Andrew 3.7-Meter Earth Station Antenna User Manual
Andrew Corporation
10500 West 153rd Street
Orland Park, IL U.S.A. 60462
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
Printed in U.S.A. 9/00
Copyright © 2000 by Andrew Corporation
Installation, Operation and Maintenance
Bulletin OM37
Type ES37( )
3.7-Meter ESA
3.7-Meter Earth Station Antenna
Revision C
Introduction
How to Use This Manual
Getting Started
Installation
Procedures
Operation
Preventive
Maintenance
Table of Contents
2
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Proprietary Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Information and Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parts Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reporting Equipment Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reporting Visible Loss or Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reporting Concealed Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inventory Equipment Received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation Sequence Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Site Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ground Mount Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
For MPK Types Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
For MPJK Types Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Main Reflector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Reflector-To-Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Subreflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Foundation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A-325 Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly (Using a Crane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly (Without a Crane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Motorizable Pedestal Ground Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Manual Pedestal Ground Mount Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Manual Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Manual Actuator Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Motorizable Pedestal Ground Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Embedded Pipe Ground Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Elevation/Azimuth Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Alignment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Enclosure (Pedestal Mount Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Reflector-to-Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Without a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Reflector-to-Mount Assembly, Embedded Pipe Ground Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Subreflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Subreflector Struts, Embedded Pipe Ground Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Subreflector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Acquiring A Satellite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Manual Actuator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Embedded Pipe Ground Mount Elevation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Azimuth Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Subreflector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Electrical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Mechanical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Local Control/Motor Drive Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Drive System Voltage and Current Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Pedestal Mount Bearing Pad Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Preservation of Component Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Aluminum Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Galvanized Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Jackscrews/Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Gear Motor/Housing Fill Drain Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Introduction
Like all Andrew earth station antennas, the 3.7-Meter Earth Station Antenna provides
high gain and exceptional pattern characteristics. The electrical performance and exceptional versatility provides the ability to configure the antenna with your choice of linearlypolarized 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 versatile pedestal mount can be purchased with either manual or motorizable capabilities. The pedestal mount features 180 degree azimuth coverage in three
continuous 120 degree overlapping ranges and executes 90 degree continuous elevation adjustment. This large adjustment range provides non-critical foundation orientation
and the ability to view geostationary satellites from horizon-to-horizon, from any location
worldwide.
The motorizable pedestal mount features self-aligning bearings for the elevation pivots,
resulting in "zero" backlash. This mount can be operated manually, but has the ability to
be upgraded for motorized operation, including steptracking/Smartrack™ applications.
The motorizable mount type is indicated by the ES37MPK or ES37MPJK letters within
the antenna type number. The addition of the letter "J" within the antenna type number
indicates that the mount includes azimuth/elevation machine jackscrews, instead of corresponding azimuth/elevation strut assemblies. The azimuth/elevation jackscrews are
equipped for integration with the optional motor drive systems.
A manual pedestal mount is also available. It provides the same strong and versatile
combination of mechanical features as the motorizable version; except that the elevation
and azimuth axes are locking types, instead of bearing mounted types. This mount type
is always equipped with manual struts and a fixed mount for the separately-ordered
combining network. This mount has been designed for manual applications only and
cannot be upgraded to a motorizable mount.
The aluminum enclosure and hot-dipped galvanized steel mount maintain pointing accuracy and ensures durability and reliability. The antenna and standard manual mount with
enclosure will survive 125 mph (200 km/h) wind, in any position of operation, without
damage or permanent deformation in moderate coastal/industrial areas. Severe conditions require additional protection.
Andrew provides a complete line of available options, including field-installed electrical
anti-icing heaters, motor drive systems (with power interfaces addressing domestic and
international standards), remote microprocessor antenna control for motor drive systems, pressurization equipment, and interconnecting HELIAX® cables and waveguide.
3
Introduction
3.7-Meter Earth Station Antenna
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
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 technical assistance portion of this this manual for the contact numbers appropriate to your
location.
