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Andrew 7.3-Meter ESA Installation, Operation And Maintenance Manual

7.3-meter earth station antenna
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Installation, Operation and Maintenance
Type ES73( )
7.3-Meter ESA
Andrew Corporation
10500 West 153rd Street
Orland Park, IL U.S.A. 60462
7.3-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 OM73
Revision F
15 August, 2005
Copyright © 2005 by Andrew Corporation

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  • Page 1 Customer Service, 24 hours: U.S.A. • Canada • Mexico: 1-800-255-1479 FAX (U.S.A.): 1-800-349-5444 U.K.: 0800 250055 • Republic of Ireland: 1 800 535358 10500 West 153rd Street 15 August, 2005 Internet: http://www.andrew.com Other Europe: +44 1592 782612 Orland Park, IL U.S.A. 60462 Copyright © 2005 by Andrew Corporation...

  • Page 2: Table Of Contents

    Table of Contents Introduction Introduction............... . 3 Proprietary Data .

  • Page 3: Introduction

    7.3-Meter Earth Station Antenna Introduction Like all Andrew earth station antennas, the 7.3-Meter Earth Station Antenna provides high gain and exceptional pattern characteristics. The electrical performance and 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 7.3-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

    Andrew supplies all appropriate hardware/parts required for the installation of your 7.3- 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 7.3-Meter Earth Station Antenna. Tool...

  • Page 8: Parts Verification

    Parts Verification Andrew Corporation thoroughly inspects and carefully packs all equipment before ship- ment. If you find that there are missing components, please notify Andrew Corporation immediately by contacting the Customer Service Center (refer to page 4). Reporting If you find that there was damage caused to the equipment during the shipping process, Equipment Loss or a claim should be filed with the carrier.

  • 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

    Installation Procedures Overview This section provides installation procedures for the 7.3-Meter Andrew Earth Station Antenna. The installation procedures include instructions on the following antenna com- ponents: • • Mount Reflector-to-Mount Assembly • • Reflector Subreflector • • Enclosure Feed System (C-, X- or Ku-band)

  • 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 5 to 90°. Azimuth adjustment is ±90° and divided into three 120° ranges with 30° overlap. Follow the subsequent procedures for proper installation of tripod ground mount assembly.

  • Page 13: Support Legs Assembly

    Support Legs Assembly Step 1 Attach 201327A joint assembly to 201313A beam assembly as shown in Figure 5. Attach 200083 angles to 201313A beam assembly as shown in Figure 5. • Use 7/8 x 2-1/4 in (57 mm) bolts and nuts for each connection Figure 5 Step 2 Attach 200088A joint assembly to 201313A beam assembly as shown in Figure 6.
  • Page 14 Step 3 Raise 201313A beam assembly to upright position and attach 201315 supports to 201327A joint assembly as shown in Figure 7. • Use 7/8 x 2-1/4 in (57 mm) bolts and nuts • Insert bolts from 201327A joint assembly to supports •...
  • Page 15 Step 5 Attach 201314 supports to 201301/201302 rear pad assemblies and 201273 joint assembly as shown in Figures 9 and 10. • Use 7/8 x 2-1/4 in (57 mm) bolts and nuts • Insert bolt from inside of joint assembly to outside of support •...

  • Page 16: Panning Frame Assembly

    Panning Frame Assembly Step 1 Attach 201487 panning frame to 221384 azimuth pivot assembly as shown in Figures 11 and 12. Note: Ensure pivot assembly resolver/limit switch mounting holes are downward. • Use 7/8 x 2-1/4 in (57 mm) hardware and apply supplied RTV to flange surfaces as indicated •...
  • Page 17 Step 2 Attach 221608 joint assemblies to panning frame as shown in Figures 13 and 14. • 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 221608 joint assemblies as shown in Figure 15. • Place supports back-to-back with edges out and flat of angle inward • Install 45967 spacer at midpoints of support pairs • Use 7/8 x 2-1/4 in (57 mm) hardware for each connection 201316 Supports Figure 15...
  • 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 201770 Plate 201487 Panning Frame 201484/201484-2 Extension Assembly Figure 17...
  • 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 201488 Outrigger Plate Figure 19 Step 8 Attach 221721 elevation axis assembly to 201487 panning frame assembly and 221608 joint assemblies as shown in Figures 20 and 21.
  • Page 21 Figure 21 Step 9 Attach 301741 right tripod joint bracket and 301742 left tripod joint bracket to 221721 elevation axis assembly as shown in Figure 22. • Use 7/8 x 2-1/4 in (57 mm) bolt, flatwasher under bolt and under nut, and nut •...
  • Page 22 Step 10 Attach 300026 tripod channel legs to tripod joint brackets as shown in Figure 23. • Use 7/8 x 2-1/4 in (57 mm) bolt, flatwasher and nut • Insert bolts from channel leg to joint bracket 300026 Tripod Channel Legs 301741/301742 Tripod Joint Brackets Figure 23...

