Andrew 5.6-Meter ESA Installating And Operation Manual

Andrew 5.6-Meter ESA Installating And Operation Manual

5.6-meter earth station antenna

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Installation, Operation and Maintenance
Type ES56( )
5.6-Meter ESA
Andrew Corporation
10500 West 153rd Street
Orland Park, IL U.S.A. 60462
5.6-Meter Earth Station Antenna
Telephone: 708-349-3300
FAX (U.S.A.): 1-800-349-5444
Internet: http://www.andrew.com
Customer Service, 24 hours: U.S.A. • Canada • Mexico: 1-800-255-1479
U.K.: 0800 250055 • Republic of Ireland: 1 800 535358
Other Europe: +44 1592 782612
Bulletin OM56
Revision C
Sept. 2004
Copyright © 2004 by Andrew Corporation

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Summary of Contents for Andrew 5.6-Meter ESA

  • Page 1 Orland Park, IL U.S.A. 60462 Customer Service, 24 hours: U.S.A. • Canada • Mexico: 1-800-255-1479 U.K.: 0800 250055 • Republic of Ireland: 1 800 535358 Other Europe: +44 1592 782612 Bulletin OM56 Revision C Sept. 2004 Copyright © 2004 by Andrew Corporation...
  • Page 2: Table Of Contents

    Table of Introduction How to Use This Manual Getting Started Installation Procedures Operation Preventive Maintenance Introduction............... . 3 Proprietary Data .
  • Page 3: Introduction

    5.6-Meter Earth Station Antenna Introduction Like all Andrew earth station antennas, the 5.6-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.
  • Page 4: Proprietary Data

    The technical data contained herein is proprietary to Andrew Corporation. It is intended for use in operation and maintenance of Andrew supplied equipment. This data shall not be disclosed or duplicated in whole or in part without express written consent of Andrew Corporation.
  • Page 5: How To Use This Manual

    Describes the controls, functions, and general operating procedures required for proper operation of the 5.6-Meter Andrew Earth Station Antenna. • Preventive Describes preventive maintenance procedures that are required to Maintenance maintain proper functional operation of your new Andrew Earth Station Antenna. How to Use This Manual...
  • Page 6: Getting Started

    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.
  • Page 7: Recommended Tools

    Tools 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 5.6-Meter Earth Station Antenna. Open End or Combination Wrenches...
  • Page 8: Parts Verification

    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.
  • Page 9: Returning Equipment

    Returning Andrew Corporation tries to ensure that all items arrive safe and in working order. Equipment 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 Andrew...
  • Page 10: Installation Procedures

    Overview This section provides installation procedures for the 5.6-Meter Andrew Earth Station Antenna. The installation procedures include instructions on the following antenna com- ponents: • Mount • Reflector • Enclosure Foundation Before beginning the installation process on the ground mount assembly, ensure that Preparation the foundation has been prepared.
  • Page 11: A-325 Tensioning

    A-325 Tensioning During the installation process, there are several references to the A-325 hardware ten- sioning procedure. The A-325 hardware must be properly tensioned to avoid slippage between bolted surfaces under high loads. Slippage can cause the corresponding assembly to move, causing antenna misalignment. When designated, the A-325 hard- ware should be tightened according to the following tensioning procedure.
  • Page 12: Tripod Ground Mount Assembly

    Tripod Ground The three-point mount is an elevation-over-azimuth mount optimized for geostationary Mount Assembly 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.
  • Page 13: Support Legs Assembly

    Support Legs Assembly Step 1 Attach 201327 joint assembly to 201313 beam assembly as shown in Figure 5. Attach 200083 angles to 201313 beam assembly as shown in Figure 5. • Use 7/8 x 2-1/4 in (57 mm) bolts and nuts for each connection Step 2 Attach 200088 joint assembly to 201313 beam assembly as shown in Figure 6.
  • Page 14 Step 3 Raise 201313 beam assembly to upright position and attach 201315 supports to 201327A joint assembly as shown in Figure 7. • Use 7/8 x 2-1/4 in (57,ivm) bolts and nuts • Insert bolts from 201327A joint assembly to supports •...
  • Page 15 Step 5 Attach 201314 supports to 201301/201302 rear pad assemblies and 201273 joint assembly as shown in Figure 9. • Use 7/8 x 2-1/4 in (57 mm) bolts and nuts • Insert bolt from inside of joint assembly to outside of support •...
  • Page 16: Panning Frame Assembly