The installation, maintenance, or removal of antenna systems requires qualified, experienced 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
4
Introduction
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. 1-(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 following:
Call From Telephone Fax
North America 1-800-255-1479 (toll free) 1-(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)
Overview
Content
The scope of this manual is intended to provide station personnel with the base installation, operation, and maintenance requirements necessary for a 3.7-Meter C- or Ku-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 3.7-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 verbage to assist you in simplifying complex procedures and clarifying 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 contained 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 3.7-
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 reporting lost or damaged equipment, and installation checklist are located in
this section.
• Installation Provides the procedures for the different phases of a 3.7-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 3.7-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.
5
How to Use This Manual
How to Use This Manual
Overview
Warnings
The installation, operation, and maintenance of the 3.7-Meter Earth Station Antenna
requires qualified and experienced personnel. Andrew installation, operation, and maintenance instructions are illustrated for such personnel. Additionally, the antenna should
be inspected by qualified personnel to verify proper installation, maintenance, and condition 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 3.7-Meter Earth Station Antenna can be
found in this section. Furthermore, this section should be reviewed BEFORE performing
the installation, operation, or maintenance. Warnings, recommended tools, and the
antenna parts can be verified and/or determined with such a review.
When installing the 3.7-Meter Earth Station Antenna, be conscious of the warnings presented below. For further information or clarification of this information, contact the
Customer Service Center. The 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, 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) lanyards.
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 placed 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
Getting Started
Recommended
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.
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 3.7Meter 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 3.7-Meter Earth Station Antenna.
Tool Size Quantity
Open End or Combination Wrenches 5/16 Inch 2
7/16 Inch 2
9/16 Inch 2
7/8 Inch 2
3/4 Inch 2
1/2 Inch 2
1-1/4 Inch 1
Crane 1 Ton Minimum Capacity, extended end 1
Nylon Web Slings (2000 pound breaking strength) 3 Inch by 14 Foot 2
Rope or Cord (2000 pound breaking strength) 50 Foot 1
Shackles 5/8 Inch 2
Ladder 10 Foot Extension 1
Drive Sockets 1/16 Inch 1
9/16 Inch 1
7/8 Inch 1
3/4 Inch 1
1-1/4 Inch 1
Breaker Bar 1/2 Inch 1
Spud Wrenches 1-1/16 Inch 1
1-1/4 Inch 1
Screw Driver Standard 1
Phillips 1
Allen Wrench 7/64 Inch 1
3/16 Inch 1
1/4 Inch 1
Tape Measure (or other measuring device) Standard 1
Felt-tip Marker (or other marking device) Standard 1
Hammer Standard 1
Rubber Mallet Standard 1
Pry Bar Standard 1
Tin Snips Standard 1
Safety Gloves (each installer) Standard 1
Table 2-1. Recommended Tools
7
Getting Started
Parts Verification
Reporting
Equipment Loss or
Damage
Reporting Visible
Loss or Damage
Reporting
Concealed
Damage
Inventory
Equipment
Received
Upon receipt of your order, the shipment should be verified to ensure that all parts have
reached your site. This process should occur before the installation process begins.
Andrew Corporation thoroughly inspects and carefully packs all equipment before shipment. If you find that there are missing components, please refer to page 9 for step-bystep instructions on how to properly report the equipment loss.
When you have received your order, verify that all parts contained in the shipment correspond to the parts listed on your packing list.
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 Damage"
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 unpacking 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 condition. When this occurs, and it is necessary to return the equipment to Andrew
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
(RM) number, as well as an address to forward the material to.
Tag or identify the defective equipment, noting the defect or circumstances. Also, be
sure to write the RM 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 original 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
• RM Number
• Problem Description
• Contact Name
NOTE: Absence of the RM number will cause a delay in processing your equipment for
repair. Be sure to include the RM 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
Sequence
Checklist
Site Preparation
Ground Mount
Assembly
For MPK Types
Only
The 3.7-Meter Earth Station Antenna requires the installation team to perform the
assembly in the sequence presented below. Moreover, this sequence should be
reviewed to ensure a smooth installation. Use the following checklist to verify and/or
determine the installation sequence.
Refer to Foundation Section for guidance in preparing location and installation of the
3.7-Meter Earth Station Antenna foundation.
