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Andrew 9.3-Meter ESA Stereo System User Manual

1. Secure Azimuth Jackscrew with rope to landing platform for safety Swivel Jack and Azimuth Pivot Assembly 201021 slowly toward opposite side of panning assembly until mount holes in Azimuth Pivot Assembly line up Use Spud wrench to assist further alignment Insert new A325 Hardware to secure Azimuth Pivot Assembly in new position Extend Jackscrew Swing Antenna using come alongs and or tag lines to align Jackscrew pivot connection with panning frame holes Use Spud wrench to assist further alignment Connect using new hardware NDREW Andrew Corporation Telephone 708 349 3300 Customer Service 24 hours U S A Canada Mexico 1 800 255 1479 10500 West 153rd Street FAX U S A 1 800 349 5444 U K 0800 250055 Republic of Ireland 1 800 535358 Printed in U S A JAN O5 Orland Park IL U S A 60462 Internet htip www andrew com Other Europe 44 1592 782612 Copyright O 2005 by Andrew Corporation 66
2. AZ AZm Where AZm azimuth at which mount is set in degrees East clockwise of True North 65 dAZ relative angle between true azimuth angle looking at satellite and mount pointing direction in degrees EL 90 T R Where EL true elevation angle to view satellite in degrees R arc cos cos 6 cos a T arc tan sin R 6 6166 cos R Pin to pin length of elevation strut in inches Equation 1 XEL V26259 7740 14970 1377 cos 27 0362 EL For the 90 to 30 dAZ Range Pin to pin length of azimuth strut in inches Equation 2 LAZ V7571 2865 6181 928 cos 105 dAZ For the 60 to 60 dAZ Range Pin to pin length of azimuth strut in inches Equation 3 LAZ V7571 2865 6181 928 cos 75 dAZ For the 30 to 90 dAZ Range Pin to pin length of azimuth strut in inches Equation 4 LAZ V7571 2865 6181 928 cos 105 dAZ NOTE Azimuth strut pin to pin length values are based upon strut attachment to right portion of structure as viewed from rear of antenna for 60 to 60 and 30 to 90 azimuth ranges Values for 90 to 30 azimuth range are based on strut attachment to left portion of structure as viewed from rear of antenna 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 ra
3. 26 Installation Procedures Grounding Cable Note Thoroughly clean exposed portions of grounding cables unplated portion of uni Attachment 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 instal lation Thoroughly remove conductive grease from hands and tools using soap and water Step 1 Refer to Figure 22 Remove existing 7 8 by 2 1 4 in 57 mm hardware at indicated posi tions and install grounding cables as shown Use supplied 7 8 by 2 3 4 in 70 mm hardware 200068 JOINT ASSEMBLY GROUNDING CABLE UNIVERSAL TERMINAL 7 8 x 2 3 4 70 mm BOLT FLATWASHER AND NUT UTS 200112 BEAM ASSEMBLY 5 16 x 1 25 mm BOLT FLATWASHER AND NUT UNIVERSAL TERMINAL Figure 22 ANDREW 27 Installation Procedures Step 2 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 nuts Note Supplied 3 4 in hardware is installed after reflector to ground mount installation 200031A PANNING ASSEMBLY 7 8 x 2 3 4 70 mm BOLT AND NUTS a J We PARAS 4 9 3 4 x3 DES 76 mm oa PP UNIVERSAL BOLT LOCKWASHER TERMINAL AND NUTS 46373 GROUNDING CABLE ert NOTES aa 25 mm INSTALLED AFTER REFLECTOR TO GROUND BOLT
4. FLATWASHER MOUNT INSTALLATION AND NUT Figure 23 Step 3 Securely tighten all remaining ground mount jack assembly hardware per hardware ten sioning procedure The tripod ground mount assembly is now completed with the necessary operational essentials All ground mount options have separate instructional bulletins located in the parts kit that contain the option The next step in the installation process is the reflector assembly Proceed to the next page to begin installation of the reflector 28 Installation Procedures Reflector Backstructure Assembly Feed Rotatin Tube 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 pro cedure in preceding installation text CAUTION Adhere to any special instructions sten ciled on crate relative to crate opening contents removal and or personnel safety Refer to Figure 24 Position six temporary supports in center of assembly area 60 apart in a 7 ft 2 m diameter circle Place drum assembly on temporary supports as shown with drum tab positioned opposite ground mount assembly Note Supports should be approximately 18 in 457 mm high and placed between bolt holes on bottom of drum assembly 77490 Toward Drum Ground Mount Assembly Assembly Tempora
5. 15 and 16 Position brackets clockwise as shown using brackets and hardware supplied as part of 300175 Subreflector Strut Kit Subreflector Bracket al 300177 9959 11 Strut Support 5 16 x 1 1 2 i Screw Ss Subreflector Bracket 9997 56 5 16 8 mm Flat Washer i 9974 17 5 16 8 mm Lock Washer 9999 59 End View 5 16 8 mm Nut Subreflector Assembly Step 1 Refer to Figure 33 Carefully remove subreflector subassembly and attached floating ring from wooden crate Remove six 3 4 in 19 mm jam nuts and washers which attach floating ring to subreflector assembly Lift floating ring from adjustment studs Figure 32 Remove 3 4 19 mm Jam Nuts and Washers Figure 33 ANDREW 35 Installation Procedures Step 2 Refer to Figure 34 Attach 300178 Subreflector Strut Brackets to 300174 Strut Assemblies Use 1 2 x 2 1 2 in 64 mm galvanized bolts 300022 backup plates lock washers and nuts Note All strut brackets should face counterclockwise as shown 9963 316 1 2 x 2 51 mm Bolt 9997 28 1 2 13 mm Fiat Washer 9963 335 1 2 x 2 1 2 64 mm Bolt 201826 Rectangular 300176 Washer 9974 4 1 2 13 mm Lock Washer 9999 109 1 2 13 mm Lock Washer 9999 109 Step 3 Step 4 Step 5 Step 6 1 2 13 mm Nut 9999 109 1 2 9974 4 13 mm 1 2 13 mm Nut Lock Washer 300178 Strut Bracket 9963 335 1 2 x 2 1 2 64 mm Floating Bolt
6. 90 DEGREES Step 3 200035 OUTRIGGER ASSEMBLY 301786 AZIMUTH LVER 7 8 x 2 25 57mm PIVOT ASSEMBLY MOUNTING HOLES Le Gos ine FIGURE 13B INDICATES OUTRIGGER STORAGE POSITION FOR AZIMUTH RANGE OF 30 TO 90 DEGREES THE AZIMUTH JACK STRUT MOUNTS TO THE RIGHT SIDE OF THE PANNING ASSEMBLY Figure 13B Apply supplied RTV to flange surfaces and loosely attach 200022 pivot assembly to out rigge as shown Use 7 8 x 2 1 4 in 57 mm hardware and apply supplied RTV to flange surfaces as indicated Attach 301786 azimuth pivot assembly to panning assembly as shown using 7 8 by 2 1 4 inch 57 mm bolts and nuts Note Mounting hardware attaching 301786 azimuth pivot assembly to 200031A panning assembly must be positioned as shown with resolver mounting holes on 301786 azimuth pivot assembly positioned in downward direction Installation Procedures Step 4 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 7 8 x 2 1 4 ENCLOSURE 57 mm DRUM ASSEMBLY BOLTS AND NUTS 200015 JOINT ASSEMBLY 3 4 x 3 LG IQ 75 mm BOLTS LOCKWASHERS AND NUTS 200021 PIVOT ELE SEMBLY O 200031A PANNING ASSEMBLY 200016 JOINT ASSEMBLY Figure 14 Slightly raising assembly and loosely attach 200016 200015 joint assemblies to bottom portions of panning assembly Step 5 Use 7 8 by 2
7. Axis West ELEVATION AXIS m ELEVATION AXIS 4 WN 8 100 2nd Side Lobe Peak aamun Axis ast AZIMUTH AXIS EAST Figure 4 2 Antenna Radiation Pattern Topographical Diagram with Plan View 50 Operation Step 7 Step 8 Step 9 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 If your antenna is equipped with a linear polarizer the antenna is aligned in azimuth and elevation signal maximized and 24 transponder signals 12 horizontal and 12 vertical are noted the polarization adjustment is set incorrectly and must be modified If 12 transponder signals are noted they may or may not be the properly polarized signals Therefore 24 transponder signals must be visually noted in order to determine the prop er polarization setting Rotate the feed assembly clockwise until 24 transponder signals are noted and of approximately equal amplitude NOTE It is more accurate and visually easier to minimize the alternate set of transpon der signals rather than maximizing the transponder of interest ATTEN 10d8 RL 10 OdBm CENTER 3 SSDOGHz SPAN 510 OMH RBW 1 OMH vBw 3 SwP 50 Ome Figure 4 3 Polarization at 45 degrees from Optimum S
8. assembly Reflector Top Drum Tab Scribe Line Levana e hee el for leveling crews i EL Readings Sight Edge of Brass Rod Holder for centering Drum Assembly X Y Translation Stage Theodolite Assembly Brass Cup Third Seam Hole 223721 Alignmant Stick 223745 Assembly Knob 223718A ABSENE l Brass Rod Holder Rib and Reflector Saam Hole 1 4 6 mm Flat Wether 1 4 6 mm Nut Figure 38 ANDREW 40 Installation Procedures Step 4 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 theodolite up or down until it sights on the scribe line using the rotary precision lift Be careful not to turn entire torque tube while turning precision lift Step 5 Focus and adjust theodolite elevation to the scribe line and record this reading as RI Relocate stick rotate theodolite focus and adjust theodolite elevation to scribe line and record this reading as R2 Add RI and R2 readings and divide by 2 Record this reading as R3 Adjust theodolite elevation angle to new angle R3 Rotate the tribach assembly adjustment screw in line with the alignment stick up or down until the theodolite is sighted on the scribe line Repeat this procedure for the diagonally opposed alignm
9. be disclosed or duplicated in whole or in part without express written consent of Andrew Corporation Andrew Corporation provides a world wide technical support network Refer to the tech nical assistance portion of this this manual for the contact numbers appropriate to your location The installation maintenance or removal of antenna systems requires qualified experi enced 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 Andrew Corporation disclaims any liability or responsibility for the results of improper or unsafe installation and maintenance practices All designs specifications and availabilities of products and services presented in this manual are subject to change without notice Copyright 1999 Andrew Corporation 24 hour Technical Assistance For technical assistance call the following numbers at anytime Call From Call To Telephone Fax North America toll free U S A 800 255 1479 800 349 5444 Any Location U S A 708 349 3300 708 349 5410 International Customer Service Center The Andrew Customer Service Center gives you direct access to the information and personnel service you need such as the following Place or change orders Check price and delivery information Request technical literature You can call from any of the follow
