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Andrew ES76PK-1 Installation, Operation And Maintenance Manual

Andrew operation manual 7.6-meter earth station antenna es76pk-1
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Installation, Operation and Maintenance
Type ES76PK-1
7.6-Meter ESA
The installation, maintenance, or removal of antenna systems requires qualified, experienced personnel. Andrew installa-
tion 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 mainte-
nance practices.
All designs, specifications, and availabilities of products and services presented in this manual are subject to change
without notice.
Andrew Corporation
10500 West 153rd Street
Orland Park, IL U.S.A. 60462
7.6-Meter Earth Station Antenna
Telephone: 708-349-3300
FAX (U.S.A.): 1-800-349-5444
Internet: http://www.andrew.com
Notice
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 OM76PK
Revision D
16 August, 2005
Copyright © 2005 by Andrew Corporation

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Summary of Contents for Andrew ES76PK-1

  • Page 1 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 mainte- nance practices.

  • Page 2: Table Of Contents

    Introduction Introduction............... . 3 How to Use This Manual Overview .

  • Page 3: Introduction

    7.6-Meter Earth Station Antenna Introduction Like all Andrew earth station antennas, the 7.6-Meter Earth Station Antenna provides high gain and exceptional pattern characteristics. The electrical performance and 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 7.6-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

    8. Should it be expected that winds will exceed 125 mph (200 km/h), it is recommended that Andrew antennas be steered to specific azimuth and elevation orientations to mini- mize 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 7.6-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 Equipment 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 Received 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 7.6-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: Pedestal Ground Mount Assembly

    Pedestal Ground The Pedestal Mount is an elevation-over-azimuth mount optimized for geostationary Mount Assembly satellite applications. The mount enables continuous elevation adjustment from 0 to 90 degree. The azimuth axis has over 180 degrees of travel with 120 degrees (+/-60 deg.) of continuous travel at each jack position.
  • Page 13 Step 3 Using the 1-1/4 in. foundation hardware supplied, level the pedestal to within +/-0.1 degrees. Tighten each anchor bolt to 912 lb/ft (126 kg/m) as shown in Figure 4. Note: Tighten each bolt using no more than 300 lb/ft (41.5 kg/m) at a time in tightening sequence shown.

  • Page 14: Azimuth Jack Arm Installation

    Step 4 Place Anchor Plates (175311) over the corresponding anchor bolts as shown in Figure 3. Note: Ensure anchor plates are oriented on the foundation bolts as shown, level and on same datum as the pedestal assembly. Using the foundation supplied hardware, tighten each anchor bolt to 912 lb/ft (126 kg/m) as shown in Figure 4.

  • Page 15: Azimuth Jackscrew Assembly

    Azimuth Jackscrew Assembly Step 1 Raise the Azimuth Jack assembly into place and attach it to the pedestal assembly as shown in Figure 7. NOTE: The bolts attaching the trunnion to the jack are supplied loose, this hardware must be torqued once the jack is installed and aligned (see Figure •...
  • Page 16 Step 2 Attach Azimuth Jack rod end assembly to the Azimuth Jack Arm as shown in Figure 8. • Use Azimuth Pin (302168) and 3/8 x 1 in. capscrew, washer and lock washer. (AZ Jack Pin, 302168) (302383) 1-1/4” Washer, 9997-188 (2) 3/8”x1.0 Bolt, 9963-632 Lockwasher, 9974-5 Washer, 9997-146...

  • Page 17: Elevation Jackscrew Assembly

    Elevation Jackscrew Assembly Raise and attach the Elevation Jack assembly to the pedestal assembly as shown in Step 1 Figure 10. Fully retract the Elevation Jack to it’s minimum length. NOTE: The bolts attaching the trunnion to the jack are supplied loose, this hardware must be torqued once the jack is installed and aligned (see Figure 10).

