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Andrew 3.7-Meter Earth Station Antenna Stereo System User Manual

1. ANNNNAN A loa H HH c 13 mm Thick Steei Plate 13 7 8 Ref 352 mm 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 18 Installation Procedures Assembly Without a Crane Step 1 Step 2 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 202680 2 manual from the packing crate Leave the steel strapping intact to avoid disengage ment 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 203314 manual 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
2. Hex Optional Welded j Clamp Segment azjmuth E evation Strut Bracket Mount 50 Locking Strut Support Set Screw hh Customer To Supply Wrench ck 25 Lockwasher 50 Strut Support Flatwasher Set Screws Manual Hex Head Screw 50 Flatwasher Hex Head Actuator 21 64 Retracted Hex Nut Hex Nut Lockwasher Screw Base Angle 39 20 Extended Drain Hole Figure 3 22b Manual Actuator Assembly 32 Installation Procedures Step 4 Step 5 Step 6 Step 7 Manual Actuator Assembly Removal Step 1 Step 2 Step 3 Motorizable Pedestal Ground Mount Assembly Step 1 Remove the two indicated strut support setscrews and attach the base angle to the cor responding strut support using the supplied 1 2 inch clamping nuts and the previously removed strut support setscrews as shown in Figure 3 22b Securely tighten the remaining mounting hardware to achieve the clamping force Follow directions for Acquiring a Satellite Repeat the entire procedure for the remaining strut assembly After the adjustments have been made the manual actuator should be removed The following steps provide the procedure for the proper removal of the manual actuator assembly Remove the manual actuator assembly by first removing the hardware securing the actuator to the base angle NOTE The adjustment kit assembly should be removed after the antenna has been adjusted Store the manual actuator assembly and the correspo
3. ating cam to open their corresponding limit switch e 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 RTV 108 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 compo nent 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 sili cone rubber sealant to
4. 3 O Clock Subreflector Stud Adjustment Hardware 9 O Clock Position 203896 Setting Bar Ku band 203896 3 46925 Setting Bar C band 47 2 9 O Clock 3 O Clock Positi Figure 3 57 Subreflector Alignment Feed System You have now completed the subreflector assembly By now you can see that your installation of the 3 7 Meter Earth Station Antenna is almost complete The feed system is the last phase of the base installation NOTE All antenna options such as feed sys tems motors anti icing etc possess installation instructions within the individual kits contained in the shipment NDREW 70 Installation Procedures Operation Overview Acquiring A Satellite Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 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 fol lowing procedures provide details on how to correctly position your antenna on the desired satellite NOTE Ensure that the feed system and all electronics are installed properly before pro ceeding Follow the procedures listed below when acquiring the desired satellite Evaluate and determine the required elevation and azimuth angles for the satellite of interest Loosely attach the manual actuator assembly P N 207882
5. 625 11 x 2 long bolt and nut assembly Note Long bolt and nut assembly should not protrude inside diameter of 49258 strut support Assemble strut bracket strut support assembly to support pipe by sliding over strut with welded tab facing 104638 U bracket Snug the strut support in place using 9953 15 50 13 x 1 5 long square head screws in three places See Figure 3 29d Note For eleva tions above 75 reverse the strut support so the welded tab faces away from U bracket 104638 U Bracket 301899 2 MO Support Pipe Bolt Lockwasher and Nut 1 2 x 1 1 2 301900 Square Head Set Screw Strut Bracket 49258 5 8 x 2 f Strut Support Bolt and Nut Assembly 3 4 x 3 Bolt Flatwasher Lockwasher and Nut Figure 3 29d Elevation Azimuth Strut Assembly 39 Installation Procedures Step 4 Attach the elevation strut to the top of the rear frame assembly as shown in Figure 3 29e using the 100537 15 M20 x 50 bolt 100526 57 nut and 100521 57 flatwasher Tighten bolts to 185 Nem 136 Ibs ft M20 x 50 Bolt Flatwasher Lockwasher and Nut Figure 3 29e Elevation Strut Attachment Attach 301917 elevation axis weldment to the front of the frame assembly in two places using 100537 15 M20 x 50 long bolt 100526 57 nut and 100522 57 lockwasher as shown in Figure 3 29f 301917 Elevation Axis Weldment M20 x 50 Bolt Lockwasher and Nut Figure 3 29f Elevation Axis Weldment Attachment 40 Install
6. Antenna 5 How to Use This Manual Getting Started Overview Warnings The installation operation and maintenance of the 3 7 Meter Earth Station Antenna requires qualified and experienced personnel Andrew installation operation and main tenance instructions are illustrated for such personnel Additionally the antenna should be inspected by qualified personnel to verify proper installation maintenance and con dition 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 pre sented 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 Insta
