Andrew 7.6-Meter ESA User Manual

Andrew Corporation

10500 West 153rd Street
Orland Park, IL U.S.A. 60462

Telephone: [phone]
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: [phone]

26 September, 2006

Copyright © 2005 by Andrew Corporation

Installation, Operation and Maintenance

Bulletin OM76

Type ES76( )

7.6-Meter ESA

7.6-Meter Earth Station Antenna

Revision E

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

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Foundation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

A-325 Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Tripod Ground Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Azimuth Beam Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Support Legs Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Panning Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Elevation Jackscrew Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Azimuth Jackscrew Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Reflector/Backstructure Installation Drawing (239501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Reflector/Backstructure Installation Drawing (239908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Theodolite & Alignment Installation Drawing (239611A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Subreflector and Subreflector Strut C-Band Installation Drawing (239906) . . . . . . . . . . . . . . . . . . 50

Subreflector and Subreflector Strut Ku-Band Installation Drawing (239909) . . . . . . . . . . . . . . . . . 52

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Acquiring A Satellite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Subreflector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Electrical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Mechanical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Local Control/Motor Drive Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Drive System Voltage and Current Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Preservation of Component Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Aluminum Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Galvanized Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Jackscrews/Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Gear Motor/Housing Fill Drain Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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 excep­tional versatility provides the ability to configure the antenna with your choice of linearly­or circularly-polarized 2-port or 4-port combining network. That versatility is provided at
the time of initial purchase, as well as in the future, as your satellite communication
requirements evolve.

The aluminum reflector is precision formed for accuracy and strength requiring minimal
assembly. The reflector assembly is 25-feet (7.6-meters) in diameter and segmented in
a sixteen piece configuration to reduce shipping volume and facilitate transport to
remote sites. Reflector panels are chromate converted and painted with a highly reflec­tive white paint.

The versatile tripod mount can be purchased with either manual or motorizable capabili­ties. The tripod 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 tripod 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 ES76 or ES76HS letters within the
antenna type number. The addition of the letter "HS" within the antenna type number
indicates that the mount includes High-Speed azimuth/elevation machine jackscrews,
instead of corresponding azimuth/elevation strut assemblies. The azimuth/elevation
jackscrews are equipped for integration with the optional motor drive systems. A cross­axis grounding kit is supplied with each mount to ensure electrical interconnectivity of
the complete structure.

The aluminum enclosure and hot-dipped galvanized steel mount maintain pointing 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 motor drive systems
(with power interfaces addressing domestic and international standards), remote micro­processor antenna control for motor drive systems, pressurization equipment, and inter-

connecting HELIAX

®

cables and waveguide.

3

Introduction

7.6-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 © 2005, 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 7.6-Meter C-, X- or Ku­Band 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 7.6-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 7.6-

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 7.6-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 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.

5

How to Use This Manual

How to Use This Manual

Overview

Warnings

The installation, operation, and maintenance of the 7.6-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 7.6-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 7.6-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 7.6­Meter 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.

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 15 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
(RMA) 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 RMA number on the tag. It would be helpful to reference the sales
order and purchase order, as well as the date the equipment was received.

Pack the equipment in its original container with protective packing material. If the 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

• RMA Number

• Problem Description

• Contact Name

NOTE: Absence of the RMA number will cause a delay in processing your equipment
for repair. Be sure to include the RMA number on all correspondence.

Ship the equipment to Andrew Corporation using UPS, U.S. Postal Service, or other
appropriate carrier; freight prepaid and insured. The material should be forwarded to the
address given by the Andrew contact in Step 1.

9

Getting Started

Overview

Foundation

Preparation

10

Installation Procedures

This section provides installation procedures for the 7.6-Meter Andrew Earth Station
Antenna. The installation procedures include instructions on the following antenna com­ponents:

• Mount • Reflector-to-Mount Assembly

• Reflector • Subreflector

• Enclosure • Feed System (C-, X- and Ku-band)

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 or your Account Manager.

• Foundation should be dimensioned as detailed in Figure 1.

• Sweep foundation clear of any dirt or debris.

• To ensure smooth surface for mount, scrape foundation pads as shown in Figure 2.

• Studs should extend 3 in. above the ground and are 7/8 in. in diameter

• Apply stick wax to stud threads to ease later connections.

Installation Procedures

Figure 1

Figure 2

A-325 Tensioning

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

11

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

Tripod Ground

Mount Assembly

Azimuth Beam

Assembly

Step 1

Step 2

Step 3

12

The three-point mount is an elevation-over-azimuth mount optimized for geostationary
satellite applications. The mount enables continuous elevation adjustment from 0 to 90°.
Azimuth adjustment is ±90° and divided into three 120° ranges with 30° overlap. Follow
the subsequent procedures for proper installation of tripod ground mount assembly.

All ground mount hardware is type A-325. Lubricate all A325 bolt threads with supplied
stick wax. Note: Do not tighten hardware until ground mount installation is complete
unless otherwise instructed.

Attach 200056 and 200057 supports to upper portion of 201408 beam assembly as
shown in Figure 3.

• Use 7/8 x 2-1/4 in (57 mm) hardware

Installation Procedures

Figure 3

Raise 201408 azimuth beam assembly and attach to front foundation pad as shown in
Figure 4.