  • Page 18: Reflector/Backstructure Assembly

    Assembly and installation of Reflector/Backstructure should only take place when winds are less than 15 mph (24 km/h) to prevent damage to reflector panels and ease the assembly process. Follow special instructions stenciled on crate relative to crate opening, contents removal and/or personnel safety. Reflector/ Backstructure Lubricate bolt threads of both stainless steel and A325 hardware with supplied Stick...
  • Page 19 Step 2 Once all 16 Short Struts are installed and securely fastened, re-install Rear Enclosure Panel. Carefully rotate the enclosure right-side-up as shown in Figure 12. Place tempo- rary wood blocks under each of the enclosure’s three support pads with the additional block positioned in between.
  • Page 20 Step 4 Install Outer Strut to assembly as shown in Figure 13. Leave hardware loose. Eccentric Bolt, 300084A Washer, 9997-101 1/2” Locknut, 9979-54 (Outer Strut, 300079) View A-A Outer Strut, 300079 View B-B 5/8”x2.0 Bolt & Nut, 45980-1 Washer, 9997-227 1/2”x1/2 Shoulder Bolt, 9858-19 1/2”...
  • Page 21 Step 5 Lift truss/rib assembly and install Long Strut as shown in Figure 14. Note: the Long Strut is installed on the opposite side of the Truss Plate. Refer to Figure 12, View D-D for pre- viously installed hardware for Inner Strut to Truss Plate connection. Leave hardware loose.
  • Page 22 Step 7 Attach stretch-formed Skirts (222765-2), Strip Spacer (300040) and Inboard Skirt (300082-2) to Reflector Panels (222677) before attaching panels to ribs. Refer to Figure 15, Section A-A & View B-B. Do not install outer-most screw on each side of skirt at this time.
  • Page 23 Step 8 Attach the reflector panels by placing them on the ribs and sliding them inward, carefully guiding the rib flange between the skirt and panel. Place seam hardware (209236 & 9974-17) in the fourth hole from the outboard edge on both sides of the panel first, fin- ger tight only.
  • Page 24 Step 11 After all 16 reflector panels are fastened to ribs. Attach the Cross Struts (300078) by placing them in-between the Inner Struts (300080) and snug tight the hardware. Refer to Figure 16. After all 16 Cross Struts are attached, tighten all hardware. NOTE: The Cross Struts are the last item to be assembled to insure the ease of Reflector Panels to be mounted on top side of the ribs.

  • Page 25: Reflector Alignment

    Reflector Alignment Temperature change during calibration or alignment of this reflector will adversely effect the alignment quality, and therefore, the performance of this antenna. Calibration and alignment should only be done during stable temperature conditions, typically after sun- set or under heavy cloud cover. Before the theodolite installation/calibration, or rerflector alignment, all panel seam hard- ware should be loose including the lifting tab hardware.
  • Page 26 1.3 Install Brass Rod Holders: Install brass rod holders in seam hole #11 on rib #2, 7, & 10 in Figures 19 and 20. Reflector seam screws must first be removed in these locations. Make sure the bottom of the rod holders are sitting flush on the reflector panels and they are pointed toward the theodolite assembly.
  • Page 27 1.5 “Clock" the Theodolite Assembly: Refer to Figure 20. The theodolite support assembly must be 'clocked' to the brass rod holders such that two of the tribrach leveling screws run parallel with ribs 2 and 10 (see enlarged view in Figure 20). This can be accomplished by rotating the top flange of the torque tube which will rotate the entire theodolite assembly.
  • Page 28 Relocate stick to rib #7. Rotate theodolite, focus and adjust elevation to the scribe line and record this reading as R2. Relocate stick to rib #10. Rotate theodolite, focus and adjust elevation to the scribe line and record this reading as R3. Calculate an average angle by adding R1, R2, &...
  • Page 29 Figure 21 Repeat the above procedure for the other axis of the X-Y translation stage 90 degrees to the first one. After centering, adjust the theodolite height as indicated below. 2.4 Adjust Height: The height adjustment of the theodolite is accomplished with the precision lift (refer to Figure 18).
  • Page 30 Relocate the stick to rib #7. Focus and adjust the elevation to align to stick scribe line. Reord as H3. The specification for height requires that H1, H2 & H3 be within +/-15 seconds (0.0042 degrees) of 90 degrees. This can only be achieved through successive leveling/center- ing sequences.
  • Page 31 EL1 (do not move elevation) located on the rib #1, which is to the right of the top panel (top center of antenna with Andrew `Flash’ logo). While still focusing to the target, have the outboard cambolt slowly rotated until the upper edge of the target screw is within +/-15 seconds (0.0042 deg.) of the theodo-...
  • Page 32 3.5.3 Repeat all 16 adjustments again. This time, after each individual adjustment, fully tighten seam hardware #24 and 25 on the rib being adjusted. The outer ring of the reflector is now `locked’ in place. 3.6 Fine Inboard Alignment: NOTE: During seam hardware tightening as described in `Fine Inbard Alignment’...

  • Page 33: Reflector To Ground Mount Assembly

    Reflector to Ground Mount Assembly Step 1 Attach 16ft. (5m) chokers with corresponding 5/8” shackles to the Lifting Tabs (206278). Attach 30ft. (9m) tag lines of suitable rope equally spaced about reflector (refer to Figure 22). Note: Ensure ground mount pedestal assembly has elevation jack in the fully retracted position.