10. cette ee 43 Subreflector Adjustment essre se hae Be ema a cae eet thao ahead eli AA Pe eaten 45 Subreflector Offset Tilt Adjustment 2 0 cee nee nena 46 Reflector Backstructure to Ground Mount Assembly Installation o ooooooo 47 OV GIVI OW viii aia ied da dea A A Boe a od a paged AA Dla AAA ieee ie a ls eS 49 Acquiring A Satellite lt lt A nee Seas Gree a ane 49 Subreflector AG UStment sarres eaae eaea ee ete we ea a ed ogee Be Sees ba ae pa 53 OVOIVIOW oia iia Pa o a a dione be in cy al A Boa A A A ble Bi ais di Ai 54 General Cleaning 2 it a a A Riek elas al Dt AS 54 Electrical Parts sera enoeet A a RADAR A AD AER RADA A 54 Mechanical PARAS i o 2i2 a da AA AAA A LA ER EOE DEAD RD RDA A AeA 55 YT A a Fe tae Re any oa OFE aig anes AE RRR a aa Ta eae HO ern ee 55 Local Control Motor Drive Controller ooooooccccccrcrcrnaa 55 ANENA sucosa ca ve bravia sede A AAA o aS 56 Drive System Voltage and Current CheckKS oooocccccocncarana 58 Preservation of Component PartS ooooooccoconorcarar a 60 Aluminum PANES iss oa ia bbs eck a a bee Pe a Pea dace A Fe bean Base a deel AA 60 Galvanized S rfaceS cerus iia A Pa iia a a Nay aoe RAR Peele Male wei E RSE 60 EUDICALIONS eere As AS AA ead Piss aca A make tab BREIL Geta we ee 60 Jackscrews MotorS ai oie etic aaa a E a A bie ee ee a wee ees 62 Gear Motor Housing Fill Drain Requirements 000 0 ccc eee 62 2 Table of Contents 9 3 Me
11. in 57 mm bolts and nuts Attach tripod pivot assembly to elevation jack assembly Use 7 8 x 2 1 2 in 63 mm bolts flat washers and nuts Securely tighten mounting hardware on both sides of pivot assembly according to A 325 Hardware Tensioning Procedure Install subreflector subassembly Use 3 4 in 19 mm jam nuts and washers making sure the subreflector is repositioned in the exact location determined at the conclusion of its adjustment Secure all hardware 48 Installation Procedures 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 fol lowing procedures provide details on how to correctly position your antenna on the desired satellite Acquiring A There are several procedures that may be used to properly acquire the satellite Andrew Satellite recommends that a spectrum analyzer be used The following procedures provide explanation as to how to use the spectrum analyzer While viewing the spectrum analyzer screen a signal as shown in Figure 4 1 will proba bly be observed Additionally some transponder signals may be observed above the noise signal as shown ATTEN 1008 RL 10 Odam CENTER 3 SS00OGH SPAN 510 OMHz RBW 1 OMHzx VBwWw 3 DMHz Swe SO Ome Figure 4 1 Minimum transp
12. is complete Refer to Figure 38 Centering is performed by focusing the theodolite on the intersection of the brass rod holder and the reflector skin Ensure theodolite center axis is in line with the adjustable axis of the X Y translation stage Focus and adjust the theodolite elevation adjustment until the edge of the rod holder is sighted Note and record this reading as TI Repeat this procedure 180 apart and record the new reading as T2 Add Tl and T2 and divide by 2 Record this number as T3 Adjust the elevation axis angle of the theodolite to T3 Using the micrometer adjustment of the X Y translation move theodolite until the crosshair is focused to the edge of the rod holder Repeat the above procedure for the other axis of the X Y translation stage 90 opposite to the first one Repeat steps 4 and 5 until the theodolite crosshair focuses to all 3 rod holder edge loca tions within 15 seconds Refer to Figure 39 The height adjustment of the theodolite is performed utilizing the precision lift assembly 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 Upon completion of the leveling and centering procedure the theodolite must be adjust ed in line with the scribe line on the alignment stick Adjust the elevation angle of the theodolite to exactly 90 00 and 00 With the theodo lite set to this angle focus to the scribe
13. mounting hardware is ready for tensioning Note Do not tighten hardware on 301786 201022 azimuth pivot assemblies at this time 21 Installation Procedures Azimuth Jack Screw Assembly Step 1 Refer to Figure 17 Apply RTV to flange surface and attach 200013 4 301841 azimuth jackscrew to 201021 azimuth pivot assembly as shown Use 1 1 4 by 3 1 2 in 89 mm bolts lock washers and nuts Note Mounting hardware is included with corresponding jack assembly hardware kit 200131 AZIMUTH JACK EXTENSION FOR USE WITH 200013 4 ONLY 200013 301841 AZIMUTH JACK SCREW 70mm BOLTS FLATWASHER AND NUTS 1 1 4 x 3 1 2 89mm BOLTS LOCKWASHERS AND NUTS Figure 17 Attach 200131 azimuth jack extension to 200013 4 azimuth jack screw manual low and medium speed applications only as shown Step 2 Use 7 8 by 2 3 4 inch 70 mm bolts flat washers and nuts Note Type 301841 azimuth jack screw is used only for high speed applications ANDREW 22 Installation Procedures Step 3 Step 4 Step 5 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 position of 200035 outrigger assem bly if utilized 7 8 x 2 3 4 70mm 200022 BOLTS AND NUTS PIVOT ASSEMBLY 200131 AZIMUTH JACK EX
14. of imbalance Ku band feeds Adjustment screws are 1 4 X 20 Move 1 turn per 1 dB of imbalance All adjustments should be continued until the desired pattern is achieved Upon completion the antenna should be properly aligned with the satellite for maximum performance 53 Operation Preventive Maintenance Overview General Cleaning Electrical Parts This section contains periodic preventive maintenance instructions for the 9 3 Meter Earth Station Antenna Included in this section are inspection and preventive mainte nance procedures including cleaning and lubrication painting and an operational volt age current checkout procedure deemed within the capabilities of the average station technician Refer to applicable vendor manuals for any repair procedures not included in this section yet designated as capable off being performed in the field rather than requiring specialized facilities tools and or test equipment as well as technically trained personnel An operational checkout procedure provides an accurate indication of the overall earth station performance and should be performed at intervals of approximately three months This procedure is essentially performed during the various modes of normal operation of the earth station In addition the operational checkout procedure should be performed after any repairs or adjustments have been made or whenever the earth sta tion is suspected of degraded operation If any discrepa
15. using air to blow off the contaminants either avoid or be careful when directing the air stream on delicate parts To remove imbedded dirt grease or oil from electrical parts use a 50 percent solution of isopropyl rubbing alcohol and apply with a soft bris tle brush It may be necessary to brush some parts vigorously with a stiff bristle brush to remove imbedded and hardened dirt particles If possible avoid excessive use of clean ing solvent on electrical insulation After cleaning allow the cleaned parts to dry for 10 to 15 minutes before placing the equipment into operation 54 Preventive Maintenance Mechanical Parts Inspection Local ControllMotor Drive Controller 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 com pressed air at 25 to 40 psi Any accumulated imbedded dirt corrosion grease or oil deposits that require further cleaning may be removed with a bristle or wire brush and a 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 The frequency of inspection is contingent upon the user s individual standards and the operational environment in which the earth station is located However a visual inspec tion of the earth station components should be performed at least semi annually Wh
16. 1 4 inch 57 mm hardware 19 Installation Procedures Step 6 Refer to Figure 15 Raise assembled panning pivot assembly and loosely attach 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 flatwashers between 301786 pivot assembly and 200068 joint assembly 718 301786 200068 AzIMUTH Pivot FLATWASHERS JOINT ASSEMBLY ASSEMBLY 718 x 2 1 2 64 mm BOLTS AND NUTS 200031A PANNING ASSEMBLY 200016 JOINT ASSEMBLY Figure 15 ANDREW 20 Installation Procedures Step 7 Step 8 Refer to Figure 16 Attach 200107 support pairs back to back with 45967 spacer at mid point Loosely attach support pairs 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 out with flat of angle facing inward 301786 AZIMUTH PIVOT ASSEMBLY SUPPORTS 7 8 x 2 3 4 70 mm BOLTS FLATWASHERS AND N 200016 JOINT ASSEMBLY UTS 45967 SPACERS 7 8 x2 1 4 57 mm 201022 BOLTS AND NUTS AZIMUTH PIVOT ASSEMBLY Figure 16 Align panning frame azimuth pivot assembly by swinging panning frame through its entire arc Slightly snug panning frame pivot assembly hardware and again swing panning frame through its entire arc Continue this procedure until
17. For bolts less than 4 diameters For bolts over four diameters 11 Installation Procedures Tripod Ground Mount Assembly Azimuth Beam Assembly Step 1 Step 2 Step 3 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 subsequent procedures for proper installation of tripod ground mount assembly All ground mount hardware is type A 325 Lubricate all A325 bolt threads with supplied stick wax Note Do not tighten hardware until ground mount installation is complete unless otherwise instructed Grease all ground mount pivot assemblies using supplied 49208 grease cartridges Attach 200056 and 200057 supports to upper portion of 200112 beam assembly as shown in Figure 3 Use 7 8 x 2 1 4 in 57 mm hardware 7 8 x 2 1 4 57 mm BOLTS AND NUTS 200057 SUPPORT 200112 BEAM ASSEMBLY Figure 3 Raise beam support assembly Apply supplied RTV to flange surface and attach 201022 pivot assembly to bottom portion of 200112 beam as shown in Figure 4 Use 7 8 by 2 3 4 in 70 mm bolts flatwashers and nuts 200112 BEAM ASSEMBLY 201022 PIVOT ASSEMBLY 7 8 x 2 3 4 70 mm BOLTS FLATWASHERS AND NUTS Figure 4 12 Installation Procedures Step 4 Raise 201112 azimuth beam assembly and attach to front founda
18. Gear X Brush SHC32 Minimum Surface Coverage 10 Feed Rotation Worm Gear X Pressure Fitting SHC32 2 Pillow Blocks X Lubricate Inspect C Change Inspection requires checking for visible signs of oil leakage draining replacing and adding oil to ensure appropriate oil level requirements Excessively dirty oil will require fresh oil replacement If oil leakage is found to be excessive refer to appropriate troubleshooting information and perform applicable corrective action Periodic inspection procedures can be less frequent after first or second scheduled inspections Initial oil change requirements include flushing gear boxes with a standard cleaning agent 1 Type HS and STHS drives only 10 oz required for gearbox on Type MS drives 2 Type HS and STHS drives only ANDREW 62 Preventive Maintenance Gearbox Level AA DRE W Pressure Fitting Gearbox Fill A Gearbox Vent Pressure Fitting Pressure Fitting Worm Gear Pillow Blocks 2 Polarization i Drive Gear is gt y 1 Gearbox to z a e E Amr TE Gearbox Gearbox Level Vent Ni prue Note Gearbox Medium speed motors f y shown for illustrative y Drain purposes only Pressure Fitting Motor Control High Speed Antenna Lubrication Points 63 Preventive Maintenance ANDREW 64 Pressure Fitting Pressure Fi