• Use 7/8 in. flatwashers and hex nuts

Note: Hex nuts and flatwashers supplied with 201630 anchor bolt kit

Figure 4

Support Legs

Assembly

Step 1

Step 2

13

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

Installation Procedures

Figure 5

Attach 200088A joint assembly to 201313A beam assembly as shown in Figure 6.

• Use 7/8 x 2-1/4 in (57 mm) bolts and nuts

Figure 6

Step 3

Step 4

14

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.

• Supports should be installed back-to-back with the flat of angle facing upwards.

• Tighten supports until assembly can support itself.

Installation Procedures

Figure 7

Attach 201301/201302 rear pad assembly to 201315 supports as shown in Figure 8.

• Use 7/8 x 2-1/4 in. (57 mm) bolts and nuts

• Insert bolt from inside of rear pad assembly to outside of support

• Supports should be installed back-to-back with the edges forward and the flats of

angles facing rear

Figure 8

Step 5

Step 6

15

Attach 201314 supports to 201301/201302 rear pad assemblies and 200884 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

• Supports should be installed back-to-back with the edges forward and the flats of

angles facing rear

Installation Procedures

Figure 9

Attach 201317 supports between angle pairs as shown in Figure 10. Select correspond­ing mounting holes so that 201317 supports are parallel to 201313A beam assembly.

• Use 7/8 x 2-1/4 in. (57 mm) hardware

• Supports attached with edges inward and flats facing up.

Figure 10

Panning Frame

Assembly

Step 1

16

Attach 201487 panning frame to 221384 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

Installation Procedures

Figure 11

Figure 12

Step 2

17

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

Installation Procedures

Figure 13

Figure 14

Step 3

Step 4

18

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

Installation Procedures

Figure 15

Attach 221345 azimuth pivot assembly to 201316 support pairs. Attach 201596 mount­ing plates to 201458 azimuth pivot assembly tab as shown in Figure 16.

• Use 7/8 x 2-1/4 in (57 mm) hardware for each connection

• Insert bolts from rear of pivot assembly to connect supports

Figure 16

Step 5

Step 6

19

Attach 201770 plate connecting 201484/201484-2 extension assembly to 201487 pan­ning frame as pictured in Figure 17.

• Use 7/8 x 2-1/4 in (57 mm) hardware

• Insert bolts from inside panning frame assembly

Installation Procedures

Figure 17

Attach 201488 outrigger plate to opposite end of 201487 panning assembly. Attach
201481/201482 supports to outrigger plate as shown in Figure 18.

• Use 7/8 x 2-1/4 in (57 mm) hardware

• Insert bolts from supports to the outrigger plate

Figure 18

Step 7

Step 8

20

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

Installation Procedures

Figure 19

Attach 221721 elevation axis assembly to 201487 panning frame assembly and 221608
joint assemblies as shown in Figures 20 and 21.

• Use 7/8 x 2-1/4 in (57 mm) hardware

• Insert bolts from elevation axis assembly to panning frame assembly and joint assem-

bly

Figure 20

Step 9

21

Installation Procedures

Figure 21

Attach 301741/301742 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

• Insert bolts from elevation axis assembly to tripod joint bracket

Figure 22

Step 10

Step 11

22

Installation Procedures

Attach 300026 tripod channel legs to 301741/301742 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

Figure 24

Figure 23

Attach 301725 tripod tube weldment to 300026 tripod channel legs as shown in Figure

24.

•

Use 7/8 x 2-1/4 in (57 mm) bolt, flatwasher and nut

• Insert bolt from channel leg to tube weldment

Elevation

Jackscrew

Assembly

Step 1

Step 2

23

Installation Procedures

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

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. Apply grease to screw shaft.
Reattach rubber boot.

Figure 26

Step 3

Step 4

24

Installation Procedures

Figure 27

Attach 301771/301736 elevation jackscrew to 301725 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.
Tighten jam nut in accordance with A-325 procedure. Apply supplied Loctite to threads
to act as locking nut.

Figure 28

Prop 301771/301736 elevation jackscrew up to align with 301725 tripod tube weldment
as shown in Figure 27.

Azimuth

Jackscrew

Assembly

Step 1

Step 2

Mount Assembly

Step 1

Step 2

25

Installation Procedures

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.

Figure 29

Apply RTV to flange surface as shown in Figure 29. Fasten jack to pivot using 7/8 x 2­3/4 in (70 mm) bolts and nuts. Mounting hardware is included with corresponding jack
assembly hardware kit.

Attach shackles to beam assembly as shown in Figure 30.

221923/223180

Figure 30

Lift support legs to azimuth beam assembly.

221738

Step 3

Step 4

26

Installation Procedures

Attach rear pad assemblies to rear foundation pads as pictured in Figure 31.

Figure 31

Connect beam assembly using 7/8 x 2-1/4 in (57 mm) hardware. Tighten supports to
beam assembly per A-325 tensioning procedure.

201327A
JOINT ASSEMBLY

201313A
BEAM ASSEMBLY

221345

PIVOT

ASSEMBLY

Step 5

Step 6

27

Installation Procedures

Hoist elevation jackscrew assembly to mount. Attach 221384 azimuth pivot assembly to
221608 joint assembly with 7/8 x 2-1/4 hardware from pivot assembly to joint assembly
as shown in Figure 32.