7. Step 4 Insert all of the joint plate bolts except for the socket head shoulder bolts All bolts should be inserted from the same direction using a 5 16 inch hardware flat washer under a lock washer and nut DO NOT TIGHTEN Note DO NOT force bolts manipulate reflector halves to allow free insertion At both antenna seams loosely install three location bolts and nuts 5 16 inch hardware adjacent to the center hole as shown in Figure 3 32 NOTE The installer positioned under the reflector should insert the bolts from the underside while the second installer inserts the flat washers under lock washers and nuts from the outside Mo z em e Figure 3 32 Seam Bolt Insertions 46 Installation Procedures VERY IMPORTANT Add the alignment hex bolts to the end holes of the joint plates as shown in Figure 3 33a outside and inside of plate to ensure that it is evenly aligned and use hex bolts to fill the rest of the joint plates as shown in Figure 3 33b THESE MUST NOT BE DRI VEN BUT INSERTED BY HAND Step 5 NOTE All bolts should be inserted from the same direction using a bolt flatwasher under a lockwasher and nut on joint plate and a bolt and locknut on the seam Figure 3 33b Alignment Bolt Insertions 47 Installation Procedures Step 6 Splice Strip and Mounting Ring Hardware Tapered M6 x 1 0 25 mm Location Bolts Washers for Mounting Ring Attachment Only and Lock Nuts Joint Plates Seal Se
8. 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 O degrees to 90 degrees 4 x1 1 2 BOLT LOCKWASHER AND NUT 5 Places SIDE VIEW ANGLE ASSEMBLY ANGLE ASSEMBLY 3 4 x2 A 325 BOLT FLAT WASHER AND NUT 2031 D AZIMUTH Sraur WELDMENT LEFT POSTION 90 TO Y 3 4 x 1 p BOLI LOCKWASHER lt L io AND NUT LJ 6 Places CENTER POSITION 60 TO 60 FRONT VIEW Figure 3 11 Azimuth Tiller Arm Step 4 Tighten the hardware using the A 325 tensioning procedure 25 Installation Procedures An illustration of the final azimuth tiller arm is shown in Figure 3 12 Figure 3 12 Azimuth Tiller Arm Final Assembly Step 5 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 Figure 3 13 Elevation and Azimuth Struts 26 Installation Procedures INDRE W Step 6 Insert pivot blocks P N 205876 onto the end of the azimuth strut using lubricated 1 2 inch bolt flatwasher and hex nut as shown in Figure 3 14 A 3 4 inch flat washer should be inserted between the strut and the spacer block Tighten hardware according to the A 325 tensioning procedure Figure 3 14 Azimuth Strut Assembly Step 7 Slide the round strut assembly
9. determine the installation sequence Site Preparation Refer to Foundation Section for guidance in preparing location and installation of the 3 7 Meter Earth Station Antenna foundation Ground Mount LJ Unpack ground mount assembly Assembly U Attach ground mount assembly to foundation a Organize ground mount hardware L wax galvanized hardware in hardware kit a Tighten ground mount hardware to foundation LJ Attach azimuth strut weldment to ground mount assembly For MPK Types U Assemble azimuth strut Only LJ Mount azimuth strut to ground mount assembly U Bolt elevation strut brackets to elevation strut LJ Mount elevation strut to ground mount assembly O Assemble manual actuator LJ Remove manual actuator after elevation azimuth adjustment ANDREW 10 Getting Started For MPJK Types Only Main Reflector Assembly U Mount azimuth pivot assembly to ground mount assembly U Bolt one jack to azimuth pivot assembly LJ Unscrew jack a Tighten galvanized hardware using A 325 tensioning procedure a Lubricate jackscrews A Pull protective boot over jackscrew Bolt elevation pivot assembly brackets to ground mount assembly U Bolt second jack to elevation pivot assembly LJ Unscrew jack a Tighten galvanized hardware using A 325 tensioning procedure a Lubricate jackscrews LJ Pull boot over jackscrew LJ Remove protective covering from crate a Pry top crate panel off a Pry sides off crate a Pry front off crate LJ Unbolt reflector
10. 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 ge Introduction How to Use This Manual Overview Content The scope of this manual is intended to provide station personnel with the base installa tion 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 pro cedures and clarifying components Photographs The photographs compliment the installation instructions by providing ac
11. Figure 4 2 Minimum transponder Signal on Spectrum Analyzer 72 Operation Step 1 Step 2 Step 3 Step 4 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 maxi mized 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
12. In addition the operational checkout procedure should be performed after any repairs or adjustments have been made or whenever the earth sta tion 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 check out procedure should be performed to verify that all discrepancies have been corrected The following paragraphs describe the inspection and preventive maintenance proce dures 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 trou bleshooting 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 par
13. Installation Procedures Mount The elevation azimuth mount design simplifies installation minimizes foundation require ments 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 Unpacking 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 Figure 3 2 Crate Unpacking z Assembly As stated previously the pedestal ground mount installation process can be conducted Using a Crane manually or by using a crane The following steps provide the necessary procedures for installing the ground mount assembly using a crane ANDREW 16 Installation Procedures Step 1 Step 2 Step 3 Step 4 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 dis engagement of the panning frame from the square tube weldment during the grou
14. 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 origi nal 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 The 3 7 Meter Earth Station Antenna requires the installation team to perform the Sequence assembly in the sequence presented below Moreover this sequence should be Checklist reviewed to ensure a smooth installation Use the following checklist to verify and or