Unpack ground mount assembly
Attach ground mount assembly to foundation
Organize ground mount hardware
Wax galvanized hardware in hardware kit
Tighten ground mount hardware to foundation
Attach azimuth strut weldment to ground mount assembly
Assemble azimuth strut
Mount azimuth strut to ground mount assembly
Bolt elevation strut brackets to elevation strut
Mount elevation strut to ground mount assembly
Assemble manual actuator
Remove manual actuator (after elevation/azimuth adjustment)
10
Getting Started
For MPJK Types
Only
Main Reflector
Assembly
Mount azimuth pivot assembly to ground mount assembly
Bolt one jack to azimuth pivot assembly
Unscrew jack
Tighten galvanized hardware using A-325 tensioning procedure
Lubricate jackscrews
Pull protective boot over jackscrew
Bolt elevation pivot assembly brackets to ground mount assembly
Bolt second jack to elevation pivot assembly
Unscrew jack
Tighten galvanized hardware using A-325 tensioning procedure
Lubricate jackscrews
Pull boot over jackscrew
Remove protective covering from crate
Pry top crate panel off
Pry sides off crate
Pry front off crate
Unbolt reflector halves from bottom of crate
Prepare assembly area with blocks of wood to assemble reflector
Lay reflector halves on prepared assembly area
Align reflector halves
Insert all hardware as outlined in Installation Procedures
11
Getting Started
Enclosure
Assembly
Reflector-To-
Mount Assembly
Add reflector-mounting ring
Mount front and back hub-mounting rings
Apply sealant to outside of reflector-mounting ring
Perform recommended string test
Remove rear and side covers from enclosure assembly
Attach enclosure to mounting ring
Apply sealant backing rod around enclosure/mounting ring mating surfaces
Apply RTV sealant
Route sling through upper holes of torsion box assembly
Route two rope tag lines through torsion box assembly to be used as guides
Place foam blocks on ground to avoid scraping reflector when lifted
Raise reflector
Bolt left bolt of enclosure bracket
Rotate reflector to align right bolt
Extend elevation strut or jackscrew, and attach to top of enclosure assembly
Tighten hardware using A-325 tensioning procedure
Carefully raise reflector to zenith position
Remove hoisting apparatus
12
Getting Started
Subreflector
Feed System
Preassemble subreflector weldment
Attach subreflector-mounting ring to strut assembly
Attach angle clips
Attach subreflector to reflector
Adjust subreflector
Tighten adjustment hardware
Refer to installation instructions packaged with the individual feed systems
13
Getting Started
Overview
Foundation
Preparation
14
Installation Procedures
This section provides installation procedures for the 3.7-Meter Andrew Earth Station
Antenna. The installation procedures include instructions on the following antenna components:
• Mount
• Reflector
• Enclosure
• Reflector-to-Mount Assembly
• Subreflector
• Feed System (Refer to installation instructions packaged with the individual feed systems)
Before beginning the installation process on the ground mount assembly, ensure that
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 shipment arrives by contacting the Customer Service Center.
Sweep foundation clean of any dirt or debris.
To ensure level, smooth surface for mount, remove excess concrete from shear caps
and anchor bolts as shown in Figure 3-1.
Installation Procedures
Figure 3-1
A-325 Tensioning
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
15
During the installation process, there are several references to the A-325 hardware tensioning 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 hardware 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 hardware.
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.
Figure 3-1a: A-325 Tensioning Procedure Figure 3-1b: A-325 Tensioning
For bolts less than 4 diameters For bolts over four diameters
Installation Procedures
Use Felt Marker
Before
Tensioning
After
Tensioning
Use Felt Marker
Before
Tensioning
After
Tensioning
Mount
Unpacking
Assembly
(Using a Crane)
16
The elevation/azimuth mount design simplifies installation, minimizes foundation requirements, and enables horizon-to-horizon coverage from any worldwide location. The
ground mount assembly enables 180 degree positioning for selected azimuth viewing.
Azimuth range coverage is plus or minus 90 degrees, divided into three 120 degree
continuous ranges with a 30 degree overlap. Elevation adjustment is continuous from 0
degrees to 90 degrees.
After ensuring that the foundation has been properly prepared, the ground mount
assembly process may begin.
The pedestal ground mount assembly arrives in a packaged wooden crate as shown in
Figure 3-2 below. The mount can be positioned manually or by using a crane; however,
Andrew recommends that this procedure be performed using a crane to ensure speed
and ease of installation.