Figure 32

Attach 221435 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.

Figure 33

221435

PIVOT ASSEMBLY

7/8 x 2-1/4”

(57mm)

BOLTS, FLATWASHERS,

AND NUTS

Step 7

Step 8

Step 9

28

Installation Procedures

Figure 34

Refer to Figure 34. Position hoisting ropes on motor/jack assembly so jack will not roll
when hoisted. Attach one rope to large motor frame next to gearbox to balance assem­bly; do not attach rope to small motor. Tie up loose conduit before lifting jack.

Raise 221923/223180 azimuth jackscrew and attach 221738 pivot assembly to 201327A
joint assembly with 1 x 2-1/2 in (63 mm) hardware. Note: Mounting position of azimuth
pivot jackscrew assembly is dependent upon azimuth range requirements and corre­sponds with mounting position of 201488 outrigger plate or extension assembly.

Note: If optional motor drive system is included, install motors at this point. Refer to
installation instructions provided with motor kits.

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 assem­bly. Tie up loose conduit before lifting jack.

Step 10

Step 11

29

Installation Procedures

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.

Figure 35

Loosen both setscrews in upper and lower collars of pin assembly at end of azimuth
jack. Do not retighten these collars. Apply supplied Loctite to pin threads and nuts.
Attach 1-1/2 in (38 mm) hex nuts to top and bottom of azimuth jackscrew pin assembly
and securely tighten mounting hardware using 6 foot (1.8 m) lever arm. Reattach rubber
boot. Tighten an outrigger plate hardware.

The tripod ground mount assembly is now completed with the necessary operational
essentials. All ground mount options have separate instructional bulletins located in the
parts kit that contain the option.

The next step in the installation process is the reflector assembly. Proceed to the next
page to begin installation of the reflector.

221923/223180

221738

200088A

30

Installation Procedures

31

Installation Procedures

32

Installation Procedures

33

Installation Procedures

34

Installation Procedures

35

Installation Procedures

36

Installation Procedures

37

Installation Procedures

38

Installation Procedures

39

Installation Procedures

40

Installation Procedures

41

Installation Procedures

42

Installation Procedures

43

Installation Procedures

44

Installation Procedures

45

Installation Procedures

46

Installation Procedures

47

Installation Procedures

48

Installation Procedures

49

Installation Procedures

50

Installation Procedures

51

Installation Procedures

52

Installation Procedures

53

Installation Procedures

Overview

Acquiring A

Satellite

54

Operation

After you have completed the assembly of your antenna, you are now ready to become
operational. In order to operate the earth station antenna, you will need to direct it to the
desired satellite adjusting both the elevation and azimuth angles appropriately. The fol­lowing procedures provide details on how to correctly position your antenna on the
desired satellite.

There are several procedures that may be used to properly acquire the satellite. Andrew
recommends that a spectrum analyzer be used. The following procedures provide
explanation as to how to use the spectrum analyzer.

While viewing the spectrum analyzer screen, a pure noise signal as shown in Figure 4-1
will probably be observed. Additionally, some transponder signals may be observed
above the noise signal as shown in Figure 4-2.

Operation

Figure 4-1: Pure Noise Signal on Spectrum Analyzer

Figure 4-2: Minimum transponder Signal on Spectrum Analyzer

Step 1

Step 2

Step 3

Step 4

55

The following steps provide the procedure for acquiring a satellite.

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.

• Return to the position yielding the greatest amplitude.

The maximum azimuth excursion from the original setting should not exceed plus or
minus 1.5 degrees or the antenna may begin to access a different satellite.

With the antenna positioned in azimuth such that the transponder signals are maxi­mized, follow the same procedure manually moving the antenna in elevation (scanning
up-and-down) to further maximize the transponder signals.

Repeat this procedure alternating between the azimuth and elevation excursions of the
antenna to peak the transponder signal amplitude.

A transponder signal amplitude of 30 dB or greater from peak to average noise signal
indicates the antenna is receiving the signal on the main beam. A transponder signal
amplitude less than 30 dB or greater indicates the antenna is receiving the signal on a
side lobe of the main beam.

With the antenna peaked on a side lobe in azimuth and/or elevation, move the antenna
in azimuth while observing the spectrum analyzer screen as shown in Figure 4-3.

Figure 4-3: Antenna Radiation Pattern Topographical Diagram with Plan View

Operation

Step 5

Step 6

Step 7

Step 8

56

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 dimin­ish 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. At
the null point (position C), the antenna is aligned with the alternate (elevation) axis. If
the antenna was peaked on a side lobe in azimuth, it was appropriately aligned with the
elevation axis; proceed with step 6. If the antenna was peaked on a side lobe in eleva­tion, it was appropriately aligned with the azimuth axis; proceed with step 6 moving the
antenna in azimuth rather than elevation.

Move the antenna in elevation while observing the spectrum analyzer screen. If the sig­nal amplitude increases, deceases and then increases again but to a lesser value, the
antenna is moving in the wrong direction; reverse the direction of the antenna move­ment. From the original null point, the signal level should increase and decrease alter­nately, but with increasing amplitude until the transponder signal increases to a level of
at least 30 dB at which time the main beam. Continue to manually peak the signal to a
maximum level using the azimuth and elevation adjustments.