15. and 9999 60 nuts as shown in Figure 3 54b View A Note At this time it is recommended but not necessary to install the Subreflector for K 8 Ku Band see Kit 301921 for C Band see Kit 301939 Step 2 Attach the 49187angle clips around the reflector perimeter at the indicated positions using 100521 51 3 8 x 1 inch bolts 9974 63 lockwashers and 9999 60 nuts See View B in Figure 3 54b 3 8 x 1 Bolt Lockwasher and Nut 49187 Angle Clip Es 300056 gt 3 8 x 2 1 4 Bolt Lockwasher Subreflector Strut and Nut Pe S 222888 s 58 Strut Supports lt 3 8 x 2 1 4 Y AN Bolt Lockwasher A and Nut Figure 3 54b Subreflector Strut Attachment Step 3 Raise and attach the pre assembled Subreflector strut assemblies between the corre sponding 49187 angle clips using a tag line Attach struts between angle clips using 9963 127 3 8 x 2 1 4 inch bolts 9974 63 lockwashers and 9999 60 nuts Step 4 Tighten strut and all hardware at this time ANDREW 67 Installation Procedures Subreflector Adjustment Step 1 Step 2 Step 3 Step 4 Step 5 After the subreflector assembly has been attached to the reflector the subreflector must be adjusted to ensure correct alignment The following steps provide the procedure for adjusting the subreflector Position the supplied setting bar P N 203896 Ku band P N 203896 3 C band on the outer edge of the subreflector as well as on the outer edge of the front ring P N 202790
16. as shown in Figure 4 3 AZIMUTH AXIS WEST Azimuth Axis West ELEVATION AXIS e ELEVATION AXIS UP F WN DQ 2nd Side Loba Peak Axis ast AZIMUTH AXIS EAST Figure 4 3 Antenna Radiation Pattern Topographical Diagram with Plan View 73 Operation Step 5 Step 6 Step 7 Step 8 If the signal amplitude diminishes and does not increase position B to the level noted when the antenna was peaked on the side lobe the antenna is moving away from the main beam reverse the direction of the antenna movement From the original side lobe position position A the signal amplitude should now dimin ish to a null point at position C minimum amplitude showing only signal noise and then symmetrically increase again to the same level at position D as noted at position A 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 eleva tion 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 sig nal amplitude increases deceases and then increases again but to a lesser value the antenna is moving in the wrong direction reverse the direct
17. halves from bottom of crate a Prepare assembly area with blocks of wood to assemble reflector a Lay reflector halves on prepared assembly area a Align reflector halves L Insert all hardware as outlined in Installation Procedures 11 Getting Started Enclosure Assembly Reflector To Mount Assembly U Add reflector mounting ring U Mount front and back hub mounting rings a Apply sealant to outside of reflector mounting ring LJ Perform recommended string test LJ Remove rear and side covers from enclosure assembly LJ Attach enclosure to mounting ring a Apply sealant backing rod around enclosure mounting ring mating surfaces a Apply RTV sealant U Route sling through upper holes of torsion box assembly LJ Route two rope tag lines through torsion box assembly to be used as guides U Place foam blocks on ground to avoid scraping reflector when lifted U Raise reflector U Bolt left bolt of enclosure bracket U Rotate reflector to align right bolt LJ Extend elevation strut or jackscrew and attach to top of enclosure assembly a Tighten hardware using A 325 tensioning procedure a Carefully raise reflector to zenith position L Remove hoisting apparatus 12 Getting Started Subreflector Feed System U Preassemble subreflector weldment L Attach subreflector mounting ring to strut assembly U Attach angle clips U Attach subreflector to reflector a Adjust subreflector a Tighten adjustment hardware LJ Refer to installation i
18. 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 motor izable capabilities The pedestal mount features 180 degree azimuth coverage in three continuous 120 degree overlapping ranges and executes 90 degree continuous eleva tion 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 cor responding 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
19. provides a world wide technical support network Refer to the tech nical assistance portion of this this manual for the contact numbers appropriate to your location The installation maintenance or removal of antenna systems requires qualified experi enced 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 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
20. to the elevation strut as shown in Figure 3 22 using the appropriate hardware NOTE The drain hole should be positioned downward for proper water drainage Ensure that the locking strut support setscrew is firmly tightened on the strut assembly as shown in Figure 3 22 Remove the two indicated strut support setscrews and attach the base angle to the cor responding strut support using the supplied 1 2 inch clamping nuts and the previously removed strut support setscrews as shown in Figure 3 22 Securely tighten the remaining mounting hardware to achieve the clamping force Repeat the entire procedure for the remaining strut assembly NOTE DO NOT loosen the Azimuth drive bearings Move the antenna to the desired azimuth angle by adjusting the manual actuator until the satellite signal has been spotted 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 71 Operation ATTEN OdB RL 10 OdBm CENTER SPAN RBW 1 OMR vEw 3 OMHz SWP SO Oms ATTEN 1008 RL 10 OdSm CENTER 3 SS00GH SPAN 510 OMHz RBW 1 OMHz vGw 3 DMHz Swe 50 Ome