19. Installation Operation and Maintenance _um m Type ES93 9 3 Meter ESA ANDREW 9 3 Meter Earth Station Antenna Andrew Corporation Telephone 708 349 3300 Customer Service 24 hours U S A Canada Mexico 1 800 255 1479 10500 West 153rd Street FAX U S A 1 800 349 5444 U K 0800 250055 Republic of Ireland 1 800 535358 Be ait SAMO TINE Orland Park IL U S A 60462 Internet http www andrew com Other Europe 44 1592 782612 uba a Copyright 2005 by Andrew Corporation Table of Contents Introduction How to Use This Manual Getting Started Installation Procedures Operation Preventive Maintenance ANDRE W Introduction isorine a e ak aaa EE E E Ee a Ae E RATA A ok E EE ese ES a 3 Proprietary Data segre seni hupeana A A a A A a ROP tad E 4 Information and ASSIS aNCe ooooooccccccc en eee eee 4 NOTICE eda at a 6 cA a al Ripe bce A EA A IA DS aaaea 4 Technical ASSISTANCE cocoa ra a a 4 OVGIVICW 0 ci AAA SAA RA AA RARA TEE DAA SAR aha eta AR RA 5 Content nesre n gaoi A ATA IRIS DATA RAT E RARAS AS Pa ache SAA VEA AR 5 OVEIVIW oct a e RA AAA ae A A i A 1 RAE ER a a cn See 6 WarninGS R E A A A Jota a a 6 Recommended Tools rigt snr it ae pie a eee eee eens 7 Parts Verifications reete T enn A EE AN A a a 8 Reporting Equipment Loss or Damage ooocccconcnconrn 8 Reporting Visible Loss or DaMage lt oooooocccccconananananananaan 8 Reporting Concealed Damage o oo
20. Ring 300022 Backup Plate Adjustment Stud Positioned Toward Top of Reflector Assembly Adjustment Stud Mounting Holes Installed Toward Bottom of Reflector Assembly Top View Figure 34 Assemble 300174 strut assemblies as shown Use 300176 angles and 1 2 x 2 in 51 mm galvanized bolts lock washers and nuts Attach floating ring to corresponding strut brackets Use 1 2 x 2 in 51 mm galvanized bolts rectangular washers flat washers lock washers and nuts Securely tighten all strut assembly hardware Note Apply stick wax to strut bracket and floating ring surface contact areas to ensure free movement during adjustment of subreflector Attach 202123B subreflector subassembly to floating ring Ensure top subreflector sub assembly adjustment stud opposite of notch in subreflector subassembly is positioned toward top of reflector assembly Lift subreflector subassembly and insert 8 in 203 mm subreflector studs into three mounting holes provided in floating ring Install 3 4 in 19 mm flat washer and two 3 4 in 19 mm jam nuts stud as shown Snug hardware Step 7 Refer to Figure 35 Raise preassembled subreflector subassembly and strut assembly and attach to subreflector supports as shown Use 1 2 x 2 1 2 in 64 mm galvanized bolts flat washers lock washers and nuts Step 8 Securely tighten mounting hardware Mount tabs on strut assemblies to right side of subreflector brackets to keep struts aligned with c
21. TENSION FOR USE WITH 200013 4 ONLY 1 x 2 1 2 63mm BOLTS AND NUTS 201021 AZIMUTH PIVOT ASSEMBLY 200013 4 301841 AZIMUTH JACK SCREW Figure 18 Refer to Figures 19A and 19B After azimuth pivot jack screw assembly has been attached to the joint assembly attach remaining hardware as shown to 1 2 13 mm stud and apply supplied Loctite to all nuts Position panning assembly to 0 azimuth and align 200022 pivot assembly with corre sponding azimuth jack screw or 200131 azimuth jack extension Remove band clamp from jack screw boot Rotate jack screw to extend to pivot assembly Attach jack screw to pivot assembly Use 7 8 by 2 3 4 in 70 mm bolts and nuts P O jack assembly hardware kit 23 Installation Procedures 201021 AZIMUTH PIVOT ASSEMBLY 0 1 2 x 2 25 LG 57mm STUD 1 2 2 251G Ermm 201021 AZDAUTH PIVOT ASSEMBLY y N 2000884 JOINT ASSEMBLY 1 2 HEX JAJA NUT Figure 19B Step 6 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 bolts 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 replace with supplied vent plug packaged with the motor assembly Note Ensure hole in vent plug is positioned downw
22. a Ja N pry N h N j e JO Average Lowest Position Average Highest Position The average is the sum divided by 20 ALP AHP divided by 2 This is the optimum theodolite elevation angle for aligning line 17 Table 3 44 Installation Procedures Subreflector Adjustment Step 1 Refer to Figure 42 Use tape measure to set rim of subreflector to required distance of 119 110 in 302 6 cm measured from the top of first seam hardware to the aperture plane of the subreflector using three subreflector adjustment studs Step 2 Attach right angle viewing piece to theodolite Move subreflector laterally to align the subreflector so it is centered with the theodolite while set at vertical 0 00 00 A hole is provided at the center of the subreflector to facilitate alignment Step 3 Ensure subreflector is centered and set at required distance Snug adjustment hardware after centering and height adjustments are complete Step 4 Check distance between subreflector aperture plane and first seam reflector hardware 9 110 2 6 cm Top of Reflector No 1 Panel Top of the First A Seam Hardware Figure 42 ANDREW 45 Installation Procedures Subreflector Offset Tilt Adjustment Step 1 Step 2 Step 3 Step 4 Step 5 Refer to Table 4 and Figure 43 Adjust top subreflector jam nuts two the distance indi cated according to the offset pointing angle in Table 4 Make the desired adjustment usin
23. acing forward position AZ 0 5 8 16 mm Shackle Typ 4 Places Angle Bracket Typ 4 Places Top View 20 4 20 6 2 mi Chokers 1 2 dia Chokers 1 2 dia Tag Line Drum Assembly Jack Tripod Assembly NOTE Two front chokers should be approximately 4 longer than rear chokers Figure 45 ANDREW 47 Installation Procedures Step 3 Step 4 Step 5 Step 6 Step 7 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 Warning Do not attempt to raise reflector backstructure if winds exceed 25 mph Raise reflector backstructure assembly and align with corresponding elevation jack panning frame assemblies using tag lines for guidance Note A minimum of three tag lines should be used during high wind conditions Do not exert force while using the tag lines during reflector installation as this will distort the panel surfaces 45980 28 3 4 x 2 1 2 63 mm Bolt Assembly with 9997 202 3 4 19 mm Flat Washer r Tag Line E 3 4 x 2 1 2 63 mm Bolt Assembly with 2 45980 28 3 4 19 mm Flat Washer 3 87 dia Elevation 7 p e Jack Extension Elevation Pivot ssembly Assembly Figure 46 Connect reflector backstructure pivot assemblies to panning frame assembly Use 7 8 x 2 1 4
24. ard 24 Installation Procedures Elevation Jackscrew Assembly Step 1 Step 2 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 nuts Note Mounting hardware is included with corresponding jack assembly hardware kit 1 1 4 x 3 1 2 89 mm BOLTS WASHERS AND NUTS TRIPOD LEG ASSEMBLY APPLY RTV 200128 ELEVATION EXTENSION ASSEMBLY 200013 3 200048 3 4 x 3 LG ELEVATION 75 mm JACK SCREW BOLTS LOCKWASHERS AND NUTS APPLY RTV Figure 20 Attach 200022 pivot assembly to enclosure tripod leg assembly Note This may also be performed during reflector assembly Use 3 4 by 3 0 in 75 mm bolts lockwashers and nuts 25 Installation Procedures Step 3 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 supplied vent plug packaged with the motor assembly only after elevation jack is in final operating position Note Ensure hole in vent plug is positioned downward 201022 PIVOT ASSEMBLY 7 8 x 2 1 4 57 mm BOLTS AND NUTS 128 EXTENSION EMBLY 200 ELEVATION ASSI Figure 21 ANDREW
25. current readings off each of the three conductors phases connect ed 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 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 Repeat steps 5 with the AZIMUTH EAST WEST switch in the alternate operating posi tion Turn the ELEVATION DOWN UP switch to either position and while the antenna is rotat ing carefully use a clamp on ammeter in accordance with the ammeter manufacturer s instructions to take current readings off each of the three conductors phases connect ed to the load side of the elevation 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 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 Repeat steps 7 with the ELEVATION DOWN UP switch in the alternate operating posi tion If all voltage a
26. d in the center of its travel 9 When the antenna is transmitting severe eye injury or injury to other parts of the body can result from exposure to radio frequency RF energy The antenna must be turned off before entering the area in front of the reflector and near the feed 6 Getting Started Recommended ANDRE W Tools 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 WARNING Additional warning information will be located in this type of format Andrew disclaims any liability or responsibility for the results of improper or unsafe installation operation or maintenance practices Andrew supplies all appropriate hardware parts required for the installation of your 9 3 Meter Earth Station Antenna All tools necessary for the installation process should be provided by the installation crew Andrew recommends the following tools to be used for a proper installation of the 9 3 Meter Earth Station Antenna Tool Open End or Combination Wrenches Drive Sockets Breaker Bar Crane Size 1 4 Inch 5 16 Inch 3 8 Inch 7 16 Inch 1 2 Inch 9 16 Inch 3 4 Inch 7 8 Inch 1 1 16 1 1 8 Inch 1 7 16 Inch 1 5 8 Inch 1 7 8 Inch 5 16 Inch 7 16 Inch 1 2 Inch 9 16 Inch 3 4 Inch 15 16 Inch 1 1 16 Inc
27. drew Corporation for either repair or replacement return can be expedited by following the procedure listed below Call the Andrew Customer Service Center and request a Return Material Authorization RMA number as well as an address to forward the material Tag or identify the defective equipment noting the defect or circumstances Also be sure to write the RMA number on the tag It would be helpful to reference the sales order and purchase order as well as the date the equipment was received Pack the equipment in its original container with protective packing material If the origi nal container and packing material are no longer available pack the equipment in a sturdy corrugated box and cushion it with appropriate packing material Be sure to include the following information when returning the equipment Your Company Name Your Company Address City State and Zip Code Telephone Number RMA Number Problem Description Contact Name NOTE Absence of the RMA number will cause a delay in processing your equipment for repair Be sure to include the RMA number on all correspondence Ship the equipment to Andrew Corporation using UPS U S Postal Service or other appropriate carrier freight prepaid and insured The material should be forwarded to the address given by the Andrew contact in Step 1 9 Getting Started Installation Procedures Overview This section provides installation procedures for the 9 3 M
