Installation, Operation and Maintenance Bulletin OM76PK Revision D Type ES76PK-1 7.6-Meter ESA 7.6-Meter Earth Station Antenna Notice The installation, maintenance, or removal of antenna systems requires qualified, experienced personnel. Andrew installation instructions have been written for such personnel. Antenna systems should be inspected by qualified personnel to verify proper installation, maintenance and condition of equipment.
Table of Contents Introduction Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Proprietary Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Information and Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Notice . . . . . . . . . . . . . .
7.6-Meter Earth Station Antenna Introduction Like all Andrew earth station antennas, the 7.6-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 7.6-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 7.6-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 Procedures Overview This section provides installation procedures for the 7.6-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 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.
Pedestal Ground Mount Assembly Pedestal Installation The Pedestal Mount is an elevation-over-azimuth mount optimized for geostationary satellite applications. The mount enables continuous elevation adjustment from 0 to 90 degree. The azimuth axis has over 180 degrees of travel with 120 degrees (+/-60 deg.) of continuous travel at each jack position. The jack can be positioned every 45 deg. around the pedestal tube. Follow the subsequent procedures for proper installation of pedestal ground mount assembly.
Step 3 Using the 1-1/4 in. foundation hardware supplied, level the pedestal to within +/-0.1 degrees. Tighten each anchor bolt to 912 lb/ft (126 kg/m) as shown in Figure 4. Note: Tighten each bolt using no more than 300 lb/ft (41.5 kg/m) at a time in tightening sequence shown. • Use 1-1/4 in. flatwashers and hex nuts.
Step 4 Place Anchor Plates (175311) over the corresponding anchor bolts as shown in Figure 3. Note: Ensure anchor plates are oriented on the foundation bolts as shown, level and on same datum as the pedestal assembly. Using the foundation supplied hardware, tighten each anchor bolt to 912 lb/ft (126 kg/m) as shown in Figure 4. Note: Tighten each bolt using no more than 300 lb/ft (41.5 kg/m) at a time in tightening sequence shown.
Azimuth Jackscrew Assembly Step 1 Raise the Azimuth Jack assembly into place and attach it to the pedestal assembly as shown in Figure 7. NOTE: The bolts attaching the trunnion to the jack are supplied loose, this hardware must be torqued once the jack is installed and aligned (see Figure 7). • Install Azimuth Trunnion Pin (302164). • Use 3/8 x 1 in. capscrew, washer and lock washer. AZ Trunnion Pin, 302164 3/8”x1.
Step 2 Attach Azimuth Jack rod end assembly to the Azimuth Jack Arm as shown in Figure 8. • Use Azimuth Pin (302168) and 3/8 x 1 in. capscrew, washer and lock washer. (AZ Jack Pin, 302168) 1-1/4” Washer, 9997-188 (2) (AZ Jack, 302281) (302383) AZ Jack Pin, 302168) 3/8”x1.
Elevation Jackscrew Assembly Step 1 Raise and attach the Elevation Jack assembly to the pedestal assembly as shown in Figure 10. Fully retract the Elevation Jack to it’s minimum length. NOTE: The bolts attaching the trunnion to the jack are supplied loose, this hardware must be torqued once the jack is installed and aligned (see Figure 10). • Use Elevation Trunnion Pin (303725) and 3/8 x 1 in. capscrew, washer and lockwasher.
WARNING Assembly and installation of Reflector/Backstructure should only take place when winds are less than 15 mph (24 km/h) to prevent damage to reflector panels and ease the assembly process. Follow special instructions stenciled on crate relative to crate opening, contents removal and/or personnel safety. Reflector/ Backstructure Assembly Step 1 Note Lubricate bolt threads of both stainless steel and A325 hardware with supplied Stick Wax (200852) to reduce friction. Do not allow wax under flat washer.
Step 2 Step 3 Once all 16 Short Struts are installed and securely fastened, re-install Rear Enclosure Panel. Carefully rotate the enclosure right-side-up as shown in Figure 12. Place temporary wood blocks under each of the enclosure’s three support pads with the additional block positioned in between. Install Ribs (222673) to enclosure strut as shown in Figure 12. Attach Target Screws supplied from Alignment Kit (223711) as shown and tighten. Leave all other hardware loose. 1/2-13x1.
Step 4 Install Outer Strut to assembly as shown in Figure 13. Leave hardware loose. Eccentric Bolt, 300084A Washer, 9997-101 1/2” Locknut, 9979-54 (Outer Strut, 300079) View A-A Outer Strut, 300079 View B-B 5/8”x2.
