Andrew 9.3-Meter ESA 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 Printed in U.S.A. 01/05 Copy[...]

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 9.3-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 9.3-Meter C-Band Earth S tation Antenna. This manual provides a convenient reference for authorized operator/service personnel requiring technical information on general system o[...]

Ov er view Warnings The installation, operation, and maintenance of the 9.3-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 refer to p age 9 for step-by- step instructio[...]

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 9.3-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 0 to 90°. Azimuth adjustment is ±90° and divided into three 120° ranges with 30° overlap. Follow the [...]

13 Installation Procedures Ste p 4 Raise 201 1 12 azimuth beam assembly and attach to front foundation p ad as shown in Figure 5. • Use 1 in. (25 mm) flatwashers and hex nuts Note: Hex nuts and flatwashers supplied with 201680 anchor bolt kit Figure 5[...]

Suppor t Le gs Assembly Ste p 1 Ste p 2 14 Attach 200068 joint assembly to 2001 14A beam assembly as shown in Figure 6. Attach 200083 angles to 2001 14A beam assembly as shown in Figure 6. • Use 7/8 x 2-1/4 in (57 mm) bolts and nut s for each connection Installation Procedures Figure 6 Attach 200088 joint assembly to 2001 14A beam assembly as sho[...]

Ste p 3 Ste p 4 15 Raise 2001 14A beam assembly to upright position and att ach 200109 supports to 200068 joint assembly as shown in Figure 8. • Use 7/8 x 2-1/4 in (57 mm) bolts and nut s • Insert bolts from 200068 joint assembly to support s • Supports should be inst alled back-to-back with the flat of angle facing upwards • T ighten suppo[...]

Ste p 5 Ste p 6 16 Attach 200108 support s to 200063/200064 rear pad assemblies and 200088 joint assembly as shown in Figure 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 facing rear [...]

17 Installation Procedures Ste p 7 Refer to Figure 12. Raise and attach assembled beam/support assembly to 2001 12 beam assembly using 7/8 by 2-1/4 in (57 mm) hardware and corresponding rear founda- tion pads as shown using 1 in flat washers and hex nut s. Ensure all A-325 mounting hardware is in place. Begin A-325 tensioning procedure at pads, and[...]

Panning F rame Assembly Ste p 1 Ste p 2 Ste p 3 18 Refer to Figures 13A and 13B. Determine azimuth range requirements from APPENDIX ‘A ’ (page 65) and loosely att ach 200035 outrigger assembly (if required) to appropriate side of 200031A panning assembly . • Use 7/8 x 2-1/4 in (57 mm) hardware and apply supplied RTV to flange surfaces as indi[...]

Ste p 4 Ste p 5 19 Installation Procedures Figure 14 Refer to Figure 14. Apply supplied RTV to flange surfaces and loosely attach 200699/200021 elevation pivot assemblies to rear of enclosure drum assembly • Use 3/4 by 3.0 inch (75 mm) hardware Slightly raising assembly and loosely attach 200016/200015 joint assemblies to bottom portions of panni[...]

Ste p 6 20 Installation Procedures Figure 15 Refer to Figure 15. Raise assembled panning/pivot assembly and loosely att ach 301786 azimuth pivot assembly to upper portion of 200068 joint assembly as shown. • Use 7/8 by 2-1/2 inch (64 mm) hardware Note: Position mounting hardware as shown to ensure proper panning frame clearance. Install 7/8 inch [...]

Ste p 7 Ste p 8 21 Installation Procedures Figure 16 301786 Refer to Figure 16. Attach 200107 support pairs back-to-back with 45967 spacer at mid- point. Loosely attach support p airs to corresponding tabs on 200015/200016 joint assem- blies and 201022 pivot assembly as shown. • Use 7/8 by 2-1/4 in (57 mm) hardware Note: Angles are attached edge [...]

Azimuth J ack Screw Assembly Ste p 1 Ste p 2 22 Installation Procedures Attach 200131 azimuth jack extension to 200013-4 azimuth jack screw (manual, low- and medium-speed applications only) as shown. • Use 7/8 by 2-3/4 inch (70 mm) bolts, flat washers and nut s. Note: T ype 301841 azimuth jack screw is used only for high-speed applications. Refer[...]