28. e 17 After adjusting all panel segments at scribe line 17 tighten all segment hardware at seam screw locations 23 through 28 Work clockwise tightening 2 seam screw rows each time around the reflector 23 24 etc Note Do not step or lean in the area of reflector seam screw locations 23 through 31 during this tightening sequence Remove special brass rod holders and replace with panel segment hardware Tighten all remaining seam hardware beginning with that corresponding to the circumference of panel segment screws 22 Work clockwise around the reflector tightening each row of corresponding panel segment screws down to the circumference of panel segment screws 1 Note Do not overtorque seam hardware Insert hardware in holes 29 31 in all panels and tighten three at a time in clockwise direction Note Do not force the fasteners thru the holes by prying with a drift pin or hammering on them Connect and tighten 40 joiner strips with supplied hardware refer to Figure 41 and sub reflector bracket connection hardware Double check for loose strut connection and panel connection hardware 9999 61 1 2 13 mm Nut 9997 64 1 2 13 mm Lock Washer 300300 Skirt Strap 9963 186 1 2 x 1 1 2 38 mm Bolt 9997 101 1 2 13 mm Flat Washer Figure 41 43 Installation Procedures Theodolite alignment data worksheet Lowest cam bolt position Highest cam bolt position 11 7 20 O 1 A fa pry a
29. e adjusted outward by loosening the screws on the subreflector and adjusting the left side northern hemisphere outward An easy way to remember this adjustment feature is through the acronym WOLD West Out Left Down If your pattern dictates a need to adjust the elevation angle the right sidelobe requires adjust ment the bottom side of the subreflector should be adjusted downward by loosening the screws between the subreflector and the struts and adjusting the bottom side of the subre flector downward An easy way to remember this adjustment is through the acronym BOLD Bold Out Left Down Each of these adjustments should be repeated until each sidelobe is of equal distance from the peak of the mainlobe After the BOLD and WOLD adjustments have been made it may be necessary to adjust the main lobe The goal is to achieve a high null depth distance between lower intersection of sidelobes and top of main lobe as shown in Figure 4 5 In order to adjust the main lobe pattern characteristics ALL subreflector adjustment screws should be adjusted at the same degree Note Because the azimuth and elevation adjust ments have been set it is very important that the null depth adjustment be carefully conduct ed Be careful not to alter any previous adjustments that have been made to the subreflector Follow the procedure listed below when adjusting the null depth of the main lobe C band feeds Adjustment screws are 3 4 X 10 Move 1 turn per 1dB
30. e applied with a brush roller or pressurized spray If necessary thin the paint with the appropriate thinner to the proper consistency Thoroughly paint over the cleaned surface and blend with the existing painted surface For long life and trouble free operation be certain not to extend the lubrication schedule beyond the frequency recommended in the Lubrication Chart The frequency should be shortened if the antenna is subjected to an adverse environment e g high tempera ture extended periods of rainfall high humidity dust storms etc Any component or part should immediately be lubricated if during inspection or operation rough jarring or intermittent motion is noted or if squeaky or other unusual noises are heard Lubrication is required on all metal to metal rolling or sliding parts Us the lubricants recommended Do not over lubricate Over lubrication can often be as damaging as under lubrication Prior to the application of lubricant to any parts use a clean cloth and or bristle brush 60 Preventive Maintenance Jackscrews Motors Gear MotorlHousing Fill Drain Requirements 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 f
31. ency Feather primer onto adjacent painted surfaces Allow primer to thoroughly dry before applying the finish paint coat Paint all RF surfaces such as the inside of the main reflector and subreflector with a high reflectance white paint This type of paint disperses light rays reducing the focus ing effect of the sun s radiation thereby reducing heat build up caused by the focused sun rays on the feed system Rear surfaces of the reflector and subreflector may be painted with a flat white enamel paint The paint can be applied with a brush roller or pressurized spray If necessary thin the paint with the appropriate thinner to the proper consistency Thoroughly paint over the primed surfaces and blend with the existing painted surface Remove all loose paint and corrosion by scraping wire brushing or using steel wool Edges of existing paint can be blended with the metal surface by using a fine grit sand paper Wipe the surface to be painted with a soft rag dampened in trichlorethylene lac quer thinner or equal be certain to remove all loose paint corrosion imbedded dirt grease and oil deposits or the paint will not adhere to the surface Lacquer thinner will dissolve paint if applied heavily and rubbed vigorously Do not use bleach soap solu tions or kerosene as it is difficult to remove the residue Allow the clean surface to dry thoroughly before painting Paint the cleaned surface with a zing rich paint The paint can b
32. ensure that the power is removed Electrical connections should be made only by qualified personnel in accordance with local regulations 2 Installation of antennas may require persons to work at elevated work stations Whenever persons are working at eight or more feet above the ground and not on a guarded platform they should wear safety belts with at least one preferably two lan yard 3 Never stand underneath any object while it is being lifted 4 Always wear a hard hat especially if someone is above you 5 Make sure no person is in or under the reflector while it is being lifted or positioned personal injury can result if the reflector assembly falls 6 Personnel should never be hoisted in or out of the reflector by the crane personal injury may result 7 Andrew earth station antennas supplied to standard product specifications will survive 125 mph winds in any operational position in moderate coastal industrial areas Severe conditions require additional protection Should it be expected that winds will exceed 125 mph it is recommended that Andrew antennas be steered to specific azimuth and elevation orientations to minimize wind forces upon the structure and thereby increase the probability of survival 8 It is recommended that all cross axis waveguide and coaxial cables are secure such that high winds will not cause excessive flexing Position the antenna to an elevation of 90 degrees The azimuth jackscrew should be place
33. ent stick positions Note Only 2 of the 3 tribach adjustment screws should be used for leveling Mark or identify 1 of the 3 and only use the remaining 2 adjustment screws Scriba Line On Stick Assembly Alignment Stick Table 2 Brief Description of Theodolite Calibration Sequences 1 Theodolite Leveling Sect 10 0 2 Theodolite Centering Sect 11 0 3 Theodolite Height Adjustment Sect 12 0 4 Repeat 1 3 as Necessary Typically 4 5 times to Achieve Calibration Specs Theodolite Calibration Specifications 1 Leveling All 3 Stick Positions Within 15 Seconds of Each Other 2 Centering All 3 Center Reading to be Within 15 Seconds of Each Other 3 Height All 3 Level Position Readings Within 10 Seconds of 90 00 00 4 Ready for Reflector Panel Adjustment Sect 13 0 Figure 39 Installation Procedures Theodolite Centering Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Theodolite Height Adjustment Step 1 Step 2 Step 3 Step 4 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 sets of long locking adjustment screws which are opposed at 90 During initial adjustment ensure that the long screws are unscrewed counterclockwise to provide free movement Note The screws will be utilized later to lock the device in place after the centering pro cedure
34. ere there are no established wear limits perform a visual inspection to locate worn or dam aged parts which could cause improper functioning of the earth station It is recommend ed that the mechanical and electrical inspection be performed on the assembled or par tially disassembled equipment to determine the extent of disassembly required prior to completely disassembling a suspected malfunctioning component or module In the absence of any special inspection requirements operational tests are the most effective means in isolating parts and assemblies requiring further inspection Any condition noted during inspection that may preclude continued proper operation of the earth sta tion prior to the next scheduled inspection should be noted The discrepant condition should be corrected repaired or replaced immediately or at the conclusion of the inspection procedure Inspection of the local control motor drive controller conforms generally to standard visu al inspection procedures on electromechanical equipment In addition to these standard procedures perform the following checks and visual inspections for the specific condi tions noted Check the front panel for illegible and indistinct panel markings Check the three position selector switches Azimuth Slow Fast Elevation Slow Fast and Polarization CCW CW for smooth operation audible clicking at each actuation left to center and return and spring return from right to center F
35. ess and other damage that may expose the jackscrew to the environment water dust etc Minor repairs can be made with RTV 108 silicone rubber sealant Visually inspect the feed window for dirt and the feed feed supports feed window and reflector for distortion foreign object damage and environmental deterioration due to ice and snow dust rain hail and high winds etc which may cause electrical compo nent and or structural deformation Check the cable attachment to the resolvers and to the LNA or LNB s and enclosure mount interface for security the cable rouging for secure hanger attachment and the cable insulation for cuts cracking abrasion and other deterioration Check the LNA or LNB s and the resolvers for a secure mechanical attachment Ensure proper torquing of polarization drive gear box setscrews and appropriate tensioning of corresponding drive chain assembly if applicable Check if applicable that the drain holes in the bottom of the enclosure are not obstructed and there is no evidence of water accumulation Check the enclosure doors for proper closure and that the door seals are intact not torn abraded or otherwise damaged Check that all other seals are intact and if not use a coating of RTV 108 sili cone rubber sealant to seal any exposed electrical fitting bolt hold or other possible water entry to electrical components in order to maintain a weatherproof condition If the enclosure is provided wit
