tie assembly down by knotting rope between lifting tabs and three 3 ft stakes as shown in Figure 45. This will prevent an unbalanced condition when adding panels one at a time.
Center portion of Andrew “flash” logo Figure 47 38 Installation Procedures
Step 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 Note: Tighten only until lock washers are flattened.
Step 6 Repeat Steps 4 and 5 to install second panel adjacent to panel segment 1 as shown in Figures 49. Install panel 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 Figure 50. Important: Do not step on panel surface when installing panel seam hardware. Apply force only on panel seam.
Step 7 Install third panel segment (adjacent to first panel segment) according to Steps 4 thru 6 and Figure 51. Figure 51 Step 8 Continue installing panel segments as described in Steps 4 thru 7 in counter-clockwise direction as shown in Figure 52. Note: Panels are numbered and should be installed in proper sequence. Note: Ensure that 9 ft supports are used at every other panel segment.
Step 9 Step 10 Prior to installing panels 15 and 16 station a man on top of the drum assembly enclosure to install panel seam hardware. Care must be taken not to apply heavy weight to surface of panel segments. Note that there are 16 panel segments each with 21 bolt holes numbered 1-21 from the center out which form concentric rings around the inside of the reflector as shown in Figure 53.
Step 15 Beginning with panel seam 1, fully tighten hardware attaching 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 attaching hardware on all reflector segments. Step 16 Install 170147 quadrapod plates at positions indicated in Figure 54 according to procedure in Figure 55. Do not tighten hardware.
Subreflector Strut Assembly Step 1 Attach subreflector strut assemblies to 170147 quadrapod plates as shown in Figures 56 and 57. Tighten hardware until snug only.
Figure 57 45 Installation Procedures
Step 2 Attach subreflector strut assemblies to opposing sides of 77943 apex bracket as shown in Figures 58 and 59.
Step 3 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, lockwashers and nuts Figure 60 Step 4 Fully tighten quadrapod plates to reflector segments, struts to quadrapod plates, struts to apex bracket, subreflector ring to strut assembly plates.
Reflector to Ground Mount Assembly Step 1 Attach 5/8 in (16 mm) shackles to three lifting tabs as shown in Figure 62. Attach 15 ft (4.5 m) tag lines to opposing quadrapod plates. Top Figure 62 Step 2 Raise reflector/backstructure assembly and align with corresponding mounting holes in drum and elevation axis assemblies using tag lines for proper guidance as shown in Figure 63.
Figure 63 Figure 64 49 Installation Procedures
Subreflector Assembly and Adjustment Step 1 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 NOTE: 5” (127mm) dimension shown is a starting reference only. Dimension will vary after adjustments are complete. Figure 65 Step 2 Refer to Figure 66. Measure and note the distance between either outermost angle clip bolt head and the subreflector rim.
Step 3 Adjust subreflector hardware to obtain appropriate setting from surface of reflector at seam bolt ring #1 to bottom of subreflector rim in a radial plane as shown in Figure 67. Securely tighten adjustment hardware. Figure 67 Step 4 Repeat the adjustment procedure performed in Step 2, until all areas of the subreflector are uniform. Adjust the jam nuts, and securely tighten the adjustment hardware.
Cross-Axis Grounding Kit Note: Thoroughly clean exposed portions of grounding cables, unplated portion of universal 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 installation. Thoroughly remove conductive grease from hands and tools using soap and water. Step 1 Refer to Figure 68.
Step 2 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 nuts. 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 second grounding cable to other side of elevation axis/panning frame assembly. Step 3 Attach foundation grounding cable connectors to each mount leg.
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 There are several procedures that may be used to properly acquire the satellite.
The following steps provide the procedure for acquiring a satellite. Step 1 Begin by obtaining the correct Az/El pointing data for the satellite of interest based on specific calculations for this particular site. Step 2 Using an inclinometer placed on the enclosure drum surface, position the antenna to the specified elevation angle.
Step 7 Move the antenna in azimuth to obtain a null, then move ± in elevation to obtain 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 explanation for polarization adjustment addresses the special case of full transponder signals. Some applications may include partial transponder signals.
Step 10 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.
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.
Preventive Maintenance Overview This section contains periodic preventive maintenance instructions for the 7.3-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 Inspection Local Control/Motor Drive Controller 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. After cleaning, allow cleaned parts to dry for 10 to 15 minutes before placing the equipment into operation.
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. • Check the relays and contactors for free operation of the armatures and contact condition.
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 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.
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 using a wire brush. Replace rather than tighten any loose A-325 structural hardware. The hardware distorts at initial installation and once loosened will not maintain the required high strength friction connection.
Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 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. Record the current draw in the equipment log and compare the readings to the reference values entered in the installation/acceptance check off.
Preservation of Component Parts Aluminum Parts 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. Wipe the surface to be painted with a soft rag dampened in trichlorethylene, lacquer thinner or equal.
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 grease fitting and corresponding pipe plug on opposite sides of the jack housing. Remove the appropriate pipe plug and fill with with grease until lubricant seeps from the pipe plug opening. Replace and securely tighten pipe plug.
Lubrication Chart Lube Components Point to be No. Lubricated 1 Frequency (Months) 3 6 12 Type of Service Type of Lube No. of Lube Points or Quantity Pressure Fitting SHC32 1 1. Elevation Jackscrew Housing X 2.1 Elevation Jackscrew Gear Housing Fill and Drain I* C** Pipe Plugs SHC624 10 Oz 3.2 Elevation Drive Intermediate Gearbox Fill and Drain I* C** Pipe Plugs SHC624 34 Oz. 4. Elevation Jackscrew Pivot Pin, upper X Pressure Fitting SHC32 1 5.
Pressure Fitting 5 9 10 Pressure Fitting Worm Gear Polarization Pillow Drive Gear Blocks (2) Gearbox Fill Pressure Fitting 4 Gearbox Fill Gearbox Fill Heater Control Gearbox Level 1 2 3 Pressure Fitting Gearbox Drain Gearbox Level 6 7 8 Gearbox Fill Local Motor Control Note Medium-speed motors shown for illustrative purposes only.
Pressure Fitting 5 9 10 Pressure Fitting Worm Gear Polarization Pillow Drive Gear Blocks (2) Pressure Fitting 4 Heater Control Gearbox Drain 1 2 3 Pressure Fitting Gearbox Drain 6 7 8 Gearbox Level Local Motor Control Gearbox Level Medium-Speed Antenna Lubrication Points 69 Preventive Maintenance