If the antenna is aligned in azimuth and elevation (signal maximized) and 24 transpon­der signals (12 horizontal and 12 vertical) are noted, the polarization adjustment is set
incorrectly and must be modified. If 12 transponder signals are noted, they may or may
not be the properly polarized signals. Therefore 24 transponder signals must be visually
noted in order to determine the proper polarization setting.

Rotate the feed assembly clockwise until 24 transponder signals are noted and of
approximately equal amplitude.

NOTE: It is more accurate and visually easier to minimize the alternate set of transpon­der signals rather than maximizing the transponder of interest.

Figure 4-4: Polarization at 45 degrees from Optimum Setting

Operation

Step 9

57

With all 24 transponder signals of approximately equal amplitude appearing on the
spectrum analyzer screen determine the specific antenna system and satellite parame­ters. Rotate the feed assembly as required until the appropriate (odd or even) transpon­der signals are maximized.

Figure 4-5: Maximizing Odd Transponders

Figure 4-6: Optimum Polarization Setting

Operation

Subreflector

Adjustment

58

Operation

After the satellite has been acquired and testing has taken place with the spectrum analyzer,
the subreflector may need to be adjusted to maximize optimum performance of your anten­na. The following procedures should be followed if a subreflector adjustment is required to
maximize optimum performance.

NOTE: All INTELSAT Type Approved antennas do not require subreflector adjustment.

Before proceeding, azimuth and elevation patterns should be conducted to determine the
adjustments that need to be made. The goal is to achieve a high peak on the main lobe and
even distances between the main lobe and sidelobes as shown in Figure 4-6.

NOTE: No adjustments should be made in the receive band.

If your pattern dictates a need to adjust the azimuth angle(the left sidelobe requires adjust­ment), the west side of the subreflector should be adjusted outward by loosening the screws
on the subreflector and adjusting the left side outward. An easy way to remember this adjust­ment feature is through the acronym WOLD (West Out Left Down).

If your pattern dictates a need to adjust the elevation angle(the right sidelobe requires adjust­ment), the bottom side of the subreflector should be adjusted downward by loosening the
screws between the subreflector and the struts and adjusting the bottom side of the subre­flector downward. An easy way to remember this adjustment is through the acronym BOLD
(Bold Out Left Down).

Each of these adjustments should be repeated until each sidelobe is of equal distance from
the peak of the mainlobe.

After the BOLD and WOLD adjustments have been made, it may be necessary to adjust the
main lobe. The goal is to achieve a high null depth (distance between lower intersection of
sidelobes and top of main lobe) as shown in Figure 4-6.

In order to adjust the main lobe pattern characteristics ALL subreflector adjustment screws
should be adjusted at the same degree (Note: Because the azimuth and elevation adjust­ments have been set, it is very important that the null depth adjustment be carefully conduct­ed. Be careful not to alter any previous adjustments that have been made to the subreflector.
Follow the procedure listed below when adjusting the null depth of the main lobe.

C-band feeds - Adjustment screws are 3/4 X 10. Move 1 turn per 1dB of imbalance.

Ku-band feeds - Adjustment screws are 1/4 X 20. Move 1 turn per 1 dB of imbalance.

All adjustments should be continued until the desired pattern is achieved. Upon completion
the antenna should be properly aligned with the satellite for maximum performance.

Overview

General Cleaning

Electrical Parts

59

Preventive Maintenance

This section contains periodic preventive maintenance instructions for the 5.6-Meter
Earth Station Antenna. Included in this section are inspection and preventive mainte­nance procedures including cleaning and lubrication, painting, and an operational volt­age/current checkout procedure deemed within the capabilities of the average station
technician. Refer to applicable vendor manuals for any repair procedures not included in
this section yet designated as capable off being performed in the “field” rather than
requiring specialized facilities, tools, and/or test equipment as well as technically trained
personnel.

An operational checkout procedure provides an accurate indication of the overall earth
station performance and should be performed at intervals of approximately three
months. This procedure is essentially performed during the various modes of normal
operation of the earth station. In addition, the operational checkout procedure should be
performed after any repairs or adjustments have been made, or whenever the earth sta­tion is suspected of degraded operation. If any discrepancy in performance exists and
the condition cannot be readily remedied to return the earth station to a proper operating
condition, the appropriate troubleshooting procedures should be referenced to locate the
fault. After the trouble is determined and the repairs affected, a final operational check­out procedure should be performed to verify that all discrepancies have been corrected.

The following paragraphs describe the inspection and preventive maintenance proce­dures for the earth station. These instructions include general cleaning and inspection,
the preservation of metal parts and lubrication. Periodic replacement of assemblies or
components as a preventive measure is not required. Malfunctions of the earth station
can be traced to components, assemblies, and parts through the use of applicable trou­bleshooting procedures.

To prevent the excessive accumulation of dust and dirt as well as the removal of such
contaminants, thoroughly clean the equipment whenever visually inspecting the earth
station components. No special cleaning procedures are required. However, a thorough
cleaning in accordance with the following procedures is required to assure continued
trouble-free operation.