  • Page 34: Subreflector Installation

    Subreflector Ensure that the Feed System is installed prior to installation of Subreflector and Struts. Installation Step 1 Place the reflector in the zenith (EL = 90 deg.) position. Step 2 Refer to Figure 23. Loosely assemble Subreflector Strut Assembly (300092) as shown using supplied Angles (300088), Subreflector Strut Brackets (300090) and corresponding mounting hardware.
  • Page 35 Step 3 Refer to Figure 23, View A-A and Figure 24. Loosely attach Subreflector Strut Supports (300089) to panel segements 8-16, 3-11, 7-15 and 4-12 as shown. Replace screws, washers, lockwashers and nuts previously installed during reflector assembly. Subreflector Strut Supports should be positioned according to Step 3 and at the 2nd and Step 4 3rd seam holes from the outboard end of the rib.
  • Page 36 Step 5 Carefully raise and attach pre-assembled subreflector/strut assembly to corresponding subreflector strut supports as shown in View A-A (Figure 23) and Figure 25 using sup- plied hardware. Step 6 Securely tighten all subreflector/strut assembly mounting hardware except for floating ring hardware shown in Figure 25.

  • Page 37: Subreflector Centering

    Subreflector Centering Step 7 Measure and note the distance between outermost subreflector strut support bolt head and the subreflector rim as shown in Figure 25. Obtain corresponding measurements from remaining subreflector struts. These measurements should have a maximum differ- ential of 0.062 in. (1.5mm). If adjustment is necessary, loosen the four floating ring bolts and slide subreflector appropriately to achieve the 0.062 in.

  • Page 38: Operation

    Acquiring A There are several procedures that may be used to properly acquire a satellite. Andrew Satellite recommends that a spectrum analyzer be used. The follwing procedures provide expla- nation as to how to use the spectrum analyzer.
  • Page 39 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 40 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 41 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 42: 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 43: Preventive Maintenance

    Preventive Maintenance Overview This section contains periodic preventive maintenance instructions for the 7.6-Meter Earth Station Antenna. Included in this section are inspection and preventive 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 44: Mechanical Parts

    These sur- Galvanized) faces include threaded holes, the azimuth bearing ring, and azimuth bearing mounting surfaces. Andrew recommends the rust preventative coating Cortec VCI-368 environments, application should be every six months. For dry environments, application once a year should be sufficient.

  • Page 45: Antenna

    • 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. •...
  • Page 46 • Check all electrical component for dirt, cracks, chips, breaks, discoloration, and other signs of deterioration and damage. A discolored, blistered, or burnt condition is evidence of overload. • Operate the azimuth and elevation drives as well as the feed rotation in both the plus and minus direction from the local control/motor drive controller at least once every three months during antenna down time.

  • Page 47: Drive System Voltage And Current Checks

    Voltage and if installed by Andrew crew. Part of this check off included voltage readings retaken to Current Checks 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.
  • Page 48 the installation/acceptance check off. If the readings differ by more than five percent, refer to appropriate troubleshooting information and perform applicable corrective action. Then take voltage readings off each of the three conductors; the readings should agree with each other within two percent. Turn the FEED CCW/OFF/CW switch to OFF. Repeat preceding step (3) with the FEED CCW/OFF/CW switch in the alternate operat- Step 4 ing position.

  • Page 49: Preservation Of Component Parts

    Preservation of When preserving the component parts, refer to the following paragraphs in this section. Component Parts Aluminum 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 window.

  • Page 50: Jackscrews/Motors

    and remove any old lubricant to prevent an excessive build-up. Remove indicated access plugs from square tube weldment and apply lubricant to panning frame tube assembly and corresponding thrust pads. Securely replace access plugs in square tube weldment. Be certain to remove any protective caps and clean off each lubrication fitting prior to injecting fresh grease.
  • Page 51 Lube Components Point to be Lubricated Azimuth/Elevation Jackscrew Housing Azimuth/Elevation Jackscrew Gear Housing Fill and Drain Polarization Drive Gear Feed Rotation Worm Gear Pillow Blocks Elevation Axis Pivot Points Azimuth Turntable Bearing X = Lubricate I = Inspect C = Change * Inspection requires checking for visible signs of oil leakage, draining replacing and adding oil to ensure appropriate oil level requirements.
  • Page 52 Antenna Lubrication Points Pressure Fitting Pressure Fitting Local Motor Control Preventive Maintenance Gearbox Level Gearbox Drain Pressure Fitting...

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