    Panning Frame Assembly Step 1 Attach 201487 panning frame to 201544 azimuth pivot assembly as shown in Figures 11 and 12. • Use 7/8 x 2-1/4 in (57 mm) hardware • Bolts should connect from panning frame to pivot assembly Figure 11 Figure 12 Installation Procedures...
  • Page 17 Step 2 Attach 201295/201296 joint assemblies to panning frame as shown in Figures 13 and • Use 7/8 x 2-1/4 in (57 mm) hardware • Insert bolts from panning frame to joint assembly Figure 13 Figure 14 Installation Procedures...
  • Page 18 Step 3 Attach 201316 support pairs to 201295/201296 joint assemblies as shown in Figure 15. • Place supports back-to-back with edges out and flat of angle inward • Install 45967 spacer at midpoints of support pairs • Use 7/8 x 2-1/4 in (57 mm) hardware for each connection Step 4 Attach 201458 azimuth pivot assembly to 201316 support pairs.
  • Page 19 Step 5 Attach 201770 plate connecting 201484/201484-2 extension assembly to 201487 pan- ning frame as pictured in Figure 17. • Use 7/8 x 2-1/4 in (57 mm) hardware • Insert bolts from inside panning frame assembly Step 6 Attach 201488 outrigger plate to opposite end of 201487 panning assembly. Attach 201481/201482 supports to outrigger plate as shown in Figure 18.
  • Page 20 Step 7 Attach second 201488 outrigger plate to 201487 panning frame assembly as shown in Figure 19. • Use 7/8 x 2-1/4 in (57 mm) hardware • Insert bolts from inside assembly to outrigger plate Step 8 Attach 201407 elevation axis assembly to 201487 panning frame assembly and 201295 joint assemblies as shown in Figures 20 and 21.
  • Page 21 Step 9 Attach 300029 tripod joint bracket to 201407 elevation axis assembly as shown in Figure 22. • Use 7/8 x 2-1/4 in (57 mm) bolt, flatwasher under bolt and under nut, and nut • Insert bolts from elevation axis assembly to tripod joint bracket Figure 21 Figure 22 Installation Procedures...
  • Page 22 Step 10 Attach 300026 tripod channel legs to 300029 tripod joint bracket as shown in Figure 23. • Use 7/8 x 2-1/4 in (57 mm) bolt, flatwasher and nut • Insert bolts from channel leg to joint bracket Step 11 Attach 300010 tripod tube weldment to 300026 tripod channel legs as shown in Figure •...
  • Page 23: Elevation Jackscrew Assembly

    Elevation Jackscrew Assembly Step 1 Attach 301771/301736 elevation jackscrew assembly to 201596 mounting plates as shown in Figure 25. Tighten connection. • Use 7/8 x 2-1/2 bolts and nuts Step 2 Loosen rubber boot from end of jackscrew. Turn elevation drive screw to extend jack to dimension 67.7 in (1719 mm) as shown in Figure 26.
  • Page 24 Step 3 Prop 301771/301736 elevation jackscrew up to align with 300010 tripod tube weldment as shown in Figure 27. Step 4 Attach 301771/301736 elevation jackscrew to 300010 tripod tube weldment as shown in Figure 28. • Use 7/8 x 5-1/4 (133 mm) bolt. Fasten with heavy hex nut and flatwasher according to A-325 procedure with the exception of tightening the nut 1/2 turn from snug condition.
  • Page 25: Azimuth Jackscrew Assembly

    Azimuth Jackscrew Assembly Step 1 Insert 22193/223180 azimuth jackscrew tube into 201287 azimuth pivot assembly as shown in Figure 29. Insert jack carefully to prevent scratching jackscrew tube. Note: Ensure jackscrew assembly remains fully retracted at this time. 22193/223180 Step 2 Apply RTV to flange surface as shown in Figure 29.
  • Page 26 Step 3 Attach rear pad assemblies to rear foundation pads as pictured in Figure 31. Step 4 Connect beam assembly using 7/8 x 2-1/4 in (57 mm) hardware. Tighten supports to beam assembly per A-325 tensioning procedure. Figure 31 Installation Procedures...
  • Page 27 Step 5 Hoist elevation jackscrew assembly to mount. Attach 201544 azimuth pivot assembly to 201327 joint assembly with 7/8 x 2-1/4 hardware from pivot assembly to joint assembly as shown in Figure 32. Step 6 Attach 201458 azimuth pivot assembly to 201408 beam assembly with a line of RTV around the plate and four 7/8 x 2-1/4 in (57 mm) holts inserted from pivot assembly to beam assembly as shown in Figure 33.
  • Page 28 Note: If optional motor drive system is included, install motors at this point. Refer to installation instructions provided with motor kits. Step 7 Refer to Figure 34. Position hoisting ropes on azimuth motor jack assembly so jack will not roll when hoisted. Attach one rope to motor frame next to gearbox to balance assem- bly.
  • Page 29 Step 10 Extend jackscrew to meet outrigger assembly. Loosely re-attach outrigger plate to pin assembly in azimuth jackscrew as shown in Figure 35. Note: Realignment of panning frame/pivot assembly may be necessary to ensure proper alignment of azimuth jackscrew pin. Snug panning frame/pivot assembly hardware and fully extend azimuth jackscrew to ensure binding does not occur throughout entire azimuth pivot range.
  • Page 30: Reflector/Backstructure Installation Drawing (239352)