Minor cleaning, such as the removal of dust and loose foreign particles can be accom­plished by one of the following:

•

Vacuuming

• Using a soft brush or lint-free cloth

• Blowing out the dust and dirt with low pressure (5 to 25 psi), dry compressed air

When using air to blow off the contaminants, either avoid or be careful when directing
the air stream on delicate parts. To remove imbedded dirt, grease, or oil from electrical
parts; use a 50 percent solution of isopropyl (rubbing) alcohol and apply with a soft bris­tle brush. It may be necessary to brush some parts vigorously with a stiff bristle brush to
remove imbedded and hardened dirt particles. If possible, avoid excessive use of clean­ing solvent on electrical insulation. After cleaning, allow the cleaned parts to dry for 10 to
15 minutes before placing the equipment into operation.

Clean mechanical parts by first removing dust, dirt, and other loose contaminants with a

Preventive Maintenance

Mechanical Parts

Inspection

Local

Control/Motor

Drive Controller

60

scraper, stiff brush (bristle or wire in the case of rust or other corrosion), or cloth or com­pressed air at 25 to 40 psi. Any accumulated imbedded dirt, corrosion, grease, or oil
deposits that require further cleaning may be removed with a bristle or wire brush and a
cleaning solvent such as trichlorethylene or equal. After cleaning, allow cleaned parts to
dry for 10 to 15 minutes before placing the equipment into operation.

The frequency of inspection is contingent upon the user’s individual standards and the
operational environment in which the earth station is located. However, a visual inspec­tion of the earth station components should be performed at least semi-annually. Where
there are no established wear limits, perform a visual inspection to locate worn or dam­aged parts which could cause improper functioning of the earth station. It is recommend­ed that the mechanical and electrical inspection be performed on the assembled or par­tially disassembled equipment to determine the extent of disassembly required prior to
completely disassembling a suspected malfunctioning component or module. In the
absence of any special inspection requirements, operational tests are the most effective
means in isolating parts and assemblies requiring further inspection. Any condition
noted during inspection that may preclude continued proper operation of the earth sta­tion prior to the next scheduled inspection should be noted. The discrepant condition
should be corrected (repaired or replaced) immediately or at the conclusion of the
inspection procedure.

Inspection of the local control/motor drive controller conforms generally to standard visu­al inspection procedures on electromechanical equipment. In addition to these standard
procedures, perform the following checks and visual inspections for the specific condi­tions noted:

• Check the front panel for illegible and indistinct panel markings.

• Check the three position selector switches (Azimuth Off/Slow/Fast, Elevation-

Off/Slow/Fast, and Polarization-CCW/Off/CW) for smooth operation, audible clicking at
each actuation (left to center and return) and spring return from right to center. For each
of the two position selector switches (Azimuth-East/West, Elevation-Up/Down, and
Local/Remote) check for smooth operation and audible clicking at each actuation.

• Inspect all wiring and cables for discolorization and burned insulation, dirt, breaks,

security of connection and other signs of deterioration. Examine connections for dirt,
flux, corrosion, and mechanical defects. Check for loose or broken lacing and cut, brittle,
abraided, frayed, or cracked insulation.

• Examine connectors for corrosion, broken inserts and stripped threads. Check con-

nector shells for distortion and dents, and contact pins for bends, misalignment, or other
deformities. Check connector inserts for carbon tracking indicating arc-over.

• Check all electrical components for dirt, cracks, chips, breaks, discoloration and other

signs of deterioration and damage. A discolored, blistered, or burnt condition is evidence
of overload. Measure actual value of suspect electrical components and compare
against specified value.

• Check transformer for an excessive wax deposit on the surface, discoloration, or a

Preventive Maintenance

Antenna

61

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.

• Check the relays and contactors for free operation of the armatures and contact con-

dition. The contacts are usable even though pitted, burned, worn, or discolored. The
contacts or contactor or relay assembly should be replaced only when the contact mate­rial has been completely torn away or worn off.

• Visually inspect all mechanical parts for freedom of operation without binding or inter-

ference. Check for security of all hardware and stripped or otherwise damaged threads.
Check metallic parts for corrosion, dents, distortion, and other deformation.

• Check for evidence of water inside the enclosure. If any water is in evidence, check

that all seals are intact and if not, use a coating of RTV-108 (silicone rubber sealant) to
seal any exposed electrical fitting, bolt hole, or other possible water entry to the
enclosed electrical components in order to maintain a waterproof condition.

• Check or change humidity absorber.

Inspection of the antenna conforms generally to standard visual inspection procedures
performed on electromechanical equipment. In addition to these procedures, perform
the following checks and visual inspections for the specific conditions noted:

• Inspect all wiring and cables particularly the network to enclosure and enclosure to

mount interfaces for discoloration and burned insulation, moisture entry, corrosion, dirt,
breaks, security of connection, and other signs of deterioration. Examine connections for
dirt, corrosion, and mechanical defects. Check for loose or broken lacing and cut,
abraided, frayed, brittle, and cracked insulation.

• Examine connectors for corrosion, broken inserts and stripped threads. Check con-

nector shells for distortion and dents, and contact pins for bends, misalignment or other
deformities. Check connector inserts for cracks, and carbon tracking, burns or charring
indicating arc-over.