36. eter Andrew Earth Station Antenna The installation procedures include instructions on the following antenna com ponents Mount Reflector to Mount Assembly Reflector Subreflector Enclosure Feed System C band Foundation Before beginning the installation process on the ground mount assembly ensure that Preparation the foundation has been prepared Foundation specifications are provided by Andrew and may be used as a reference by civil engineering personnel when preparing the foundation for local soil conditions These specifications are available before the ship ment arrives by contacting the Customer Service Center or your Account Manager Foundation should be dimensioned as detailed in Figure 1 Sweep foundation clear of any dirt or debris To ensure smooth surface for mount scrape foundation pads as shown in Figure 2 Studs should extend 3 in above the ground and are 7 8 in in diameter Apply stick wax to stud threads to ease later connections 5 0 127 mm 111 0 2820 mm 1803 mm 6 0 152 mm PAD 1 4 07 12 0 102 mm 304 mm l Figure 2 ANDREW 10 Installation Procedures A 325 Tensioning Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 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 cau
37. etting 51 Operation Step 10 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 ATTEN 10065 RL 10 OgBm CENTER 3 SS00GH SPAN 510 DMHz RBW 1 OmHz VEw 3 OMHz SWP S50 Oms ATTEN 1096 RL 10 OdBm CENTER 2 SSO00GH SPAN 510 OMhHz RBW 1 OMH VvBw 3 OMH SwP SO Ome Figure 4 5 Optimum Polarization Setting 52 Operation 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 anten na 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 Before proceeding azimuth and elevation patterns should be conducted to determine the adjustments that need to be made The goal is to achieve a high peak on the main lobe and even distances between the main lobe and sidelobes NOTE No adjustments should be made in the receive band If your pattern dictates a need to adjust the azimuth angle the left sidelobe requires adjust ment the west side northern hemisphere of the subreflector should b
38. g the floating ring and subreflector jam nuts Note Before making any adjustment mark the starting position of the jam nuts in rela tion to the floating ring with a pencil then mark the floating ring to indicate the proper distance of the turn Table 4 Offset Operating Angle Top Stud Nut Adjustment 10 20 1 3 4 turns 30 1 5 8 turns 40 1 1 2 turns 50 1 turn 60 7 8 turn Table 4 shows the distance the subreflector must be lowered Use only the top adjust ment stud to obtain the proper offset tilt Once the offset tilt adjustment is completed do not disturb adjustments Match mark the subreflector subassembly and the floating ring Remove 3 4 19 mm jam nuts and washers and lower the subreflector subassembly Place subreflector subassem bly in safe location to secure it from damage during reflector backstructure installation Remove theodolite and theodolite mounting assembly from feed support tube Top Stud Movement of Subreflector Figure 43 46 Installation Procedures Reflector Back structure to Ground Mount Assembly Installation Step 1 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 tag line to for ward left of jack tripod assembly Note Two front chokers should be approximately 4 in 102 mm longer than rear chok ers Step 2 Extend azimuth jack until panning assembly is f
39. ge or Reporting Concealed Damage procedures when filing a claim with the carrier Make a note of any loss or evidence of external damage on the freight bill or receipt and have it signed by the carrier s agent Failure to adequately describe such external evidence of loss or damage may result in the carrier refusing to honor a damage claim The form required to file such a claim will be supplied by the carrier Concealed damage means damage which does not become apparent until the unit has been unpacked The contents may be damaged in transit due to rough handling even though the carton may not show external damage If you discover damage after unpack ing the unit make a written request for an inspection by the carrier s agent then file a claim with the carrier since such damage is most likely the carrier s responsibility After opening your shipment an inventory of the parts should occur immediately Check each item received in your shipment against the packing slip included with the shipment If any items are missing please notify Andrew Corporation immediately by contacting the Customer Service Center 8 Getting Started Returning Equipment Step 1 Step 2 Step 3 Step 4 Step 5 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 condi tion When this occurs and it is necessary to return the equipment to An
40. h 1 1 8 Inch 1 7 16 Inch 1 7 8 Inch 3 4 Inch 18 Ton Minimum Capacity extended end Nylon Web Slings 2000 pound breaking strength 3 Inch by 20 Foot Rope or Cord 2000 pound breaking strength Shackles Ladder Ladder Drift Pin Drift Pin Spud Wrench Screw Drivers Bucket Truck Allen Wrenches Torque Wrench Adjustable Wrenches Drill Tape Measure or other measuring device Felt tip Marker or other marking device Hammer Rubber Mallet Pry Bar Tin Snips Safety Gloves each installer Table 2 1 7 50 Foot 5 8 Inch 10 Foot Step 18 Foot Extension 5 8 to 7 8 Inch 1 4 to 1 2 Inch 1 1 8 Inch Standard Phillips Set 250 ft lb 8 and 12 Inch Electric Standard Standard Standard Standard Standard Standard Standard Recommended Tools Getting Started Quantity ABA AMP BMP SP SMP BBB BABA aANNNNNA HA PAN A HAN ANNNNANNNNNNNNNNNNN NH Parts Verification Reporting Equipment Loss or Damage Reporting Visible Loss or Damage Reporting Concealed Damage Inventory Equipment Received Andrew Corporation thoroughly inspects and carefully packs all equipment before ship ment If you find that there are missing components please refer to page 9 for step by step instructions on how to properly report the equipment loss If you find that there was damage caused to the equipment during the shipping process a claim should be filed with the carrier Follow the Reporting Visible Loss or Dama
41. h a vent fan check for free operation of the fan blade The fan bearings are permanently lubricated any binding abnormal noise or vibration necessi tates replacement of he fan assembly Check and replace the fan filter element if it appears dirty or obstructed with dust 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 57 Preventive Maintenance Drive System Voltage and Current Checks Step 1 Step 2 Step 3 Check security of antenna mounting and interconnecting assembly hardware Be cer 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 All other assembly and instal lation hardware should be tightened to its original torqued condition When installing new structural hardware do not use a wrench with a lever arm longer than two feet Examine painted aluminum and galvanized surface
42. heck that this condition can be tolerated from a safety as well as an operational stand point and that the electrical limits are not reached before the testing is concluded Reaching an electrical limit before concluding a test necessitates rotating the antenna or feed in the opposite direction a sufficient distance to permit retesting in the desired direction Turn the FEED CCW CW switch to either the CW or CCW position and while the feed is rotating carefully use a clamp on ammeter in accordance with the ammeter manufactur er s instructions to take current readings off each of the three conductors phases con nected to the load side of the polarization 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 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 58 Preventive Maintenance Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Repeat preceding step 3 with the FEED CCW OFF CW switch in the alternate operat ing position Turn 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
43. ing Call From Telephone Fax North America 800 255 1479 toll free 800 349 5444 toll free United Kingdom 00 800 0 255 1479 toll free 00 800 0 349 5444 toll free Australia 0011 800 0 255 1479 toll free 0011 800 0 349 5444 toll free China 00 800 0 255 1479 toll free 00 800 0 349 5444 toll free New Zealand 00 800 0 255 1479 toll free 00 800 0 349 5444 toll free Hong Kong 001 800 0 255 1479 toll free 001 800 0 349 5444 toll free ge Introduction How to Use This Manual Overview Content The scope of this manual is intended to provide station personnel with the base installa tion operation and maintenance requirements necessary for a 9 3 Meter C 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 The tables and figures presented in this manual are used as communication aids for the installation operation and maintenance of the 9 3 Meter Earth Station Antenna These tables and figures instantly convey messages as well as make the procedures easier to understand This manual uses tables and figures for the following references Tables The tables allow you to locate information quickly and easily Drawings The drawings supplement the installation instructions by using a combi nation of graphics and verbiage to assist you in simplifying complex pro cedures and cla
44. line on the alignment stick and make any up or down adjustment as necessary using the lift assembly Be careful not to rotate torque tube when turning the precision lift Move the alignment stick 180 and check if the theodolite is lining up with the scribe line Repeat this procedure with the diagonal stick locations Repeat theodolite leveling centering and height adjustment procedures to achieve calibration specifications per Table 2 Notice The above described sequences must be followed in order to properly calibrate the theodolite to the reflector assembly Deviation from the above procedures and sequence will make it more difficult to calibrate the device and may result in incorrect alignment of the reflector panels 42 Installation Procedures Reflector Panel Adjustment Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Figure 40 INDRE W 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 cambolts on back struts to move the panel to the highest possible position Using the theodolite target the surface of each panel segment at scribe line 17 Record these measurements for each cam bolt Refer to Table 3 Average these values Add the average value for the highest and lowest panel positions and divide by two The result is the optimum theodolite elevation angle for scribe lin