Installation Procedures
Figure 3-2: Crate Unpacking
As stated previously, the pedestal ground mount installation process can be conducted
manually or by using a crane. The following steps provide the necessary procedures for
installing the ground mount assembly using a crane.
Step 1
Step 2
Step 3
Step 4
17
Carefully remove the ground mount assembly (P/N 208800 - motorizable or P/N
202680-2 manual) from the packing crate. Leave the steel strapping intact to avoid disengagement of the panning frame from the square-tube weldment during the ground
mount installation.
Securely attach the crane to the ground mount assembly using a sling, and carefully
raise the entire ground mount as shown in Figure 3-3.
Installation Procedures
Figure 3-3: Raising Ground Mount Assembly
Align the ground mount assembly directly over the anchor bolts (P/N 203314 - manual
or P/N 203666 - motorizable), which should have been previously mounted in the foundation pad.
NOTE: Ground mount positioning on the foundation is dependent upon predetermined
azimuth viewing requirements. The ground mount assembly arm should be positioned
opposite the satellite requirement. If your site is in the Northern hemisphere, your satellite will be located in the South. If your site is in the Southern hemisphere, your satellite
will be located in the North.
Lower the ground mount assembly onto the anchor bolts with the corresponding hole
pattern.
Step 5
Step 6
Step 7
18
Attach the ground mount assembly to the eight corresponding anchor bolts using a 3/4
inch flat washer and 2-3/4 inch hex nuts as shown in Figure 3-4a. One 3/4 inch hex nut
is supplied with the anchor bolt kit and the second 3/4 inch hex nut is supplied with the
antenna.
Installation Procedures
Figure 3-4a: Ground Mount Assembly Base Hardware
Remove the steel strapping from the ground mount assembly.
Tighten the foundation hardware using the A-325 tensioning procedure.
Figure 3-4b shows the ground mount assembly attached to the foundation.
Figure 3-4b: Ground Mount Assembly Base Hardware
Assembly
(Without a Crane)
Step 1
Step 2
19
As stated earlier, Andrew recommends the use of a crane during this installation
process; however, we recognize that a crane may not always be available. If a crane is
not available, the following steps provide the procedure for installing the ground mount
assembly without a crane.
Carefully remove the ground mount assembly (P/N 208800-motorizable or P/N 2026802- manual) from the packing crate. Leave the steel strapping intact to avoid disengagement of the panning frame from the square-tube weldment during the ground mount
installation.
Lay the ground mount assembly on its side, in line with the anchor bolts (P/N 203314manual or P/N 203666-motorizable) as shown in Figure 3-5.
NOTE: Ground mount positioning on the foundation is dependent upon predetermined
azimuth viewing requirements. The ground mount assembly panning-frame arm should
be opposite of the satellite requirement. If your site is in the Northern hemisphere, your
satellite will be located in the South. If your site is in the Southern hemisphere, your
satellite will be located in the North.
Installation Procedures
Figure 3-5: Ground Mount Assembly Alignment with Anchor Bolts
Step 3
20
Lift the ground mount assembly into an upright position. In the absence of a crane, it is
recommended that a minimum of two people assist in the lifting of the mount assembly
as shown in Figure 3-6a and Figure 3-6b.
Installation Procedures
Figure 3-6a: Manual Lift
Figure 3-6b: Manual Lift
Step 4
Step 5
Step 6
21
Figure 3-7: Mount Alignment/Adjustment
NOTE: You may need to adjust the mount when lifting it to ensure that the anchor bolts
are aligned directly underneath the base of the ground mount assembly as shown in
Figure 3-7.
Attach the ground mount assembly to the eight corresponding anchor bolts using a 3/4
inch flat washer and 2-3/4 inch hex nuts as shown in Figure 3-3a.
NOTE: Ground mount positioning on the foundation is dependent upon predetermined
azimuth viewing requirements. The ground mount assembly arm should be opposite the
satellite requirement. If your site is in the Northern hemisphere, your satellite will be
located in the South. If your site is in the Southern hemisphere, your satellite will be
located in the North.
Remove the steel strapping from the ground mount assembly.