    Installation Procedures...
  • Page 31 Installation Procedures...
  • Page 32 Installation Procedures...
  • Page 33 Installation Procedures...
  • Page 34 Installation Procedures...
  • Page 35 Installation Procedures...
  • Page 36 Installation Procedures...
  • Page 37: Subreflector And Subreflector Strut Installation Drawing (239438)

    Installation Procedures...
  • Page 38 Installation Procedures...
  • Page 39: Operation

    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.
  • Page 40 The following steps provide the procedure for acquiring a satellite. Step 1 Manually move the antenna in the azimuth (scanning back-and-forth) to achieve the maximum (greatest amplitude) transponder signals. • Scan in one direction until the amplitude continues to diminish and then scan in the opposite direction until the same condition occurs.
  • Page 41 Step 5 If the signal amplitude diminishes and does not increase (position B) to the level noted when the antenna was peaked on the side lobe, the antenna is moving away from the main beam; reverse the direction of the antenna movement. From the original side lobe position (position A), the signal amplitude should now dimin- ish to a null point at position C (minimum amplitude showing only signal noise) and then symmetrically increase again to the same level at position D as noted at position A.
  • Page 42 Step 9 With all 24 transponder signals of approximately equal amplitude appearing on the spectrum analyzer screen determine the specific antenna system and satellite parame- ters. Rotate the feed assembly as required until the appropriate (odd or even) transpon- der signals are maximized. Figure 4-5: Maximizing Odd Transponders Figure 4-6: Optimum Polarization Setting Operation...
  • Page 43: Subreflector Adjustment

    Subreflector After the satellite has been acquired and testing has taken place with the spectrum analyzer, Adjustment 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.
  • Page 44: Overview

    Preventive Maintenance Overview General Cleaning Electrical Parts This section contains periodic preventive maintenance instructions for the 5.6-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.
  • Page 45: Mechanical Parts

    Mechanical Parts 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.
  • Page 46: Antenna

    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 pushbutton is pressed.
  • Page 47: Preventive Maintenance

    and minus direction from the local control/motor drive controller at least once every three months during antenna down time. Check the mechanical limit switches provided at the end points stop antenna and feed movement, and limit travel to prevent structural interference and damage.
  • Page 48: Drive System Voltage And Current Checks

    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 Drive System determine if proper voltage was available.
  • Page 49 Step 4 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 Step 5 instructions to take current readings off each of the three conductors (phases) connect- ed to the load side of the azimuth drive motor circuit breaker.
  • Page 50: Preservation Of Component Parts

    Preservation of Component Parts Remove all loose paint and corrosion by scraping, wire brushing, or using steel wool. If using steel wool near the feed window, make sure that none remains on the feed horn Aluminum Parts window. Edges of existing paint can be blended with the metal surface by using a fine grit sandpaper.
  • Page 51: Jackscrews/Motors

    Use of a modified level stick will not correctly gauge the appropriate amount of oil in the gear housings. Lube Point Parts to be Lubricated Action Service Lube Quantity Andrew Frequency Type Type Preventive Maintenance /Points Number...
  • Page 52 Lube Components Point to be Lubricated Elevation Jackscrew Housing Elevation Jackscrew Gear Housing Fill and Drain Elevation Drive Intermediate Gearbox Fill and Drain Elevation Jackscrew Pivot Pin, upper Azimuth Jackscrew Pivot Pin, front Azimuth Jackscrew Housing Azimuth Jackscrew Gear Housing Fill and Drain Azimuth Drive Intermediate Gearbox Fill and Drain...
  • Page 53 Pressure Fitting Gearbox Gearbox Fill Fill Gearbox Gearbox Gearbox Drain Level Vent Pressure Fitting Worm Gear Polarization Pillow Drive Gear Blocks (2) Pressure Fitting High-Speed Antenna Lubrication Points Heater Control Gearbox Gearbox Local Fill Motor Control Note Medium-speed motors shown for illustrative purposes only.
  • Page 54 Pressure Fitting Pressure Fitting Gearbox Gearbox Drain Level Medium-Speed Antenna Lubrication Points Pressure Fitting Worm Gear Polarization Pillow Drive Gear Blocks (2) Heater Control Local Motor Control Pressure Fitting Gearbox Gearbox Drain Level Preventive Maintenance...

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