Step 5 Lift truss/rib assembly and install Long Strut as shown in Figure 14. Note: the Long Strut is installed on the opposite side of the Truss Plate. Refer to Figure 12, View D-D for previously installed hardware for Inner Strut to Truss Plate connection. Leave hardware loose. Hardware installed at Step 3, Figure 12, View D-D (Truss Plate, 300081) (300080) (Inner Strut, 300080) (300081) (300076) View A-A Long Strut, 300076 5/8”x2.
Step 7 Attach stretch-formed Skirts (222765-2), Strip Spacer (300040) and Inboard Skirt (300082-2) to Reflector Panels (222677) before attaching panels to ribs. Refer to Figure 15, Section A-A & View B-B. Do not install outer-most screw on each side of skirt at this time. NOTE: Do not overtighten skirt panel screws. It may deform the panel. Tighten screws only enough to fully compress the lockwashers.
Step 8 Attach the reflector panels by placing them on the ribs and sliding them inward, carefully guiding the rib flange between the skirt and panel. Place seam hardware (209236 & 9974-17) in the fourth hole from the outboard edge on both sides of the panel first, finger tight only. Then place all remaining hardware, finger tight only. then attach skirt to rib hardware as shown in Figure 15, View B-B, finger tight only.
Step 11 After all 16 reflector panels are fastened to ribs. Attach the Cross Struts (300078) by placing them in-between the Inner Struts (300080) and snug tight the hardware. Refer to Figure 16. After all 16 Cross Struts are attached, tighten all hardware. NOTE: The Cross Struts are the last item to be assembled to insure the ease of Reflector Panels to be mounted on top side of the ribs.
Reflector Alignment Notice Temperature change during calibration or alignment of this reflector will adversely effect the alignment quality, and therefore, the performance of this antenna. Calibration and alignment should only be done during stable temperature conditions, typically after sunset or under heavy cloud cover. Before the theodolite installation/calibration, or rerflector alignment, all panel seam hardware should be loose including the lifting tab hardware.
1.3 Install Brass Rod Holders: Install brass rod holders in seam hole #11 on rib #2, 7, & 10 in Figures 19 and 20. Reflector seam screws must first be removed in these locations. Make sure the bottom of the rod holders are sitting flush on the reflector panels and they are pointed toward the theodolite assembly. Attach the alignment stick to the rod holder in rib #2 with the knob assembly. 1.
1.5 “Clock" the Theodolite Assembly: Refer to Figure 20. The theodolite support assembly must be 'clocked' to the brass rod holders such that two of the tribrach leveling screws run parallel with ribs 2 and 10 (see enlarged view in Figure 20). This can be accomplished by rotating the top flange of the torque tube which will rotate the entire theodolite assembly. Step 2 Calibration: Note: Before adjustments, make sure that all the hardware connecting the torque tube to the reflector are fully tightened.
Relocate stick to rib #7. Rotate theodolite, focus and adjust elevation to the scribe line and record this reading as R2. Relocate stick to rib #10. Rotate theodolite, focus and adjust elevation to the scribe line and record this reading as R3. Calculate an average angle by adding R1, R2, & R3 together and dividing by 3. Record this as R4. Adjust theodolite elevation angle to this new angle R4.
Figure 21 Repeat the above procedure for the other axis of the X-Y translation stage 90 degrees to the first one. After centering, adjust the theodolite height as indicated below. 2.4 Adjust Height: The height adjustment of the theodolite is accomplished with the precision lift (refer to Figure 18). This device can lower or raise the theodolite to the desired height by rotating the large rim located at the center of the upper body of the device.
Relocate the stick to rib #7. Focus and adjust the elevation to align to stick scribe line. Reord as H3. The specification for height requires that H1, H2 & H3 be within +/-15 seconds (0.0042 degrees) of 90 degrees. This can only be achieved through successive leveling/centering sequences. Step 3 Repeat as Necessary: Repeat 2.2, 2.3, and 2.4 until the calibration specifications are achieved.
3.3 Rough Outboard Alignment: Adjust theodolite elevation angle to the ‘EL1’ value indicated in Figure 19. Point and focus the scope of the theodolite to target EL1 (do not move elevation) located on the rib #1, which is to the right of the top panel (top center of antenna with Andrew `Flash’ logo). While still focusing to the target, have the outboard cambolt slowly rotated until the upper edge of the target screw is within +/-15 seconds (0.0042 deg.) of the theodolite crosshair.
3.5.3 Repeat all 16 adjustments again. This time, after each individual adjustment, fully tighten seam hardware #24 and 25 on the rib being adjusted. The outer ring of the reflector is now `locked’ in place. 3.6 Fine Inboard Alignment: NOTE: During seam hardware tightening as described in `Fine Inbard Alignment’ take extra precaution not to step on the center of the panels as your weight will displace the panel during tightening.