21. Antenna notice that it is delivered in a wooden crate and covered with a white nylon sheath The protective crate covering shields the product from being damaged during the shipment process While unpacking the shipment ensure that the correct parts are included by checking them against the packing list The following steps provide the procedure for unpacking the crate The crate arrives on site covered in a white sheath domestic pack or wood export pack See Figure 3 30a and Figure 3 30b Remove the protective covering from crate Pry the top crate panel off with a pry bar Figure 3 30a Domestic Pack 43 Installation Procedures Step 3 Step 4 Step 5 Step 6 Figure 3 30b Export Pack Figure 3 30c Unpacking Pry the short ends of the crate off by using a pry bar and hammer as shown in Figure 3 30c NOTE Notice that the parts of your order are boxed and banded to your crate Remove these boxes by snipping the banding with tin snips Take the front long side of the crate off Unbolt the reflector halves from the bottom of the crate DO NOT PRY Find a flat area for the reflector assembly The area must be large enough for the reflec tor halves to lay adjacent to each other Pieces of wood such as 2 X 4 pieces can be positioned to provide a level surface for the reflector to rest on which will prevent scratching of the reflector Note This area must be level or there may be problems in correctly
22. Facing the reflector the right bolt should be inserted to hold the reflector in place using the appropriate hard ware Figure 3 48 Enclosure Bracket Alignment 59 Installation Procedures Step 7 Extend the elevation strut or elevation jackscrew and attach it to the top rear of the enclosure assembly as shown in Figure 3 49 Figure 3 49 Elevation Jack Enclosure Attachment Step 8 Tighten the hardware using the A 325 tensioning procedure Step 9 Carefully raise the reflector enclosure assembly to the zenith elevation 90 degrees position and securely tighten the strut support setscrews to 40 foot pounds Step 10 Remove all hoisting apparatus 60 Installation Procedures ANDREW The Reflector to Mount components can be verified and or clarified in the following diagram 3 4 x2 A 325 BOLT FLAT WASHER AND NUT ELEVATION STRUT ASSEMBLY AZIMUTH GROUND MOUNT STRUT SUPPORT ANGLE ASSEMBLIES SET SCREWS 2 PLACES MECHANICAL STOP A 325 BOLTS FLAT WASHERS HARDWARE AND NUTS 2 PLACES ELEVATION STRUT SUPPORT AZIMUTH CWC SET SCREWS STRUT WELDMENT 3 4 x 3 3 4 z AZIMUTH STRUT BOLT LOCKWASHER a ASSEMBLY AND NUT RE Figure 3 50a Reflector to Mount 61 Installation Procedures Reflector to Mount Assembly Embedded Pipe Ground Mount Step 1 Lift the reflector carefully onto the mount as shown in Figure 3 50b Secure the reflector to the mount using 100537 15 M20 x 50 l
23. Installation Operation and Maintenance lt L Revision C Type ES37 ge 3 7 Meter ESA ANDREW 3 7 Meter Earth Station Antenna Andrew Corporation Telephone 708 349 3300 Customer Service 24 hours U S A Canada Mexico 1 800 255 1479 10500 West 153rd Street FAX U S A 1 800 349 5444 U K 0800 250055 Republic of Ireland 1 800 535358 Orland Park IL U S A 60462 Internet http www andrew com Other Europe 44 1592 782612 ORA Copyright 2000 by Andrew Corporation Table of Contents Introduction Introduction Sic is A A A a A ta ee er eas A P ee aaa 3 Proprietary Data ocio it a A GZ PA eae ee hae ee 4 Information and Assistance ooococccocccco ene eens 4 NOUCE 5 ii EN AV Aa LAS EE O AE ah Gaus 4 Technical ASSISTANCE 00 iia a A tdi BYE ay it 4 How to Use This Manual OVINA a A wit ane AS LEA 5 Content iii A A AA AAA O EAS A AA AA 5 Getting Started VVS da a al A PRA A A DAD we A 6 Warnings seee be Sie etre A a A A A ci 6 Recommended TO0 S ooooocccnccccanan wazna na ES 7 Parts Verification ia 2 2 iii w i dpa E Bale Skins a a G R Ge we baja oe 8 Reporting Equipment Loss or Damage o oooccccccccnnn nnn nn nnnnnnaniih 8 Reporting Visible Loss or Damage oooooooooororcrrcrnrraaaaa eens 8 Reporting Concealed Damage eaaaaaaaaaaaaa zaawan eens 8 Inventory Equipment Received oooooococococcccc enea nana nana naannnniiia 8 Returning Equipme
24. aligning the reflector 44 Installation Procedures Step 7 Step 8 Step 9 Step 10 Assembly Step 1 Step 2 Lay the first half of the reflector which has the flash located at twelve o clock face down on the blocks of wood Lay the second half of the reflector face down on the blocks of wood Unbolt the mounting ring from the crate and set with the rest of the parts to be assem bled Improve timeliness of clean up by discarding unneeded materials while unpacking the crate You can place all wood and unneeded materials in one area away from the instal lation site Once the crate has been unpacked you can begin assembling your Andrew earth sta tion antenna The reflector halves are placed next to each other to begin the assembly The following steps provide the procedure for assembling the 3 7 Meter reflector Note Figure 3 33c provided at the end of this section shows a diagram of the reflector assembly Station an installer under the reflector halves to begin the assembly See that the joint plates are clean and then bring the reflector halves together aligning the joint plate holes NOTE The lip of one half fits over the other half and the bolts match exactly when placed together correctly Additionally each half has a serial number and a red stripe that must match to ensure that you have the correct halves in the correct place Figure 3 31 Reflector Seam Alignment 45 Installation Procedures Step 3