  • 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 Figure 25 Step 2 Loosen rubber boot from end of jackscrew. Turn elevation drive screw to extend jack to dimension 67.7 in (1719 mm) as shown in Figure 26.
  • Page 24 Step 3 Prop 301771/301736 elevation jackscrew up to align with 301772 tripod tube weldment as shown in Figure 27. 301771/301736 Elevation Jackscrew Figure 27 Step 4 Attach 301771/301736 elevation jackscrew to 301772 tripod tube weldment as shown in Figure 28. •...

  • Page 25: Azimuth Jackscrew Assembly

    Azimuth Jackscrew Assembly Step 1 Insert 221923/223180 azimuth jackscrew tube into 221738 azimuth pivot assembly as shown in Figure 29. Insert jack carefully to prevent scratching jackscrew tube. Note: Ensure jackscrew assembly remains fully retracted at this time. 221738 221923/223180 Figure 29 Step 2 Apply RTV to flange surface as shown in Figure 29.
  • Page 26 Step 3 Attach rear pad assemblies to rear foundation pads as pictured in Figure 31. 201327A 201313A Figure 31 Step 4 Connect beam assembly using 7/8 x 2-1/4 in (57 mm) hardware. Tighten supports to beam assembly per A-325 tensioning procedure. Installation Procedures...
  • Page 27 Step 5 Hoist elevation jackscrew/panning frame assembly to mount as shown in Figures 32A/32B. Figure 32A Figure 32B Step 6 Apply RTV to flange surfaces and attach 221384 azimuth pivot assembly to 201327A joint assembly with 7/8 x 2-1/4 hardware from pivot assembly to joint assembly as shown in Figure 32C.
  • Page 28 Step 7 Attach 221345 azimuth pivot assembly to 201408 beam assembly with a line of RTV around the plate and four 7/8 x 2-1/4 in (57 mm) holts inserted from pivot assembly to beam assembly as shown in Figure 33. Note: Use one 7/8 by 2-3/4 inch (70 mm) bolt, flat washer and nut for later attachment of grounding cable.
  • Page 29 Step 10 Extend jackscrew to meet outrigger assembly. Loosely attach outrigger plate to pin assembly in azimuth jackscrew as shown in Figure 35A. Note: Realignment of panning frame/pivot assembly may be necessary to ensure proper alignment of azimuth jackscrew pin. Snug panning frame/pivot assembly hardware and fully extend azimuth jackscrew to ensure binding does not occur throughout entire azimuth pivot range.

  • Page 30: Reflector/Subreflector/Feed Assembly

    Reflector/ Type A-325 hardware is utilized during the reflector attachment to the ground mount. Subreflector/ Use of A-325 hardware eliminates slippage between mating surfaces under high loading Feed Assembly conditions as well as the need for future retightening. Refer to the A-325 tensioning pro- cedure in preceding installation text.
  • Page 31 Step 3 Align tabs on 77639 feed rotating tube assembly with corresponding tabs on drum assembly. Attach rotating tube to center of drum assembly using 3/8 x 1-3/4 in (44 mm) bolts, lockwashers and nuts as shown in Figure 38. Do not tighten. Figure 38 Installation Procedures...
  • Page 32 Step 4 Attach 77874 feed supports between rotating tube tabs and corresponding drum tabs as shown in Figure 38. Fully tighten. • Use 1/2 x 1-1/8 (29 mm) shoulder bolts, lockwashers and nuts Note: Ensure shoulder bolts are fully seated and feed support angles are installed edge down with flats of angles facing upward.
  • Page 33 Step 7 Attach 77646-2 feed horn mounting pipe to 201606/301808 feed horn assembly as shown in Figure 40. • Use 1/2 x 2-1/2 in (63 mm) hex screws, lockwashers and nuts • Insert bolts from feed horn to mounting pipe Figure 40 Installation Procedures...
  • Page 34 Step 8 Install circular waveguide assembly through 77639 rotating tube assembly and attach feed horn/mounting pipe assembly to rotating tube as shown in Figure 41A. Install 201065A circular waveguide support assembly as shown in Figure 41B. • Use 1/2 x 2 in (51 mm) bolts, lockwashers and nuts •...
  • Page 35 Step 9 Rotate drum assembly into upright position. Level drum with shims until no side can bounce, as shown in Figure 42. Figure 42 Installation Procedures...