• Check all electrical component for dirt, cracks, chips, breaks, discoloration, and other

signs of deterioration and damage. A discolored, blistered, or burnt condition is evidence
of overload.

•

Operate the azimuth and elevation drives as well as the feed rotation in both the plus

Preventive Maintenance

62

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. Check the mechanical limit switches for corrosion and water
entry and the arm on each feed limit switch for free movement without binding. Be cer­tain both feed rotation limit switch arms are not distorted and ride centrally on the actu­ating cam to open their corresponding limit switch.

• Inspect the azimuth and elevation jackscrew boots for security of attachment at both

ends, for abrasion, tears, cuts, brittleness and other damage that may expose the
jackscrew to the environment (water, dust, etc.). Minor repairs can be made with RTV­108 silicone rubber sealant.

• Visually inspect the feed window for dirt and the feed, feed supports, feed window,

and reflector for distortion, foreign object damage and environmental deterioration due
to ice and snow, dust, rain, hail, and high winds, etc. which may cause electrical compo­nent and/or structural deformation.

•

Check the cable attachment to the resolvers and to the LNA or LNB’s and enclosure

mount interface for security, the cable rouging for secure hanger attachment and the
cable insulation for cuts, cracking, abrasion, and other deterioration. Check the LNA or
LNB’s and the resolvers for a secure mechanical attachment. Ensure proper torquing of
polarization drive gear box setscrews and appropriate tensioning of corresponding drive
chain assembly, if applicable.

•

Check (if applicable) that the drain holes in the bottom of the enclosure are not

obstructed and there is no evidence of water accumulation. Check the enclosure doors
for proper closure and that the door seals are intact, not torn, abraided or otherwise
damaged. Check that all other seals are intact and if not, use a coating of RTV-108 (sili­cone rubber sealant) to seal any exposed electrical fitting, bolt hold, or other possible
water entry to electrical components in order to maintain a weatherproof condition. If the
enclosure is provided with a vent fan, check for free operation of the fan blade. The fan
bearings are permanently lubricated; any binding, abnormal noise or vibration necessi­tates replacement of he fan assembly. Check and replace the fan filter element if it
appears dirty or obstructed with dust.

• Check for the appearance of surface lubricants that will cause the accumulation of dirt

and grime. Clean off all excess surface lubricants with a cloth and if required, a cloth
dampened not wetted with trichlorethylene, or equal.

•

Visually inspect all mechanical parts for freedom of operation with no misalignment,

binding or interference. Check all cabling for sufficient slack to prevent cable strain as
well as adequate restraint to prevent abrasion or chaffing during antenna and feed
movement.

• Check security of antenna mounting and interconnecting assembly hardware. Be cer-

Preventive Maintenance

Drive System

Voltage and

Current Checks

Step 1

Step 2

Step 3

63

tain all electrical grounding connections (including cross-axis grounding straps) are
intact and secure, not corroded or broken. Thoroughly clean any noticeable corroded
portions of grounding cables, unplated portion of universal terminals and corresponding
mounting surfaces using a wire brush. Replace rather than tighten any loose A-325
structural hardware. The hardware distorts at initial installation and once loosened will
not maintain the required high strength friction connection. All other assembly and instal­lation hardware should be tightened to its original torqued condition. When installing
new structural hardware, do not use a wrench with a lever arm longer than two feet.

• Examine painted aluminum and galvanized surfaces and tough-up where required.

At the conclusion of the installation procedure prior to turning the system over to the sta­tion facility, an installation acceptance check off sheet was prepared and duly signed off
if installed by Andrew crew. Part of this check off included voltage readings retaken to
determine if proper voltage was available. Current readings were also taken as a refer­ence for future comparison to serve as a troubleshooting aid in determining possible
equipment degradation and shortened life. Any current reading taken during the follow­ing procedure that varies by more than five percent from the pre-established reference
values necessitates troubleshooting the particular system involved to determine the
cause and required corrective action.

Approximately every three months and during a period of down time, disconnect as
applicable the RF transmitter and all power supplies. The main disconnect switch in the
main load center box at the antenna site must be in the ON position and the
LOCAL/REMOTE switch in the local control motor drive controller must be in the LOCAL
position.

Open the outer local control/motor drive controller door at the antenna site to gain
access to the conductors supplying power to the azimuth, elevation, and polarization
drive motors.

NOTE: During the following procedures, the antenna drives (azimuth, elevation, and
polarization) will be powered to rotate the antenna and feed in both directions of travel.
Check that this condition can be tolerated from a safety as well as an operational stand­point, and that the electrical limits are not reached before the testing is concluded.
Reaching an electrical limit before concluding a test necessitates rotating the antenna or
feed in the opposite direction a sufficient distance to permit retesting in the desired
direction.

Turn the FEED CCW/OFF/CW switch to either the CW or CCW position and while the
feed is rotating, carefully use a clamp on ammeter in accordance with the ammeter man­ufacturer’s instructions to take current readings off each of the three conductors (phases)
connected to the load side of the polarization motor circuit breaker. Record the current
draw in the equipment log and compare the readings to the reference values entered in
the installation/acceptance check off. If the readings differ by more than five percent,
refer to appropriate troubleshooting information and perform applicable corrective action.
Then take voltage readings off each of the three conductors; the readings should agree
with each other within two percent. Turn the FEED CCW/OFF/CW switch to OFF.
Repeat preceding step (3) with the FEED CCW/OFF/CW switch in the alternate operat­ing position.