25. am All Around Ring Mounting Ring Tabs Red Line Match Marks Serial No On Joint Plates Splice Stri 4 P Joint Plate Hardware 2 0 31 x 1 25 32 mm Socket Head Shoulder Bolts 7 0 31 x 1 25 32 mm Bolts Plus Flat Washers Lock Washers and Nuts Serial No Figure 3 33c Alignment Bolt Insertions TIGHTEN TYPICAL Note Cavity side of hex bolt should be facing the reflector Figure 3 33d Alignment Bolt Insertions Tighten the hardware if the seam is correct starting from the center and working towards the outside of the reflector Before tightening hardware verify that the reflector seam gap is even along its length Push from both directions of the seam if necessary NOTE The installer positioned inside the reflector must hold the bolt head with a wrench while the nut on the outside is tightened 48 Installation Procedures Step 7 Add the reflector mounting ring to the assembled reflector Notice that the notches in the mounting ring fit over the reflector seam indicating where the mounting ring should be placed There is also a red stripe placed on the mounting ring This red stripe must be aligned with the red stripe on the reflector as shown in Figure 3 34a When all bolts are inserted tighten in a clockwise sequence tabs on the mounting ring must be flush with the reflector as shown in Figure 3 34b Figure 3 34a Mounting Ring Placement Figure 3 34b Mounting Ring Placement 49 Installation Procedu
26. ary to tem porarily remove one square head bolt for fine adjusting the threaded rod After fine adjustment it is recommended that the fine adjustment rod assembly remain in place If the threaded rod is removed the square head bolt must be replaced Attach 49712 3 bracket to strut using 9956 67 U bolt 9999 109 50 13 nut and 9974 4 lockwasher See Figure 3 29i Repeat for elevation strut 9997 166 Flatwasher and 9999 167 3 4 Brass Hex Nut 40188 3 Threaded Rod 9956 67 U Bolt 1 2 Lockwasher and 1 2 Hex Nut Bracket Figure 3 29i Fine Azimuth Adjustment Attachment I NDREW 42 Installation Procedures Reflector Unpacking Step 1 Step 2 The ground mount assembly is now completed with the necessary operational essen tials All ground mount options such as motors have separate instructional bulletins located in the parts kit that contains the option The next step in the installation process is the reflector assembly Proceed to the instructions on assembling the reflector The precision spun aluminum reflector assembly enables ease of installation and ensures accurate surface contour providing exceptional operating characteristics in the C Ku frequency band NOTE The instructions below are provided for the split reflector style 3 7 Meter Earth Station Antenna If you are installing the full reflector style skip this section and proceed to Step 7 Upon receiving your 3 7 Meter Earth Station
27. 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 accu racy 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 condi tions 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 sys tems pressurization equipment and interconnecting HELIAX cables and waveguide 3 Introduction 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
28. at the twelve o clock top position Sweep the bar across the corresponding subreflector edge and note the relative posi tion Repeat this procedure at the six o clock bottom position Use the noted position to indicate the required directional movement of the top portion of the subreflector aperture which is relative to the aperture bottom using the subreflec tor stud adjustment hardware 3 places as shown in Figure 3 55 Figure 3 55 Subreflector Alignment Repeat Steps 1 4 at the three o clock and the nine o clock positions to indicate the prop er aperture side adjustment 68 Installation Procedures Step 6 Step 7 Step 8 Repeat the entire procedure until all four noted positions indicate that the subreflector aperture is set parallel to the ring P N 202790 as shown in Figure 3 56 Temporarily tighten the adjustment hardware until after step 10 has been completed Figure 3 56 Subreflector Alignment Measure and note the distance between either outermost angle clip bolt head and the subreflector rim 69 Installation Procedures Step 9 Obtain the corresponding measurements from the remaining subreflector struts and adjust the subreflector mounting hardware 4 places to achieve a maximum differential of 1 16 inch Step 10 Repeat the adjustment procedure performed in Steps 1 4 until all areas of the subre flector are uniform Step 11 Adjust the jam nuts and securely tighten the adjustment hardware
29. ation Procedures Step 5 Attach the azimuth strut to the bottom rear of the frame assembly as shown in Figure 3 29g using the 100537 15 M20 x 50 long bolt 100526 57 nut 100521 57 flatwasher and 100522 57 lockwasher Attach the strut to the foundation anchor as shown in Figure 3 29g Step 6 Install 301931 pointer where shown in Figure 3 29g by removing the mount bolt at spec ified location then reinstalling with 100521 51 flatwasher and pointer Choose appropri ate 221027 azimuth label for antenna location Northern or Southern Hemisphere and attach to 11809 24 clamp Slide scale behind pipe and align with pointer and tighten See Figures 3 29g and 3 29h M20 x 50 Bolt Flatwasher Lockwasher and Nut 301931 Pointer M16 Flatwasher Add Flatwasher When Replacing Hardware M20 Flatwasher Lockwasher and Nut Figure 3 29g Azimuth Strut Pointer Attachment 11809 24 Screw kz Clamp ee MM E M 221027 Azimuth Label 180 Mark yy janie For Northern Hemisphere CHOOS APPROPRIATE AZIMJIII SCALE FOR LOCATILIN f p gt For Southern Hemisphere Figure 3 29h Azimuth Label Clamp 41 Installation Procedures Step 7 Install fine az adjustment attach 40188 3 thread rod to 49712 3 bracket with 9999 167 5 10 nuts and 9997 166 flatwasher Slide threaded rod through welded tab and fasten using 9999 167 75 10 nuts and 9997 166 flatwasher Note It will be necess