  • Page 36: Reflector/Backstructure Assembly

    Reflector/ Backstructure Assembly Step 1 Attach back strut assemblies to lower drum ring brackets as shown in Figures 43 and • Use 1/2 x 1-1/2 in (38 mm) bolts, lockwashers and nuts Figure 43 Figure 44 Installation Procedures...
  • Page 37 Figure 45 Step 4 Install reflector panel segment 1 with the center of the Andrew “flash” logo to upper drum ring assembly ring bracket 180° opposite tripod mounting holes as shown in Figures 46 and 47. Do not tighten.
  • Page 38 Center portion of Andrew “flash” logo Figure 47 Installation Procedures...
  • Page 39 Step 5 Install back strut members to reflector segment tee section as shown in Figure 48. Use minimum torque to tighten hardware connecting back strut to reflector segment, reflector segment to upper drum ring assembly and back strut to lower ring drum assembly. •...
  • Page 40 Step 6 Repeat Steps 4 and 5 to install second panel adjacent to panel segment 1 as shown in Figures 49. Install panel seam hardware connecting panel segments 1 and 2 with step ladder. Do not tighten. • Use 5/16 x 3/4 in (19 mm) special bolts, 3/8 in flatwasher, 5/16 in lockwasher, and 5/16 in nut as shown in Figure 50.
  • Page 41 Step 7 Install third panel segment (adjacent to first panel segment) according to Steps 4 thru 6 and Figure 51. Figure 51 Step 8 Continue installing panel segments as described in Steps 4 thru 7 in counter-clockwise direction as shown in Figure 52. Note: Panels are numbered and should be installed in proper sequence.
  • Page 42 Step 9 Prior to installing panels 15 and 16 station a man on top of the drum assembly enclo- sure to install panel seam hardware. Care must be taken not to apply heavy weight to surface of panel segments. Step 10 Note that there are 16 panel segments each with 21 bolt holes numbered 1-21 from the center out which form concentric rings around the inside of the reflector as shown in Figure 53.
  • Page 43 Step 15 Beginning with panel seam 1, fully tighten hardware attaching panels to upper drum assembly ring, reflector tee segment to back strut assembly, back strut assembly to lower drum assembly ring and back strut assembly pairs. Continue tightening attaching hardware on all reflector segments.

  • Page 44: Subreflector Strut Assembly

    Subreflector Strut Assembly Step 1 Attach subreflector strut assemblies to 170147 quadrapod plates as shown in Figures 56 and 57. Tighten hardware until snug only. • Use 1/2 x 1-1/2 in (38 mm) bolts, lockwashers and nuts Figure 56 Installation Procedures...
  • Page 45 Figure 57 Installation Procedures...
  • Page 46 Step 2 Attach subreflector strut assemblies to opposing sides of 77943 apex bracket as shown in Figures 58 and 59. • Use 1/2 x 1-1/4 in (32 mm) bolts, lockwashers and nuts Figure 58 Figure 59 Installation Procedures...
  • Page 47 Step 3 Attach subreflector ring to corresponding strut assembly plates as shown in Figure 60. Ensure subreflector ring assembly is installed with indicated adjustment stud hole at 3 o’clock position as shown. Do not tighten mounting hardware. • Use 1/2 x 1-1/4 in (32 mm) holts, flatwashers, lockwashers and nuts Figure 60 Step 4 Fully tighten quadrapod plates to reflector segments, struts to quadrapod plates, struts...