Preventive Maintenance

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

64

Turn the AZIMUTH EAST/WEST switch to either position and while the antenna is rotat­ing, carefully use a clamp on ammeter in accordance with the ammeter manufacturer’s
instructions to take current readings off each of the three conductors (phases) connect­ed to the load side of the azimuth drive motor circuit breaker. Record the current draw in
the equipment log and compare the readings to the reference values entered in the
installation/acceptance check off. If the readings differ by more than five percent, refer to
appropriate troubleshooting information and perform applicable corrective action. Then
take voltage readings off each of the three conductors; the readings should agree with
each other—within two percent. Turn the AZIMUTH switch to OFF.

Repeat steps (5) with the AZIMUTH EAST/WEST switch in the alternate operating posi­tion.

Turn the ELEVATION DOWN/UP switch to either position and while the antenna is rotat­ing, carefully use a clamp on ammeter in accordance with the ammeter manufacturer’s
instructions to take current readings off each of the three conductors (phases) connect­ed to the load side of the elevation drive motor circuit breaker. Record the current draw
in the equipment log and compare the readings to the reference values entered in the
installation/acceptance check off. If the readings differ by more than five percent, refer to
appropriate troubleshooting information and perform applicable corrective action. Then
take voltage readings off each of the three conductors; the readings should agree with
each other within two percent. Turn the ELEVATION switch to OFF.

Repeat steps (7) with the ELEVATION DOWN/UP switch in the alternate operating posi­tion.

If all voltage and current readings are within tolerance, close the local control/motor
drive controller inner door and place the LOCAL/REMOTE switch in the REMOTE posi­tion to return antenna control to the studio. Then close and lock the outer local
control/motor drive controller door.
When preserving the component parts, refer to the following paragraphs in this section.

Preventive Maintenance

Preservation of

Component Parts

Aluminum Parts

Galvanized

Surfaces

Lubrication

65

Remove all loose paint and corrosion by scraping, wire brushing, or using steel wool. If
using steel wool near the feed window, make sure that none remains on the feed horn
window. Edges of existing paint can be blended with the metal surface by using a fine
grit sandpaper. Wipe the surface to be painted with a soft rag dampened in trichlorethyl­ene, lacquer thinner or equal. Be certain to remove all loose paint, corrosion, imbedded
dirt, grease, and oil deposits or the paint will not adhere to the surface. Lacquer thinner
will dissolve paint if applied heavily and rubbed vigorously. The reflector may be washed
with plain water if necessary. Do not use bleach, soap solutions, or kerosene as it is dif­ficult to remove the residue. Allow the cleaned surface to dry thoroughly before priming.

Prime the cleaned surface by applying zinc chromate primer. The primer can be applied
with a brush, roller, or pressurized spray. If necessary, thin the primer with lacquer thin­ner to the proper consistency. Feather primer onto adjacent painted surfaces;. Allow
primer to thoroughly dry before applying the finish paint coat.

Paint all RF surfaces, such as the inside of the main reflector and subreflector with a
high-reflectance white paint. This type of paint disperses light rays, reducing the focus­ing effect of the sun’s radiation, thereby reducing heat build-up caused by the focused
sun’ rays on the feed system. Rear surfaces of the reflector and subreflector may be
painted with a flat white enamel paint. The paint can be applied with a brush, roller, or
pressurized spray. If necessary, thin the paint with the appropriate thinner to the proper
consistency. Thoroughly paint over the primed surfaces and blend with the existing
painted surface.

Remove all loose paint and corrosion by scraping, wire brushing, or using steel wool.
Edges of existing paint can be blended with the metal surface by using a fine grit sand­paper. Wipe the surface to be painted with a soft rag dampened in trichlorethylene, lac­quer thinner, or equal. be certain to remove all loose paint, corrosion, imbedded dirt,
grease, and oil deposits or the paint will not adhere to the surface. Lacquer thinner will
dissolve paint if applied heavily and rubbed vigorously. Do not use bleach, soap solu­tions, or kerosene as it is difficult to remove the residue. Allow the clean surface to dry
thoroughly before painting.

Paint the cleaned surface with a zing-rich paint. The paint can be applied with a brush,
roller, or pressurized spray. If necessary, thin the paint with the appropriate thinner to
the proper consistency. Thoroughly paint over the cleaned surface and blend with the
existing painted surface.

For long life and trouble-free operation be certain not to extend the lubrication schedule
beyond the frequency recommended in the Lubrication Chart. The frequency should be
shortened if the antenna is subjected to an adverse environment (e.g., high tempera­ture, extended periods of rainfall, high humidity, dust storms, etc). Any component or
part should be immediately be lubricated if during inspection or operation, rough, jarring,
or intermittent motion is noted, or if squeaky or other unusual noises are heard.
Lubrication is required on all metal-to-metal rolling or sliding parts. Us the lubricants rec­ommended. Do not over lubricate. Over lubrication can often be as damaging as under
lubrication. Prior to the application of lubricant to any parts, use a clean cloth and/or
bristle brush 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

Preventive Maintenance

Jackscrews/Motors

Gear

Motor/Housing Fill

Drain

Requirements

66

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. The elevation and azimuth jackscrew assemblies
are equipped with a grease fitting and corresponding pipe plug on opposite sides of the
jack housing. Remove the appropriate pipe plug and fill with with grease until lubricant
seeps from the pipe plug opening. Replace and securely tighten pipe plug.