30. bracket P N 203875 on the end of the azimuth strut and hand tighten the1 2 inch setscrews before mounting it on the ground mount assem bly as shown in Figure 3 15 Figure 3 15 Azimuth Strut Bracket Assembly Step 8 Mount the second azimuth support plate P N 205875 pivot assembly to the rear end of the ground mount assembly as shown in Figure 3 16 Spacer blocks P N 205874 and 5 8 inch hardware hex bolt flatwasher hex nut should be inserted as shown in Figure 3 10 27 Installation Procedures E 1 Figure 3 16 Azimuth Pivot Assembly Step 9 Mount the azimuth strut to each bracket on the ground mount assembly as shown in Figure 3 17a and Figure 3 17b The front and rear brackets should be aligned as shown in Figure 3 18 Figure 3 17a Azimuth Strut Assembly Front 28 Installation Procedures Figure 3 17b Azimuth Strut Assembly Rear Figure 3 18 illustrates a final azimuth strut assembly mounted to the ground mount assembly Figure 3 18 Azimuth Strut Assembly Final Assembly 29 Installation Procedures Step 10 The next step is to install the elevation strut assembly Begin by bolting the elevation strut tube assembly P N 205872 to the ground mount assembly as shown in Figure 3 19 a A AF U p U i 4 o 4 gt Figure 3 19 Elevation Strut Pick Up Assembly Top View Step 11 Bolt the elevation bracket support plates P N 205873 to the elevation strut tube assem bly using 5 8 inch hard
31. 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 mate rial 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
32. djustments 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 77 Operation Preventive Maintenance Overview General Cleaning Electrical Parts This section contains periodic preventive maintenance instructions for the 3 7 Meter Earth Station Antenna Included in this section are inspection and preventive mainte nance procedures including cleaning and lubrication painting and an operational volt age current checkout procedure deemed within the capabilities of the average station technician 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
33. e mounting ring on the reflector using the appropriate hardware as shown in Figure 3 39a and Figure 3 39b VERY IMPORTANT Figure 3 39a Enclosure Hardware 3 4 x 3 BOLTS 3 PLACES 202934A ENCLOSURE ASSEMBLY ENCLOSURE FRONT RING REFLECTOR MOUNTING RING 205936 CONVEX re WASHERS FLATWASHERS Bway APPLY BLU SUPPLIED ua gt gt 205936 RTV CONVEX 1 SEALANT A p WASHERS FLATWASHERS 3 PLACES S PLACES 3 4 3 4 BACKING LOCKWASHERS AND NUTS ROD 3 PLACES MATERIAL REFLECTOR MOUNTING RING Failure to properly install 1 flatwashers and convex washers will result in reflector distortion i Figure 3 39b Enclosure Hardware AANDRE W 53 Installation Procedures Step 3 Step 4 Step 5 Install the supplied sealant backing rod material around entire circumference of the mounting ring enclosure mating surfaces as shown in Figure 3 40 INSTALL BACKING ROD MATERIAL AND APP Y SUPPLIED RTV SEALANT Figure 3 40 Backing Rod Assembly Securely tighten the enclosure mounting hardware using the A 325 tensioning proce dure Apply the supplied RTV sealant around the outer perimeter of the reflector mounting ring enclosure assembly junction as shown in Figure 3 41 Figure 3 41 RTV Sealant You have now completed the assembly of the enclosure and have mounted the enclo sure to the reflector Proceed to the next page for instructions on mounting the reflector to the grou
34. e of bracket U bolt assembly to push or pull antenna Finally tighten the M20 elevation pivot bolts to 185 Nem 136 Ibs ft and check all other fasteners relating to the elevation strut Slightly loosen the eight M16 nuts on the main azimuth hinge u bolts and square head bolts and nut connecting bracket to concrete Operate the azimuth adjustment strut in the same manner as the elevation adjuster When adjustment is complete tighten the square head bolts and nut connecting bracket to concrete and finally tighten the eight nuts M16 on the u bolts to 95 Nem 70 Ibs ft Check that the fasteners on the mount are tightened to the following torque levels M16 95 N m 70 Ibs ft M20 185 N m 136 Ibs ft 76 Operation Subreflector Adjustment 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 anten na 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 Using the provided setting bar and procedures will correctly place the subreflector 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 sho
35. eS Be ea es fo 75 Subreflector Adjustment a Ari i ah A ae ee ee ee le eae 76 Preventive OVErVIEWO a iene e daa oe eee Mah ag SD utah hinds ahaa bee ihe ala ater 77 Maintenance General Cleanings a snos csar Anena nee nnn nnn 77 Electrical Parts 02d IEA A E AAA A A wate Ue WWP Speen a Ga AND EW ONY 77 Mechanical Parts oaan pad alina o ol DE Bid ad GA A II E DA GTA 78 INSDECION Didi O a A o w Sod a St nae Sg Nie A O a 78 Local Control Motor Drive Controller oooooococccccccnccnc eens 78 Antennas di A OA A a Bate OW A E a 79 Drive System Voltage and Current Checks 0 00 cece cence eens 81 Pedestal Mount Bearing Pad AdjustMeMt oooccccccccc nana ana na na riii 82 Preservation of Component PartS aauaaaaaaaaaaaawaaa eens 83 Aluminum RAS a iS zie oe E A AA O EGO Palo A AE PA 83 Galvanized Surfaces oi a O Eee dA RA Re 83 LUD FICATION it A Ma OE do PAG a Gre ata 83 JackScreWS Mot rs za icine gg A Wad E TEn AAA A KA RERE DZK ANA WIE 84 RPL Gear Motor Housing Fill Drain Requirements oooococccccncnnrcan nan 84 ANDREW 2 Table of Contents 3 Meter Earth Station Antenna 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 excep tional versatility provides the ability to configure the antenna with your choice of linearly polarized 2 port or 4 port combining
36. ector with a high reflectance white paint This type of paint disperses light rays reducing the focus ing 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 sand paper Wipe the surface to be painted with a soft rag dampened in trichlorethylene lac quer 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 solu tions 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 ex