45. motor housings to avoid hindering the heat exchange with the ambient air Slight dirt accumulation on the air vent screw through splash oil cannot be avoided however keep vent screw clean to ensure proper pressure compensation Lube points 2 3 7 and 8 shown in the Lubrication Chart require removal of the indicat ed drain plugs and collecting measuring the amount of SHC624 drain oil using measur ing cup The specified amount of oil must be added to the gear motor housing after installing the drain plug via the fill vent plug opening using supplied funnel Addition of the oil requires use of an appropriate filling utensil Use of a modified level stick will not correctly gauge the appropriate amount of oil in the gear housings 61 Preventive Maintenance Lubrication Chart Lube Components Frequency Type No of Lube Point to be Months of Points or Lubricated 3 6 Service a Elevation Jackscrew Housing Pressure Fiting Pressure Fiting sHcsz 1 Elevation Jackscrew Gear Housing Pipe Plugs SHC624 10 Oz Fill and Drain 3 2 Elevation Drive Intermediate Gearbox po c Pipe Plugs SHC624 34 Oz Fill and Drain Elevation Jackscrew Pivot Pin upper Le pee Se Pressure Fitting SHC32 Azimuth Jackscrew Pivot Pin front MEA Pressure Fitting SHC32 7 1 Azimuth Jackscrew Gear Housing pr Es Pipe Plugs SHC624 4 Oz Fill and Drain 8 2 Azimuth Drive Intermediate Gearbox pr c Pipe Plugs SHC624 34 Oz Fill and Drain Polarization Drive
46. ncy in performance exists and the condition cannot be readily remedied to return the earth station to a proper operating condition the appropriate troubleshooting procedures should be referenced to locate the fault After the trouble is determined and the repairs affected a final operational check out procedure should be performed to verify that all discrepancies have been corrected The following paragraphs describe the inspection and preventive maintenance proce dures for the earth station These instructions include general cleaning and inspection the preservation of metal parts and lubrication Periodic replacement of assemblies or components as a preventive measure is not required Malfunctions of the earth station can be traced to components assemblies and parts through the use of applicable trou bleshooting procedures To prevent the excessive accumulation of dust and dirt as well as the removal of such contaminants thoroughly clean the equipment whenever visually inspecting the earth station components No special cleaning procedures are required However a thorough cleaning in accordance with the following procedures is required to assure continued trouble free operation Minor cleaning such as the removal of dust and loose foreign particles can be accom plished by one of the following Vacuuming Using a soft brush or lint free cloth Blowing out the dust and dirt with low pressure 5 to 25 psi dry compressed air When
47. nd current readings are within tolerance close the local control motor drive controller and place the LOCAL REMOTE switch in the REMOTE position to return antenna control to the studio Then close and lock the outer local control motor drive controller door 59 Preventive Maintenance Preservation of Component Parts Aluminum Parts Galvanized Surfaces Lubrication 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 Wipe the surface to be painted with a soft rag dampened in trichlorethyl ene lacquer thinner or equal Be certain to remove all loose paint corrosion imbedded dirt grease and oil deposits or the paint will not adhere to the surface Lacquer thinner will dissolve paint if applied heavily and rubbed vigorously The reflector may be washed with plain water if necessary Do not use bleach soap solutions or kerosene as it is dif ficult to remove the residue Allow the cleaned surface to dry thoroughly before priming Prime the cleaned surface by applying zinc chromate primer The primer can be applied with a brush roller or pressurized spray If necessary thin the primer with lacquer thin ner to the proper consist
48. nd hex nuts Ensure all A 325 mounting hardware is in place Begin A 325 tensioning procedure at pads and work upward Note Do not tighten 201022 pivot assembly hardware at this time r HEX NUTS 7 8 x 2 1 4 57 mm BOLTS AND NUTS 200068 JOINT ASSEMBLY 1 FLATWASHERS 200108 SUPPORTS 7 8 x 2 1 4 57 mm BOLTS AND NUTS 200112 BEAM ASSEMBLY SUPPORTS 201022 PIVOT ASSEMBLY 200063 REAR PAD ASSEMBLY 200064 REAR REAR PAD ASSEMBLY FOUNDATION PAD Figure 12 17 Installation Procedures ANDREW 18 Panning Frame Assembly Refer to Figures 13A and 13B Determine azimuth range requirements from APPENDIX A page 65 and loosely attach 200035 outrigger assembly if required to appropriate Step 1 side of 200031A panning assembly Use 7 8 x 2 1 4 in 57 mm hardware and apply supplied RTV to flange surfaces as indicated 200031A PANNING ASSEMBLY EMBLY 200022 PIVOT ASSEMBLY FOR AZIMUTH RANGE 60 TO 60 DEGREES RESOLVER RTY le a x 2 25 57mm 200022 MOUNTING HOLES BOLTS FLATWASHERS PIVOT ASSEMBLY AND NUTS FOR AZIMUTH RANGE 301786 90 TO 30 DEGREES AZIMUTH 7 8 x 2 25 57mm PIVOT ASSEMBLY BOLTS AND NUTS FIGURE 134 INDICATES OUTRIGGER STORAGE POSITION FOR AZIMUTH RANGE OF 90 TO 30 DEGREES OR THE OUTRIGGER MOUNTING POSITION FOR AZIMUTH RANGE OF 60 TO 60 DEGREES Figure 13A Step 2 2000314 PANNING ASSEMBLY 200022 PIVOT ASSEMBLY FOR AZIMUTH RANGE 30 TO
49. nding drum pivot mount assemblies as shown Use 3 4 x 2 in 51 mm bolts lock washers and nuts 9963 714 3 4 x 2 51 mm Bolts Lock Washers and Nuts 9963 726 1 x 2 1 2 63 mm Bolts Lock Washers 78116 101 Tripod Leg 9963 706 3 4 x 5 1 2 140 mm Bolts Lock Washers Tripod Braces Drum Pivot Mount 4 781 16 103 R H Assembli and Nuts emblies 78116 102 L H 9963 714 3 4 x 2 51 mm Bolts Lock Washers and Nuts 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 tab Use 3 4 x 2 in 51 mm bolt lock washer and nut Note Keep angled corners of side plates toward drum assembly 31 Installation Procedures Reflector Assembly Step 1 Refer to Figure 27 Assemble 20 right and left hand back to back strut assembly pairs Type 78082 and 78083 as shown Use 1 2 x 1 1 2 in 38 mm bolts spacers lock washers and nuts Tighten strut spacer bolt 9963 186 1 2 x 1 1 2 38 mm Bolt 77546 Strut Spacer 78083 LH Backstrut Member 9974 64 1 2 13 mm Lock Washer A 9999 81 GT ve 13 mm Nut Back to Back Strut Assembly Pairs Figure 27 Step 2 Refer to Figure 28 From inside of drum assembly attach end of back to back strut assembly slanted angles to lower ring on drum assembly Use 1 2 x 4 1 2 in 114 mm bolts special washers lock washers and nuts Tighten until snug Note Special wa
50. nge 60 60 to 90 30 Refer to APPENDIX A A Tools Required 2 Spud Wrenches 2 1 7 16 open end wrenches 2 1 5 8 open end wrenches 1 5 8 Socket for 3 4 drive 1 7 16 Socket for 3 4 drive 3 4 Drive ratchet 2 9 16 wrenches 2 come alongs 2 Tag lines 2 Experienced riggers Extension Ladder Man lift Recommended 9 64 Allen Wrench Set 2 2 wrenches 9 16 socket amp ratchet Safety Harnesses Hammer Set of Replacement Hardware apos3Z azATT sao a90TD B Procedure 1 2 DARA ON 10 12 13 14 15 16 act Disable Tracking System Remove vertical handrails from Maintenance Platform and Landing Platform to allow antenna to go to a high elevation angle for less wind loads Loosen or remove upper mechanical Elevation limit Increase Elevation Angle to maximum while watching for interference near Elevation Pivot Assembly Retract Azimuth Jackscrew within about 1 foot of full retraction Stabilize reflector using 2 come alongs Attach between panning assembly support legs 200107 and rear support legs 200109 Repeat on opposite side Loosen and Remove Jackscrew hardware between 200035 outrigger and 200022 pivot assembly Adjust jackscrew to full retraction using hand wheel Loosen Remove Jackscrew Pivot Assembly hardware except for 1 2 x2 25 Lg stud as shown in Figure 19A on page 24 of manual Remove maintenance platform attachments if present i e ladder
51. onder Signal on Spectrum Analyzer ANDREW 49 Operation 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 Step 2 Using an inclinometer position the antenna to the specified elevation angle Step 3 Manually move the antenna in the azimuth scanning back and forth around the direc tion of the specified azimuth angle 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 5 degrees or the antenna may begin to access a different satellite Step 4 With the antenna positioned in azimuth such that the transponder signals are maxi mized follow the same procedure manually moving the antenna in elevation scanning up and down to further maximize the transponder signals Step 5 Repeat this procedure alternating between the azimuth and elevation excursions of the antenna to peak the transponder signal amplitude Step 6 With the antenna peaked in azimuth and or elevation check to see if you re peaked on a sidelobe Move the antenna in azimuth while observing the spectrum analyzer screen Refer to Figure 4 2 AZIMUTH AXIS WEST Azimuth
52. oocccccnonann eee eee 8 Inventory Equipment Received oooooooooocccccccanan eee ene 8 Returning Equipment ooo a ingen ee eee ica 9 O orca dick O E NN a GEG 10 Foundation Preparations 25 2 5 2 5 ci ee Ree See dee wale BE eG be pee 10 A 325 Tensloning esses 2 se Fis ag nie A ed oh Re ee edie eee eg a 11 Tripod Ground Mount Assembly sssssasananananannananananannananan anana 12 Azimuth Beam Assembly a ieee denii di Baek A a ee a Pe eee e a 12 SUPPOrt LEgS ASSEMDIY 00 A A A A he 14 Panning Frame Assembly sisean ii A a are dd 18 Azimuth Jack Screw Assembly ooooooccocenenana enn eee eens 22 Elevation Jack Screw Assembly a an 0 ccc ee 25 Grounding Cable Attachment 00 0 ccc ee 27 Reflector Backstructure Assembly ooooocccccccorn ee 29 Feed Rotating Tube Assembly 0 ccc ccc 29 Jack Tripod Assembly inne it Sted E sel Sg sce A bce ees ho Sela eyelet See el ge 31 Reflector Assembly irre randama A Beagle A A RA obs ave NE A nip eee 32 Subreflector ASSEMDIY i ren ii a dc aie a A ee atta aca RA e a td 35 Theodolite ASSEeMDIV ocio iia ia ide A A Hag AR aa 38 Theodolite Installati0N ooooooooommmrcnrarara eee nee 38 Theodolite Levelling ois iisec6 coer e 0 3 alg tence A ia ae Be eae eve BO a 40 Theodolite Centering iii a ad ade ates adn ee ah eg ea ge be gee ea a Slee 42 Theodolite Height Adjustment ooooocccorcnnnn eee eee eee 42 Reflector Panel Adjustment 0 0 0 0 ccc