Ste p 3 Ste p 4 Ste p 5 23 Installation Procedures Figure 18 Refer to Figure 18. Raise the azimuth pivot/jack screw assembly , and attach to 200088A joint assembly . • Use 1 by 2-1/2 inch (63 mm) hardware. Note: Mounting position of azimuth/pivot jack screw assembly is dependent upon azimuth range requirements and corresponds with mounting positi[...]

Ste p 6 24 Installation Procedures Figure 19A Replace previously removed jack screw band clamp assembly . Note: Attach .jack extension to pivot assembly using 7/8 by 2-3/4 in (70 mm) bolt s and nuts (P/O jack assembly hardware kit), for 200013-4 azimuth jack applications. For motorized mounts only , remove oil plug on motor assembly gearbox and rep[...]

Ele v ation J ackscrew Assembly Ste p 1 Ste p 2 25 Installation Procedures Figure 20 Refer to Figure 20. Apply supplied RTV to indicated flange surfaces and attach 200013- 3/200048 elevation jack screw to 200128 elevation extension assembly as shown. • Use 1-1/4 by 3-1/2 in (89 mm) bolts, washers and nut s Note: Mounting hardware is included with[...]

Ste p 3 26 Installation Procedures Figure 21 Refer to Figure 21. Apply supplied RTV to flange surface and attach remaining end of 200128 elevation extension assembly to corresponding 201022 pivot assembly as shown. • Use 7/8 by 2-1/4 in (57 mm) hardware. For motorized mounts only , remove oil plug on motor assembly gearbox and replace with suppli[...]

Grounding Ca ble Attachment Ste p 1 27 Installation Procedures Figure 22 Note: Thoroughly clean exposed portions of grounding cables, unplated portion of uni- versal terminals and corresponding mounting surfaces using a wire brush. Liberally apply supplied 203233-2 conductive grease to all connection surfaces prior to and after inst al- lation. Tho[...]

Ste p 2 Ste p 3 28 Installation Procedures Refer to Figure 23. Remove existing 7/8 by 2-1/4 in (57 mm) hardware from both eleva- tion pivot/joint assemblies at indicated positions and install grounding cables as shown. • Use supplied 7/8 by 2-3/4 in (70 mm) bolts and nut s Note: Supplied 3/4 in hardware is installed af ter reflector to ground mou[...]

R eflector/ Backstructure Assembly Feed R otating T ube Assembly Ste p 1 29 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 A-325 tens[...]

Ste p 2 Ste p 3 30 Installation Procedures Refer to Figure 25. Align tabs on feed rotating tube assembly 77639 or non-rotating tube 78334 with corresponding angle brackets on drum assembly . Apply supplied RTV as shown and attach rot ating tube to center of drum assembly . • Use 3/8 x 1-1/2 in (38 mm) bolts, lock washers and nut s If 78334 non-ro[...]

J ack T ripod Assembly Ste p 1 Ste p 2 Ste p 3 Ste p 4 31 Installation Procedures Figure 26 Attach side plates to jack tripod assembly leg. • Use 1 x 2-1/2 in (64 mm) bolt, lock washer and nut Attach side plates to drum t ab. • Use 3/4 x 2 in (51 mm) bolt, lock washer and nut Note: Keep angled corners of side plates toward drum assembly . Refer[...]

32 Installation Procedures R eflector Assembly Ste p 1 Ste p 2 Refer to Figure 27. Assemble 20 right- and left-hand back-to-back strut assembly pairs T ype 78082 and 78083 as shown. • Use 1/2 x 1-1/2 in (38 mm) bolts, sp acers, lock washers and nuts. T ighten strut spacer bolt. Figure 28 Figure 27 Refer to Figure 28. From inside of drum assembly [...]