37. ee with each other within two percent Turn the FEED CCW OFF CW switch to OFF 82 Preventive Maintenance Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Pedestal Mount Bearing Pad Adjustment Step 1 Step 2 Step 3 Step 4 Step 5 Repeat preceding step 3 with the FEED CCW OFF CW switch in the alternate operat ing position Turn the AZIMUTH EAST WEST switch to either position and while the antenna is rotat ing carefully use a clamp on ammeter in accordance with the ammeter manufacturer s instructions to take current readings off each of the three conductors phases connect ed to the load side of the azimuth drive motor circuit breaker 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 posi tion Turn the ELEVATION DOWN UP switch to either position and while the antenna is rotat ing 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 connect ed to
38. ens 33 Embedded Pipe Ground Mount Assembly oooocccccnccn nanan 38 Elevation Azimuth Strut Assembly 0c eee 39 REMC CON gt DA Bo GAO EE HE See ORT 9 OE Reese Ma Dae DRE Pe 43 Unpacking ai ii A ee OR Mie wk ed RE er a ee eed nee ee 43 PSSOMDIY s se a a EE os Sie ce PE ded PO A a ean ange ga dosed ete Boel a 45 Alignment TESE ccevecsncteseh ct peje a are ee Le ass Hee AA ewe 51 Enclosure Pedestal Mount Only ccc eee ees 52 Reflector to Mount Assembly ooooccccccccan nes 55 Using a Crane ei been a eee E ds Rie ADA Sees eer ery VA 55 Withouta Crane sis iiccicitiacoi o dali wo A AR Bahar UE a BU ae aca a BOA 57 Reflector to Mount Assembly Embedded Pipe Ground Mount uuaaaasaaaaaanaii 62 Subreflector gis 552 5 5 gale Riana EA dice Des Rs Ak A E e de Wig AA a 1 63 Subreflector Struts Embedded Pipe Ground Mount 20000200ee cece eee e eens 67 Subreflector Adjustment 5 0 a BE ek Pe ee EE Ye 68 Feed System Sou iii A A A ah ee Gis aie as we ce ne eh Mole booted aed Eisler booted 70 Operation OVGrVieW Nad he OW dain A a bibles a aia con 71 Acquiring A Satellite m iep eo A a paid U AE a cee a ee 71 Manual Actuator Assembly Removal uuaeaeaaeeaaaee ana n ene nnnee 75 Embedded Pipe Ground Mount Elevation Adjustment ooooooooonoronrncnnnn o 75 Azimuth Adjustment 0 A nae ee we ee PY ee ee ees 75 CONCLUSION nesmi per Soe ee eg ec a aoa Heed NA GZW EE Gene nde pele Psa Gain O
39. grease until lubricant seeps from the pipe plug opening Replace and securely tighten pipe plug The following is a list of the lubricant characteristics e 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 Lightning 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 lubrica tion 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 corre sponding 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 p
40. 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 unpack ing 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 condi tion 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
41. he top of the reflector s hook so that it can be lifted straight up Figure 3 44b Crane Lift ANDREW 56 Installation Procedures ha Without a Crane The following steps provide the procedure for installing the reflector to the mount with out the use of a crane Figure 3 44c Crane Lift Step 1 Route one rope tag line through two consecutive holes at the top of the reflector in the torsion box assembly Step 2 Place foam blocks provided as packaging material on the bottom lip of the reflector between the ground mount and the reflector to prevent the reflector from scraping the ground as it is lifted 57 Installation Procedures Step 3 Position three people at the top of the reflector to lift the reflector on its end facing for ward as shown in Figure 3 45 Y Figure 3 45 Manual Lift of the Reflector to the Mount Step 4 Position one person of the three on the mount to guide the reflector to the mount Refer to Figure 3 46 Figure 3 46 Reflector to Mount 58 Installation Procedures Step 5 Align the enclosure bracket to the ground mount assembly The left bolt should be inserted to hold reflector in place using 3 4 A 325 hardware hex bolt flatwasher and nuts as shown in Figure 3 47 and Figure 3 48 Figure 3 47 Enclosure Bracket Step 6 Have the two people on the ground rotate the reflector to connect with the right bolt of the enclosure bracket against the ground mount angle bracket
42. individual standards and the operational environment in which the earth station is located However a visual inspec tion 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 dam aged parts which could cause improper functioning of the earth station It is recommend ed that the mechanical and electrical inspection be performed on the assembled or par tially 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 sta tion 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 visu al inspection procedures on electromechanical equipment In addition to these standard procedures perform the following checks and visual inspections for the specific condi tions noted Check the front panel for illegible and indistinct panel markings Check the three position selector sw
43. intersection to the first string as shown in Figure 3 37 If the strings touch then the reflector has been correctly aligned If they do not touch then check all previous steps to ensure proper assembly before continuing NOTE A 1 16 inch gap is permitted Figure 3 37 Reflector Alignment Reposition the first string above the second string to check the accuracy of the first test NOTE The reflector should be facing downward when the string test is performed The person that is positioned under the dish should ensure that the strings are aligned cor rectly during the test You have completed the assembly of the reflector Proceed to the next page for instruc tions on the enclosure assembly 51 Installation Procedures Enclosure The enclosure P N 202934A assembly attaches to the rear of the reflector The enclo Pedestal Moum sure provides weather protection for RF equipment and can accommodate up to a 4 On ly port combiner network An example of the assembled enclosure is presented in Figure 3 38a and Figure 3 38b Figure 3 38a Enclosure Final Assembly Figure 3 38b Enclosure Final Assembly Before assembling the enclosure verify that the appropriate parts are present The fol lowing steps provide the procedure for the enclosure assembly Step 1 Remove the rear covers and corresponding side panels from the enclosure assembly 52 Installation Procedures Step 2 Raise the enclosure assembly and attach to th