53. operation including steptracking Smartrack applications The motorizable mount type is indicated by the ES93 or ES93HS letters within the antenna type number The addition of the letter HS within the antenna type number indicates that the mount includes High Speed azimuth elevation machine jackscrews The azimuth elevation jackscrews are equipped for integration with the optional motor drive systems A cross axis grounding kit is supplied with each mount to ensure electrical interconnectivity of the complete structure The aluminum enclosure and hot dipped galvanized steel mount maintain pointing accu racy and ensures durability and reliability The antenna and mount with enclosure will survive 125 mph 200 km h wind in any position of operation without damage or per manent deformation in moderate coastal industrial areas Severe conditions require additional protection Andrew provides a complete line of available options including motor drive systems with power interfaces addressing domestic and international standards remote micro processor antenna control for motor drive systems pressurization equipment and inter connecting HELIAX cables and waveguide 3 Introduction Proprietary Data Information and Assistance Notice Technical Assistance 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
54. or each of the two position selector switches Azimuth East West Elevation Up Down and Local Remote check for smooth operation and audible clicking at each actuation Inspect all wiring and cables for discolorization and burned insulation dirt breaks security of connection and other signs of deterioration Examine connections for dirt flux corrosion and mechanical defects Check for loose or broken lacing and cut brittle abraded frayed or cracked insulation Examine connectors for corrosion broken inserts and stripped threads Check con nector shells for distortion and dents and contact pins for bends misalignment or other deformities Check connector inserts for carbon tracking indicating arc over 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 55 Preventive Maintenance Antenna 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 push button as the alternate pushb
55. orresponding reflector segment sec tions Adjustment Stud Positioned Toward Top of Reflector Strut 300030 Backup her c4 Wi 9999 109 300177 1 2 13 mmy _Strut 9963 335 Nut Support 1 2 x 2 1 2 64 mm Bolt 9974 4 j 1 2 13 mm Lock Washer Reflector Panel End View Floating Ring Reflector Segment Tee Section Figure 35 ANDREW 37 Installation Procedures Theodolite Refer to Figure 36 The Andrew Theodolite Kit 223711 contains 1 theodolite mounting Assembly assembly and 1 alignment stick assembly A Wild T2 or Topcon DT 05A theodolite is used but not included as part of the Andrew Theodolite Kit Note The theodolite mounting assembly comes preassembled The theodolite mounting assembly includes the lift adapter flange mount assembly X Y translation stage and tri brach Refer to the theodolite operation manual for theodolite operation instructions Wild T2 or Topcon DT 05A Theodolite Stage Wild Lift and Adaptor Flange Mount Assembly Theodolite Installation Step 1 Refer to Figure 36 Before installing theodolite kit onto the torque tube assembly be sure to set the height of the theodolite and support assembly as illustrated Ensure all hardware connecting the torque tube assembly to the enclosure are fully tightened Figure 36 Note Any loose hardware will cause improper theodolite alignment 38 Installation Procedures Step 2 Refer to Figure 37 Install theodolite
56. procedures that are required to Maintenance maintain proper functional operation of your new Andrew Earth Station Antenna 5 How to Use This Manual Getting Started Overview Warnings The installation operation and maintenance of the 9 3 Meter Earth Station 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 maintenance and con dition of equipment as described in Preventive Maintenance The basic equipment and accessories are either manufactured or design controlled by Andrew Corporation The prerequisite information necessary for the 9 3 Meter Earth Station Antenna can be found in this section Furthermore this section should be reviewed BEFORE performing the installation operation or maintenance Recommended warnings recommended tools and the antenna parts can be verified and or determined with such a review When installing the 9 3 Meter Earth Station Antenna be conscious of the recommended warnings presented below For further information or clarification of this information contact the Customer Service Center The recommended warnings are as follows 1 Electrical shock from voltages used in this antenna system may cause personal injury or death Prior to making any electrical connections or performing maintenance or repair
57. resh 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 The following is a list of the lubricant characteristics e Mobil Temp SHC32 A non soap hydrocarbon fluid type grease Operating tempera ture range is 65 degrees to 350 degrees Fahrenheit 54 degrees to 177 degrees Celsius Mobil SHC624 A low temperature synthetic oil for worm gear reducers Operating temperature range is 40 degrees to 125 degrees Fahrenheit 40 degrees to 52 degrees Celsius Moly Grease A grease lubricant containing molybdenum disulfide Operating temperature range is 85 degrees to 300 degrees Fahrenheit 29 degrees to 149 degrees Celsius Periodically inspect lifting screws on jackscrew assemblies to ensure adequate lubrica tion Loosen Jackscrew boot clamps to expose the lifting screw assembly Fully extend jackscrew assembly being careful not to exceed preset mechanical limits Brush thin coating of Mobil SHC32 grease on exposed lifting screw Replace boot and attach corre sponding boot clamps If lifting screw is rusty remove existing lubricant with solvent and wire brush rusted area Rinse with solvent and apply fresh grease Periodically inspect and remove dust or dirt deposits from the
58. rifying components Photographs The photographs compliment the installation instructions by providing actual examples of the steps being performed which allow you to view the installation in concrete form The manual is divided into five distinct sections each dealing with a specific technical topic relating to either system or component subsystem information The sections con tained in this manual are described and listed under the following technical headings How to Use Describes the manual s purpose content and communication aids This Manual Additionally this section lists the related documentation for the 9 3 Meter Earth Station Antenna Getting Provides the preliminary information needed to perform a successful Started installation This section should be reviewed prior to the installation The warnings recommended tools parts verification instructions on report ing lost or damaged equipment and installation checklist are located in this section Installation Provides the procedures for the different phases of a 9 3 Meter Earth Procedures Station Antenna base installation This section will help you easily find requirements for an individual task as well as displays the sequence for each task execution Operation Describes the controls functions and general operating procedures required for proper operation of the 9 3 Meter Andrew Earth Station Antenna Preventive Describes preventive maintenance
59. rioration Examine connections for dirt corrosion and mechanical defects Check for loose or broken lacing and cut abrad ed frayed brittle and cracked insulation Examine connectors for corrosion broken inserts and stripped threads Check con nector shells for distortion and dents and contact pins for bends misalignment or other deformities Check connector inserts for cracks and carbon tracking burns or charring indicating arc over 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 56 Preventive Maintenance 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 struc tural 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 Be certain both feed rotation limit switch arms are not distorted and ride centrally on the actuating cam to open their corresponding limit switch Inspect the azimuth and elevation jackscrew boots for security of attachment at both ends for abrasion tears cuts brittlen
60. rts as shown in Figure 9 Use 7 8 x 2 1 4 in 57 mm bolts and nuts Insert bolt from inside of rear pad 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 15 Installation Procedures Step 5 Attach 200108 supports 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 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 LO f S t ds 0 gt Step 6 Attach 200873 supports between angle pairs as shown in Figure 11 Select correspond ing mounting holes so that 200873 supports are parallel to 200114A beam assembly Use 7 8 x 2 3 4 in 70 mm hardware Supports attached with edges inward and flats facing up 7 8 x 2 1 4 718 x 2 3 4 57 mm 70 mm BOLTS AND NUTS BOLTS FLATWASHERS AND NUTS 200108 SUPPORT 7 8 x 2 1 4 57 mm BOLTS AND NUTS 200063 REAR PAD ASSEMBLY 20008A 200068 OINT ASSEMBLY 00098 EETRI 200064 ASSEMBLY REAR PAD 57 mm BOLTS AND NUTS ASSEMBLY Figure 11 16 Installation Procedures Step 7 Refer to Figure 12 Raise and attach assembled beam support assembly to 200112 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 a
61. ry Supports ane 457 mm Figure 24 29 Installation Procedures Step 2 Step 3 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 rotating tube to center of drum assembly Use 3 8 x 1 1 2 in 38 mm bolts lock washers and nuts If 78334 non rotating tube is used unbolt flange assembly apply RTV to both flange faces and assemble to drum Use 3 8 x 2 in 51 mm hardware provided Attach feed support angles to feed rotating tube tabs and drum assembly angle brackets Use 1 2 x 1 1 8 in 29 mm shoulder bolts lock washers and nuts Note Ensure shoulder bolts are fully seated and feed support angles are installed edge down with flat of angles facing upward 9963 181 cala ye 1 2 x 1 1 8 3 8 x 1 1 2 29 mm 38 mmj Shoulder Bolt Bolts Lock Washers Lock Washer and Nut and Nuts Feed Rotating Tube Assembly Non rotating Tube Assembly 78334 Not Shown Use Provided Hardware 77650 Shoulder Drum Assembly Panel Insert Do Not Step On Temporary Supports 6 Required Figure 25 30 Installation Procedures Jack Tripod Assembly Step 1 Step 2 Step 3 Step 4 Refer to Figure 26 Assemble jack tripod by connecting tripod braces to tripod leg Use 3 4 x 5 1 2 in 140 mm bolts lock washers and nuts Attach jack tripod assembly braces to correspo
62. s and touch up where required At the conclusion of the installation procedure prior to turning the system over to the sta tion facility an installation acceptance check off sheet was prepared and duly signed off if installed by Andrew crew Part of this check off included voltage readings retaken to determine if proper voltage was available Current readings were also taken as a refer ence for future comparison to serve as a troubleshooting aid in determining possible equipment degradation and shortened life Any current reading taken during the follow ing procedure that varies by more than five percent from the pre established reference values necessitates troubleshooting the particular system involved to determine the cause and required corrective action Approximately every three months and during a period of down time disconnect as applicable the RF transmitter and all power supplies The main disconnect switch in the main load center box at the antenna site must be in the ON position and the LOCAL REMOTE switch in the local control motor drive controller must be in the LOCAL position Open the outer local control motor drive controller door at the antenna site to gain access to the conductors supplying power to the azimuth elevation and polarization drive motors NOTE During the following procedures the antenna drives azimuth elevation and polarization will be powered to rotate the antenna and feed in both directions of travel C