33 Installation Procedures Ste p 3 Refer to Figure 29. Carefully remove reflector panel segment s from packing crates. Begin with center flash panel (if applicable) and att ach to corresponding angle tab on upper drum ring as shown. • Using 5/8 x 1-3/4 in (44 mm) bolt, spacer , lock washer and nut. T ighten the panel to drum angle hardware until [...]

34 Installation Procedures Ste p 4 Ste p 5 Refer to Figure 30. Install reflector segment formed tee section between corresponding back strut members and attach. • Use 1/2 x 1-7/16 in (37 mm) eccentric bolt, lock washer and nut Note: Ensure eccentric bolt is fully seated and bolt head marking is positioned at right angle to panel segment. It is re[...]

35 Installation Procedures Ste p 6 Subreflector Assembly Ste p 1 Refer to Figure 32. Loosely attach 300177 Subreflector S trut Supports to reflector as shown ensuring brackets are inst alled on seam hole positions 15 and 16. Position brackets clockwise as shown using bracket s and hardware supplied as part of 300175 Subreflector S trut Kit. Figure [...]

Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 Refer to Figure 34. Attach 300178 Subreflector S trut Brackets to 300174 S trut Assemblies. • Use 1/2 x 2-1/2 in (64 mm) galvanized bolts, 300022 backup plates, lock washers and nut s. Note: All strut brackets should face counterclockwise as shown. Figure 34 Assemble 300174 strut assemblies as shown. • Us[...]

37 Installation Procedures Ste p 7 Ste p 8 Refer to Figure 35. Raise preassembled subreflector subassembly and strut assembly and attach to subreflector support s as shown. • Use 1/2 x 2-1/2 in (64 mm) galvanized bolts, flat washers, lock washers and nut s. Securely tighten mounting hardware. Mount tabs on strut assemblies to right side of subref[...]

38 Installation Procedures T heodolite Assembly T heodolite Installation Ste p 1 Refer to Figure 36. The Andrew Theodolite Kit (22371 1) contains 1 theodolite mounting assembly and 1 alignment stick assembly . A Wild T2 or T opcon DT -05A theodolite is used but not included as part of the Andrew Theodolite Kit. Note: The theodolite mounting assembl[...]

38 Installation Procedures Ste p 2 Refer to Figure 37. Install theodolite support assembly to feed support tube. Secure theodolite support assembly by attaching lower flange adapter to feed support tube. • Use 3/8 x 1-1/2 in (38 mm) bolts, lock washers and nut s Figure 37[...]

T heodolite Le v eling Ste p 1 Ste p 2 Ste p 3 40 Installation Procedures Figure 38 Refer to Figure 38. Assemble 3 brass rod holders as shown. The brass rod holders used for calibration of the theodolite to the reflector and subsequent alignment of the reflector , must be installed in the third seam holes at the panel seams shown. Before taking any[...]

Ste p 4 Ste p 5 41 Installation Procedures Refer to Figures 38 and 39. With the height of the theodolite and its support kit set as indicated in Figure 24, the theodolite should sight near the scribe line of the alignment stick when theodolite elevation is set to 90° 00’ 00”. If not, set the theodolite elevation angle to 90° and move the theo[...]

T heodolite Centering Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 T heodolite Height Adjustment Ste p 1 Ste p 2 Ste p 3 Ste p 4 42 Installation Procedures Refer to Figures 38 and 39. Centering of the theodolite is performed using the X-Y translation stage. This device has 2 sets of micrometer adjustments and 2 set s of long locking adjustment s[...]

43 Installation Procedures R eflector Panel Adjustment Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 Ste p 6 Ste p 7 Ste p 8 Figure 40 Refer to Figure 40. Each panel segment has a scribe line, which defines the circumfer- ence of all corresponding screw locations at the number 17 position. Adjust panel segment using cambolt s on back struts to move the p[...]

44 Installation Procedures T able 3[...]

Subreflector Adjustment Ste p 1 Ste p 2 Ste p 3 Ste p 4 45 Installation Procedures Refer to Figure 42. Use tape measure to set rim of subreflector to required dist ance of 1 19.1 10 in (302.6 cm) measured from the top of first seam hardware to the aperture plane of the subreflector using three subreflector adjustment studs. Attach right angle viewi[...]