Reflector to Ground Mount Assembly Step 1 Attach 16ft. (5m) chokers with corresponding 5/8” shackles to the Lifting Tabs (206278). Attach 30ft. (9m) tag lines of suitable rope equally spaced about reflector (refer to Figure 22). Note: Ensure ground mount pedestal assembly has elevation jack in the fully retracted position. Carefully raise the reflector assembly, position it over the pedestal and gently lower the assembly onto the pedestal. Attach and tighten using indicated hardware in Figure 22.
Subreflector Installation NOTE: Ensure that the Feed System is installed prior to installation of Subreflector and Struts. Step 1 Place the reflector in the zenith (EL = 90 deg.) position. Step 2 Refer to Figure 23. Loosely assemble Subreflector Strut Assembly (300092) as shown using supplied Angles (300088), Subreflector Strut Brackets (300090) and corresponding mounting hardware.
Step 3 Step 4 Refer to Figure 23, View A-A and Figure 24. Loosely attach Subreflector Strut Supports (300089) to panel segements 8-16, 3-11, 7-15 and 4-12 as shown. Replace screws, washers, lockwashers and nuts previously installed during reflector assembly. NOTE: Subreflector Strut Supports should be positioned according to Step 3 and at the 2nd and 3rd seam holes from the outboard end of the rib. Refer to Figure 25.
Step 5 Step 6 Carefully raise and attach pre-assembled subreflector/strut assembly to corresponding subreflector strut supports as shown in View A-A (Figure 23) and Figure 25 using supplied hardware. Securely tighten all subreflector/strut assembly mounting hardware except for floating ring hardware shown in Figure 25. Remove temporary nylon slings.
Subreflector Centering Step 7 Measure and note the distance between outermost subreflector strut support bolt head and the subreflector rim as shown in Figure 25. Obtain corresponding measurements from remaining subreflector struts. These measurements should have a maximum differential of 0.062 in. (1.5mm). If adjustment is necessary, loosen the four floating ring bolts and slide subreflector appropriately to achieve the 0.062 in. (1.5mm) differential. Make sure to re-tighten bolts when finished.
Operation Overview Acquiring A Satellite 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. There are several procedures that may be used to properly acquire a satellite.
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.
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 7.6-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 all electrical components for dirt, cracks, chips, breaks, discoloration and other signs of deterioration and damage. A discolored, blistered, or burnt condition is evidence of overload. Measure actual value of suspect electrical components and compare against specified value. • 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 electrical component for dirt, cracks, chips, breaks, discoloration, and other signs of deterioration and damage. A discolored, blistered, or burnt condition is evidence of overload. • Operate the azimuth and elevation drives as well as the feed rotation in both the plus and minus direction from the local control/motor drive controller at least once every three months during antenna down time.
• Visually inspect all mechanical parts for freedom of operation with no misalignment, binding or interference. Check all cabling for sufficient slack to prevent cable strain as well as adequate restraint to prevent abrasion or chaffing during antenna and feed movement. • 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.
the installation/acceptance check off. If the readings differ by more than five percent, refer to appropriate troubleshooting information and perform applicable corrective action. Then take voltage readings off each of the three conductors; the readings should agree with each other within two percent. Turn the FEED CCW/OFF/CW switch to OFF. Step 4 Repeat preceding step (3) with the FEED CCW/OFF/CW switch in the alternate operating position.
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.
and remove any old lubricant to prevent an excessive build-up. Remove indicated access plugs from square tube weldment and apply lubricant to panning frame tube assembly and corresponding thrust pads. Securely replace access plugs in square tube weldment. Be certain to remove any protective caps and clean off each lubrication fitting prior to injecting fresh grease.
Lubrication Chart Lube Components Point to be No. Lubricated 1 Frequency (Months) 3 6 Type of Service Type of Lube No. of Lube Points or Quantity X Pressure Fitting SHC32 1 C** Pipe Plugs SHC624 10 Oz 12 1. Azimuth/Elevation Jackscrew Housing 2.1 Azimuth/Elevation Jackscrew Gear Housing Fill and Drain 3. Polarization Drive Gear X Brush SHC32 Minimum Surface Coverage 4. Feed Rotation Worm Gear Pillow Blocks X Pressure Fitting SHC32 2 5.
Pressure Fitting 5 3 4 1 Gearbox 2 Level 5 Pressure Fitting Gearbox Drain 6 Pressure Fitting Local Motor Control Antenna Lubrication Points 54 Preventive Maintenance