63. se the corresponding assembly to move causing antenna misalignment When designated the A 325 hard ware should be tightened according to the following tensioning procedure NOTE Tensioned bolts are for final connections only and should not be loosened for reuse Lubricate the bolt threads with the provided stick wax to reduce friction Insert the bolt and add a flat washer if required Do not allow wax under the flat washer Add the nut and finger tighten After the connections are complete tighten the bolts until the surfaces are joined and the nuts are snug for example full effort of a person using an ordinary spud wrench Do not proceed with Steps 5 and 6 unless the connection is final and is not intended to be loosened again Note If the bolts are loosened after Steps 5 and 6 discard and replace with new hard ware Using a felt tip marker mark the nuts and the ends of the bolts with a straight line as shown in Figure 3 1a and Figure 3 1b Tighten the nuts further with an extra long wrench until the nuts are moved 1 3 turn 120 degrees as shown in Figure 3 1a for bolt lengths less than four diameters and 1 2 turn 180 degrees as shown in Figure 3 1b for bolt lengths over four diameters Use Felt Marker F 2 Before After Tensioning Tensioning Use Felt Marker is Le 4 Before After Tensioning Tensioning Figure 3 1a A 325 Tensioning Procedure Figure 3 1b A 325 Tensioning
64. shers must be installed between back to back strut and lower ring of drum 73083 Back Strut Member 78082 Back Strut Member 9999 61 1 2 13 mm Nut 9974 64 1 2 13 mm Lock Washer 9997 101 1 2 13 mm Flat Washer 9963 310 1 2 x 4 1 2 114 mm Bolt Figure 28 ANDREW 32 Installation Procedures Step 3 Refer to Figure 29 Carefully remove reflector panel segments from packing crates Begin with center flash panel if applicable and attach 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 Tighten the panel to drum angle hardware until lock washer is compressed then back off one half turn Do not over torque Note Use 10 ft temporary support to raise outer portion of reflector segment Use addi tional temporary supports as necessary to provide support prior to installation of adja cent reflector segment panel Pad top of temporary support to prevent damaging reflec tor segment panel Do not step on drum panel inserts 170330 Spacer 9999 72 5 8 16 mm Nut 5 8 16 mm Lock Washer Drum Panel Inserts Temporary Support yA b S j A Lit gS Figure 29 ANDREW 33 Installation Procedures Step 4 Step 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 nu
65. 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 nuts Theodolite Assembly 223744 Adaptor Wild T2 Theodolito or 223744 2 Adaptor Tapeon DT 05A Theodolite 223712 Theodolita Support Assembly 207953 Precision Lift 38 Wild T2 or Topcon DT 05A Theodolits Tribrach 300061 Theodolite Interface Plate 223716 X Y Transtation Staga 1 2 x 2 51 mm Bolts Flatwashers Lockwashers and Nuts Lower Flange Adaptor Faad Support Tube Torque Tube Assembly Figure 37 Installation Procedures Theodolite Leveling Step 1 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 Step 2 Before taking any readings allow the theodolite to become acclimated to ambient condi tions for at least 15 to 20 minutes prior to operation Step 3 Notice proper installation orientation setting of tribrach assembly and the position of the tribrach leveling screws with relation to the brass rod holders After installation of theodolite onto the torque tube assembly it is necessary to level the theodolite to the reflector This procedure is performed by adjusting the three leveling screws of the trib ach
66. t Note Ensure eccentric bolt is fully seated and bolt head marking is positioned at right angle to panel segment It is recommended stick wax be applied to the shaft of the eccentric bolt to facilitate its insertion and later adjustment All 20 eccentric bolt head markings must be at right angles to panel 77320 1 2 x 1 7 16 36 mm Eccentric Bolt Tee Section 9974 64 1 2 13 mm Lock Washer 9999 61 Bolt Head f 1 2 13 mm Nut Marking 78082 78083 Struts Figure 30 Refer to Figure 31 Install remaining reflector panels opposite each other to balance the enclosure assembly being sure to install panel segment seam hardware finger tight in holes 1 28 Note that screw locations in reflector segments are numbered 1 31 from the center out Panel segment seams are numbered 1 20 Use special nut with shoulder at hardware location 17 on all 20 panel segment seams Tighten until nut shoulder is prop erly seated inside the formed Tee section hole Note Do not place hardware in holes 29 31 at this time Reflector 209236 Segments k 5 16 x 3 4 19 mm Seam Bolt 9997 74 5 16 8 mm Fiat Washer 9974 17 i Note Use 300287 special shoulder 5 16 8 mm nut with seam hardware at bolt hole Lock Washer location 17 no washers 9999 59 Figure 31 34 Installation Procedures Step 6 Refer to Figure 32 Loosely attach 300177 Subreflector Strut Supports to reflector as shown ensuring brackets are installed on seam hole positions
67. ter Earth Station Antenna Introduction Like all Andrew earth station antennas the 9 3 Meter Earth Station 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 versatility is provided at the time of initial purchase as well as in the future as your satellite communication requirements evolve The aluminum reflector is precision formed for accuracy and strength requiring minimal assembly The reflector assembly is 30 feet 9 3 meters in diameter and segmented in a twenty piece configuration to reduce shipping volume and facilitate transport to remote sites Reflector panels are chromate converted and painted with a highly reflective white paint The versatile tripod mount can be purchased with motorizable capabilities The tripod mount features 180 degree azimuth coverage in three continuous 120 degree overlap ping ranges and executes 90 degree continuous elevation adjustment This large adjust ment range provides non critical foundation orientation and the ability to view geosta tionary satellites from horizon to horizon from any location worldwide The motorizable tripod mount features self aligning bearings for the elevation pivots resulting in Zero backlash This mount has the ability to be upgraded for High Speed motorized
68. tion pad 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 200112 BEAM ASSEMBLY 201022 PIVOT ASSEMBLY 1 FLATWASHERS SHEAR CAP FRONT FOUNDATION PAD Figure 5 ANDREW 13 Installation Procedures Support Legs Assembly Step 1 Attach 200068 joint assembly to 200114A beam assembly as shown in Figure 6 Attach P 200083 angles to 200114A beam assembly as shown in Figure 6 Use 7 8 x 2 1 4 in 57 mm bolts and nuts for each connection 7 8 x 2 1 4 57 mm eos AND NUTS 200068 JOINT ASSEMBLY 200083 ANGLES 200114A BEAM ASSEMBLY 7 8 x 2 1 4 57 mm BOLTS AND NUTS Figure 6 Step 2 Attach 200088 joint assembly to 200114A beam assembly as shown in Figure 7 Use 7 8 x 2 1 4 in 57 mm bolts and nuts 200088A 7 8 x2 1 4 JOINT ASSEMBLY 57 mm BOLTS AND NUTS 7 8 x 2 1 4 57 mm BOLTS AND NUTS 201313A BEAM ASSEMBLY Figure 7 ANDREW 14 Installation Procedures Step 3 Step 4 Raise 200114A beam assembly to upright position and attach 200109 supports to 200068 joint assembly as shown in Figure 8 Use 7 8 x 2 1 4 in 57 mm bolts and nuts Insert bolts from 200068 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 Figure 8 Attach 200063 200064 rear pad assemblies to 200109 suppo
69. tting Worm Gear Pillow Blocks 2 Polarization Drive Gear a laa to MA Pressure PA O ig Fitting Gearbox Gearbox Drain Level Pressure Fitting a Motor Control i A Gearbox Gearbox Pi de Drain Level lt Medium Speed Antenna Lubrication Points Preventive Maintenance APPENDIX A This section contains the formulas for determining the point ing capabilities of the modular mount earth station 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 earth station latitude longitude azimuth set ting of mount AZm and satellite longitude over the equa tor the following calculations can be made For earth stations north of the equator AZ 180 arc tan tan 0 sin a For earth stations south of the equator AZ 360 arc tan tan sin a Where AZ true azimuth to view satellite in degrees East clock wise of True North a earth station latitude in degrees 8 satellite longitude minus earth station longitude in degrees NOTE Earth station latitude values are positive for sites located north of the equator and negative for sites south of the equator Longitude values are positive for earth station sites or satellite positions west of Greenwich and negative east of Greenwich dAZ
70. utton is pressed Check the relays and contactors for free operation of the armatures and contact con dition The contacts are usable even though pitted burned worn or discolored The contacts or contactor or relay assembly should be replaced only when the contact mate rial has been completely torn away or worn off Visually inspect all mechanical parts for freedom of operation without binding or inter ference Check for security of all hardware and stripped or otherwise damaged threads Check metallic parts for corrosion dents distortion and other deformation Check for evidence of water inside the enclosure If any water is in evidence clean area thoroughly and check that all seals are intact and if not use a coating of RTV 108 silicone rubber sealant to seal any exposed electrical fitting bolt hole or other possible water entry to the enclosed electrical components in order to maintain a waterproof con dition Check or change humidity absorber Inspection of the antenna conforms generally to standard visual inspection procedures performed on electromechanical equipment In addition to these procedures perform the following checks and visual inspections for the specific conditions noted Inspect all wiring and cables particularly the network to enclosure and enclosure to mount interfaces for discoloration and burned insulation moisture entry corrosion dirt breaks security of connection and other signs of dete

Andrew 9.3-Meter ESA Stereo System User Manual

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