Tighten the foundation hardware using the A-325 tensioning procedure.
Figure 3-8a illustrates the ground mount assembly attached to the foundation.
Installation Procedures
Figure 3-8a: Ground Mount Assembly Base Hardware
Motorizable
Pedestal Ground
Mount Assembly
Step 1
Step 2
Step 3
Step 4
22
Installation Procedures
The ground mount assembly enables 180° positioning for selected azimuth viewing.
Azimuth range coverage is ±90° divided into three 120° continuous ranges with 30°
overlap. Elevation adjustment is continuous from 0 to 90°.
Position and mount 204737 azimuth tiller arm weldment to ground mount assembly as
shown using 0.75 x 1.75 in. A-325 bolts and nuts. Tighten hardware per A-325 tensioning procedure. NOTE: Mounting position of azimuth tiller arm weldment is dependent
upon predetermined azimuth range requirements as shown.
Apply supplied stick lubricant to set screw threads. Loosely install 0.50 x 1.0 in. set
screws in azimuth and 0.50 x 1.50 in. set screws in elevation strut supports.
Position and mount 204754 elevation support angle assembly to ground mount as
shown using 0.50 x 1.75 in. A-325 bolts, flat washers and nuts. Tighten hardware per A325 tensioning procedure.
Loosely install supplied 0.75 x 2.00 in. A-325 bolts, flat washers and nuts in elevation
support angle assembly. This hardware along with the upper elevation strut hardware
will be attached to the antenna and tightened to the A-325 tensioning procedure at the
time of antenna installation.
Support Plate
1/2 x 1” Bolt and
Flat Washer
3/4” Threaded
Rod
3/4” Flat
Washer
Pivot Block
3/4 x 1-3/4”
Bolt and Nut
EL SPT Angle
Assembly
AZ Tiller Arm
Weldment
3/4 x 2” Bolt and Flat Washer
(2 Washers per Bolt, one each
on Reflector and Mount Side)
Figure 3-8b: Ground Mount Assembly Tiller Arm Hardware
Figure 3-8c: Ground Mount Assembly Elevation Support Angle
23
Installation Procedures
1/2” Flat
Washer
1/2 x 1-3/4”
Bolt and Nut
Universal Terminal
5/16 x 3/4” Hex Head
Screw and Lock Washer
Grounding
Cable
Figure 3-8d: Ground Mount Assembly Tiller Arm Hardware
Figure 3-8e: Ground Mount Assembly Tiller Arm Hardware
Left Position
-90° To +30°
Right Position
-30° To +90°
Center Position
-60° To +60°
Manual Pedestal
Ground Mount
Assembly
Step 1
Step 2
24
Prepare the ground mount hardware in the mount hardware kit by sorting all bolts, nuts,
and flat washers into separate sections as shown in Figure 3-9.
Installation Procedures
Figure 3-9: Hardware Separation
Wax two sides of each galvanized bolt with the stick wax provided. This allows a smooth
installation of each galvanized bolt as shown in Figure 3-10.
Figure 3-10: Waxing Bolts
Step 3
Step 4
25
Position and mount the azimuth tiller arm (P/N 203112) to the tiller-arm bracket on the
left side (facing the satellite) of the ground mount assembly. This mounting position of
the azimuth tiller arm is dependent upon pre-determined azimuth range requirements as
shown in Figure 3-11.
NOTE: The ground mount assembly enables 180 degrees positioning for selected
azimuth viewing. Azimuth range coverage is plus or minus 90 degrees, divided into
three 120 degree continuous ranges with a 30 degrees overlap. Elevation adjustment is
continuous from 0 degrees to 90 degrees.
Installation Procedures
Figure 3-11: Azimuth Tiller Arm
Tighten the hardware using the A-325 tensioning procedure.
Step 5
26
Figure 3-12: Azimuth Tiller Arm - Final Assembly
Locate the elevation and azimuth struts (P/N 202951-2-manual) as shown in Figure 3-13.
NOTE: The azimuth strut is the strut on the right and the elevation strut is on the left.
Installation Procedures
Figure 3-13: Elevation and Azimuth Struts
An illustration of the final azimuth tiller arm is shown in Figure 3-12.
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