The following is a list of the lubricant characteristics:

• Mobil Temp SHC32 A non-soap hydrocarbon fluid type grease. Operating tempera-

ture range is -65 degrees to 350+ degrees Fahrenheit (-54
degrees to 177+ degrees Celsius).

• Mobil SHC624 A low temperature synthetic oil for worm gear reducers.

Operating temperature range is -40 degrees to 125+ degrees
Fahrenheit (-40 degrees to 52+ degrees Celsius).

•

Moly Grease A grease lubricant containing molybdenum disulfide. Operating

temperature range is -85 degrees to 300+ degrees Fahrenheit
(-29 degrees to 149+ degrees Celsius).

Periodically inspect lifting screws on jackscrew assemblies to ensure adequate lubrica­tion. Loosen Jackscrew boot clamps to expose the lifting screw assembly. Fully extend
jackscrew assembly being careful not to exceed preset mechanical limits. Brush thin
coating of Mobil SHC32 grease on exposed lifting screw. Replace boot and attach corre­sponding boot clamps. If lifting screw is rusty, remove existing lubricant with solvent and
wire brush rusted area. Rinse with solvent and apply fresh grease.

Peiordically inspect and remove dust or dirt deposits from the motor housings to avoid
hindering the heat exchange with the ambient air. Slight dirt accumulation on the air
vent screw through splash oil cannot be avoided; however, keep vent screw clean to
ensure proper pressure compensation.

Lube points 2, 3, 7 and 8, shown in the Lubrication Chart, require removal of the indicat­ed drain plugs and collecting/measuring the amount of SHC624 drain oil using measur­ing cup. The specified amount of oil must be added to the gear motor/housing (after
installing the drain plug) via the fill/vent plug opening using supplied funnel. Addition of
the oil requires use of an appropriate filling utensil. Use of a modified level stick will not
correctly gauge the appropriate amount of oil in the gear housings.

Preventive Maintenance

67

Preventive Maintenance

Lube Components Frequency Type Type No. of Lube
Point to be (Months) of of Points or
No. Lubricated 13612Service Lube Quantity

1. Elevation Jackscrew Housing X Pressure Fitting SHC32 1

2.

1

Elevation Jackscrew Gear Housing I* C** Pipe Plugs SHC624 10 Oz
Fill and Drain

3.

2

Elevation Drive Intermediate Gearbox I* C** Pipe Plugs SHC624 34 Oz.
Fill and Drain

4. Elevation Jackscrew Pivot Pin, upper X Pressure Fitting SHC32 1

5. Azimuth Jackscrew Pivot Pin, front X Pressure Fitting SHC32 1

6. Azimuth Jackscrew Housing X Pressure Fitting SHC32 2

7.

1

Azimuth Jackscrew Gear Housing I* C** Pipe Plugs SHC624 4 Oz.
Fill and Drain

8.

2

Azimuth Drive Intermediate Gearbox I* C** Pipe Plugs SHC624 34 Oz.
Fill and Drain

9. Polarization Drive Gear X Brush SHC32 Minimum Surface
Coverage

10. Feed Rotation Worm Gear X Pressure Fitting SHC32 2

Pillow Blocks

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. Excessively dirty oil will require fresh oil replacement. If oil leakage is found to be excessive, refer to
appropriate troubleshooting information and perform applicable corrective action. Periodic inspection procedures can be
less frequent after first or second scheduled inspections.

** Initial oil change requirements include flushing gear boxes with a standard cleaning agent.
1 Type ‘HS’ and ‘STHS’ drives only. 10 oz. required for gearbox on Type ‘MS’ drives.
2 Type ‘HS’ and ‘STHS’ drives only.

Lubrication Chart

High-Speed Antenna Lubrication Points

5

9

10

6
7
8

4

1
2
3

Local

Motor

Control

Heater

Control

Pressure

Fitting

Pressure

Fitting

Gearbox

Fill

Gearbox

Vent

Gearbox

Level

Gearbox

Fill

Gearbox

Vent

Gearbox

Level

Polarization

Drive Gear

Worm Gear

Pillow

Blocks (2)

Note

Medium-speed motors

shown for illustrative

purposes only.

Pressure

Fitting

Pressure

Fitting

Gearbox

Fill

Gearbox

Drain

Gearbox

Fill

Gearbox

Drain

68

Preventive Maintenance

Medium-Speed Antenna Lubrication Points

5

9

10

6
7
8

4

1
2
3

Local

Motor

Control

Heater

Control

Pressure

Fitting

Pressure

Fitting

Gearbox

Level

Gearbox

Drain

Gearbox

Level

Gearbox

Drain

Polarization

Drive Gear

Worm Gear

Pillow

Blocks (2)

Pressure

Fitting

Pressure

Fitting

69

Preventive Maintenance