  • Page 48: Reflector To Ground Mount Assembly

    Reflector to Ground Mount Assembly Step 1 Attach 5/8 in (16 mm) shackles to three lifting tabs as shown in Figure 62. Attach 15 ft (4.5 m) tag lines to opposing quadrapod plates. Figure 62 Step 2 Raise reflector/backstructure assembly and align with corresponding mounting holes in drum and elevation axis assemblies using tag lines for proper guidance as shown in Figure 63.
  • Page 49 Figure 63 Figure 64 Installation Procedures...

  • Page 50: Subreflector Assembly And Adjustment

    Subreflector Assembly and Adjustment Step 1 Install subreflector subassembly to subreflector ring by inserting studs on subassembly into adjustment stud mounting holes as shown in Figure 65. • Use 3/4 in (19 mm) flatwasher, nut and jam nut NOTE: 5” (127mm) dimension shown is a starting reference only.
  • Page 51 Step 3 Adjust subreflector hardware to obtain appropriate setting from surface of reflector at seam bolt ring #1 to bottom of subreflector rim in a radial plane as shown in Figure 67. Securely tighten adjustment hardware. Figure 67 Step 4 Repeat the adjustment procedure performed in Step 2, until all areas of the subreflector are uniform.

  • Page 52: Cross-Axis Grounding Kit

    Cross-Axis Note: Thoroughly clean exposed portions of grounding cables, unplated portion of uni- Grounding Kit versal terminals and cor-responding mounting surfaces using a wire brush. Liberally apply supplied 203233-2 conductive grease to all connection surfaces prior to and after instal- lation.
  • Page 53 Step 2 Refer to Figure 69. Attach lugs to universal terminals at each end of 46373 grounding cable as shown, using 5/16 by 1 inch (25 mm) bolts, flat washers and nuts. Attach cable to available hole in panning frame, using 7/8 by 2-1/4 inch (57 mm) bolt and nut. Attach other end of cable to existing 5/8 by 2 inch (51 mm) bolt on tripod as shown.

  • Page 54: 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 55 The following steps provide the procedure for acquiring a satellite. Step 1 Begin by obtaining the correct Az/El pointing data for the satellite of interest based on specific calculations for this particular site. Step 2 Using an inclinometer placed on the enclosure drum surface, position the antenna to the specified elevation angle.
  • Page 56 Step 7 Move the antenna in azimuth to obtain a null, then move ± in elevation to obtain a large peak signal. If not, move the antenna in the opposite azimuth direction through the peak and again move ± in elevation to obtain a large peak signal. If a larger peak is not found, you were on the main lobe.
  • Page 57 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. Figure 4-4: Maximizing Odd Transponders Figure 4-5: Optimum Polarization Setting Operation...

  • Page 58: 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 59: Overview

    Preventive Maintenance Overview This section contains periodic preventive maintenance instructions for the 7.3-Meter Earth Station Antenna. Included in this section are inspection and preventive 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 60: 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 61: 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 62: 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 the antenna and feed movement, and limit travel to prevent struc- tural interference and damage.

  • Page 63: 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 64 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 65: 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 66: Jackscrews/Motors

    Use of a modified level stick will not correctly gauge the appropriate amount of oil in the gear housings. Requirements Lube Service Lube Quantity Andrew Point Parts to be Lubricated Action Frequency Type Type...
  • Page 67 Lubrication Chart Lube Components Frequency Type Type No. of Lube Point to be (Months) Points or Lubricated Service Lube Quantity Elevation Jackscrew Housing Pressure Fitting SHC32 Elevation Jackscrew Gear Housing Pipe Plugs SHC624 10 Oz Fill and Drain Elevation Drive Intermediate Gearbox Pipe Plugs SHC624 34 Oz.
  • Page 68 Pressure Fitting Pressure Fitting Worm Gear Polarization Pillow Drive Gear Blocks (2) Gearbox Fill Pressure Fitting Heater Control Gearbox Gearbox Gearbox Gearbox Fill Fill Level Vent Pressure Gearbox Fitting Local Fill Motor Control Note Gearbox Medium-speed motors Gearbox Drain Gearbox Gearbox shown for illustrative Drain...
  • Page 69 Pressure Fitting Pressure Fitting Worm Gear Polarization Pillow Drive Gear Blocks (2) Pressure Fitting Heater Control Gearbox Gearbox Drain Level Pressure Fitting Local Motor Control Gearbox Gearbox Drain Level Medium-Speed Antenna Lubrication Points Preventive Maintenance...

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Es73

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