Subreflector Offset Tilt Adjustment Ste p 1 Ste p 2 Ste p 3 Ste p 4 Ste p 5 46 Installation Procedures Refer to T able 4 and Figure 43. Adjust top subreflector jam nuts (two) the distance indi- cated according to the offset pointing angle in T able 4. Make the desired adjustment using the floating ring and subreflector jam nuts. Note: Before making[...]

R eflector/Back- structur e to Ground Mount Assembly Installation Ste p 1 Ste p 2 47 Installation Procedures Refer to Figure 45. Attach 5/8 in (16 mm) shackles with corresponding 20 ft (6 m) chok- ers to four drum assembly angle brackets as shown. Attach 15 ft (4.5 m) t ag line to for- ward left of jack tripod assembly . Note: T wo front chokers sh[...]

Ste p 3 Ste p 4 Ste p 5 Ste p 6 Ste p 7 48 Installation Procedures Refer to Figure 46. Extend elevation jack extension assembly to 7 ft (2 m) dimension as shown. Raise assembly and secure to forward ground mount beam assembly , using 6 ft (2 m) choker and winch assembly . W arning: Do not attempt to raise reflector/backstructure if winds exceed 25 [...]

Ov er view Acquiring A Satellite 49 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 50 The following steps provide the procedure for acquiring a satellite. Begin by obtaining the correct Az/El pointing data for the satellite of interest. Using an inclinometer , position the antenna to the specified elevation angle. Manually move the antenna in the azimuth (scanning back-and-forth aro[...]

Ste p 7 Ste p 8 Ste p 9 51 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. If your antenna is equi[...]

Ste p 10 52 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 53 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 54 Prev entiv e Maintenance This section contains periodic preventive maintenance instructions for the 9.3-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 55 Clean mechanical part s 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 com- pressed air at 25 to 40 psi. Any accumulated imbedded dirt, corrosion, grease, or oil deposi[...]

Antenna 56 • 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-af te[...]

57 • 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 the antenna and feed movement, and limit travel to prevent stru[...]

Driv e System V olta g e and Cur rent Checks Ste p 1 Ste p 2 Ste p 3 58 • Check security of antenna mounting and interconnecting assembly hardware. Be cer- 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[...]

Ste p 4 Ste p 5 Ste p 6 Ste p 7 Ste p 8 Ste p 9 59 Repeat preceding step (3) with the FEED CCW/OFF/CW switch in the alternate operat- ing position. 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 [...]

Preser v ation of Component Par ts Aluminum P ar ts Galv anized Surfaces Lubrication 60 When preserving the component part s, 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[...]

J ackscrews/Motors Gear Motor/Housing Fill Drain R equirements 61 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 pro[...]

62 Prev entiv e Maintenance Lube Components Frequency T ype T ype No. of Lube Point to be (Months) of of Points or No. Lubricated 1361 2 Service Lube Quantity 1. Elevation Jackscrew Housing X Pressure Fitting SHC32 1 2. 1 Elevation Jackscrew Gear Housing I* C** Pipe Plugs SHC624 10 Oz Fill and Drain 3. 2 Elevation Drive Intermediate Gearbox I* C** [...]

High-Speed Antenna Lubrication P oints 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-Speed Antenna Lubrication P oints 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 64 Prev entiv e Maintenance[...]

APPENDIX ‘A ’ This section contains the formulas for determining the point- ing capabilities of the modular mount earth st ation antenna. Formulas for calculating true azimuth ( AZ ), true elevation ( EL ), relative angle between true azimuth and mount point- ing angle ( dAZ ) and strut lengths of the earth station are given below: Given the ea[...]

APPENDIX ‘B’ Sector Change Process The following is a generalized procedure of the actions required to change the 9.3M tripod mount from an existing azimuth range (sector) to a new one. (For example: from Azimuth range -60/+60 to -90/+30. Refer to APPENDIX ‘A ’.) A. T ools Required: a. (2) S pud W renches b. (2) 1 7/16" open end wrench[...]