44. ion of the antenna move ment From the original null point the signal level should increase and decrease alter nately 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 transpon der 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 transpon der signals rather than maximizing the transponder of interest ATTEN 1008 RL 10 Odfim CENTER 3 SSOOGHz SPAN 510 OMH R W 1 OMH vGw 2 SwP 50 Om Figure 4 4 Polarization at 45 degrees from Optimum Setting 74 Operation Step 9 With all 24 transponder signals of approximately equal amplitude appearing on the spectrum analyzer screen determine the specific antenna system and satellite parame ters Rotate the feed assembly as required until the appropriate odd or even transp
45. is in the Southern hemisphere your satellite will be located in the North Pe x aS d Figure 3 5 Ground Mount Assembly Alignment with Anchor Bolts 19 Installation Procedures Step 3 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 Figure 3 6a Manual Lift Figure 3 6b Manual Lift 20 Installation Procedures Step 4 Step 5 Step 6 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 fo
46. isting painted surface For long life and trouble free operation be certain not to extend the lubrication schedule beyond the frequency recommended in Table 5 1 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 84 Preventive Maintenance JackscrewsiMotors Gear MotorlHousing Fill Drain Requirements remove any old lubricant to prevent an excessive build up Remove indicated access plugs from square tube weldment and apply lubricant to panning frame tube assembly and corresponding thrust pads Securely replace access plugs in square tube weldment Be certain to remove any protective caps and clean off each lubrication fitting prior to injecting fresh grease 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
47. itches 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 79 Preventive Maintenance Antenna Check transformer for an excessive wax deposit on the surface discoloration or a pungent odor indicative of burning vanish denoting overheating or a total breakdown Check all terminal boards for
48. kage is found to be excessive refer to appropriate trou bleshooting 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 86 Preventive Maintenance
49. lamp at the end as shown in Figure 3 26 Note Position condensation drain holes downward Figure 3 26 Protective Boot Attachment 35 Installation Procedures Step 8 Bolt the elevation pivot assembly brackets P N 208370 left and P N 208371 right to the inside of the ground mount assembly as shown in Figure 3 27 J SD ADA TA de Figure 3 27 Elevation Pivot Bracket Assembly Step 9 Bolt the jack to the elevation pivot assembly using 5 8 inch hardware hex bolts flat washers and nuts as shown in Figures 3 28a and 3 28b 36 Installation Procedures Figure 3 28b Elevation Jack Step 10 Loosen the clamp on the jack boot Step 11 Unscrew the jack by using a spud wrench until the jack connects to the back of the enclosure as shown in Figure 3 28c Figure 3 28c Elevation Jack Extension Step 12 Tighten the hardware using the A 325 tensioning procedure Step 13 Lubricate the jackscrews using the maintenance procedures Step 14 Pull the protective boot over the jackscrew and clamp it at the end as was performed with the azimuth jackscrew 37 Installation Procedures Embedded Pipe Refer to Figure 3 29a for an overall view of the assembled embedded pipe ground Ground Mount mount assembly reflector and subreflector assemblies Assembly Assembly Ground Mount Assembly Reflector Assembly Figure 3 29a Typical Embedded Pipe Mount Earth Station Antenna Step 1 Attach the 104320
50. left side frame to the 168 tube using four 104326 U bolts 100526 51 M16 nuts and 100522 51 lockwashers Add an 100536 21 M16 X 40 long bolt 100526 51 nut and two 100522 51 lockwashers at the top of the tube as shown in Figure 3 29b Arrange this bolt so that a flat rests on the top of the tube M16 Bolt Lockwashers 2 and Nut 104320 Left Side Frame M16 Nut M16 x4 P Lockwasher ROSE 104326 U Bolt gt a Figure 3 29b Left Side Frame Attachment NDREW 38 Installation Procedures Step 2 ElevationiAzimuth Strut Assembly Step 3 Attach the 104319 front frame to the left side frame as shown in Figure 3 29c Attach the 104325 braces to the left side by means of the U bolts Attach the right side frame and braces to the front frame and the right side frame to the left side frame also shown For all of these joints use 100532 21 M16x40 long bolts 100526 51 nuts and 100522 51 lockwashers When assembly is in place tighten to 95 N m 70 Ibs ft 104321 Right Side Frame ye 9 nN 104325 _ Brace M16 M16 Hex Bolt Nut i MI6 UN S5 Nen V M AL y AT M16 Lockwasher Figure 3 29c Front Frame Attachment Attach 104638 U bracket to one end of each 301899 support pipe using 100537 87 M20 X 100 hex bolt 100526 57 M20 hex nut and 100522 57 lockwasher Attach 301900 strut bracket to 49258 strut support using 45980 1
51. llation 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 lan yards 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 expo
52. located at the six o clock posi tion Strut Weldment Subreflector Hex Nut Adjustment Lockwasher Strut Support Plate Oversized 0 375 Flatwahser Figure 3 53a Subreflector Assembly 64 Installation Procedures Step 3 202776 STRUT ANGLES 4 PLACES wus k SUSREFLECTOR MOUNTING RING iu c 08 ADJUSTMENT STUD 6 o ctock position 3 8 x 17 BOLTS OVERSIZED FLATWASHERS STRUT SUPPORT LOCKWASHERS ANO NUTS PLATES 4 Places 4 PLACES Figure 3 53b Subreflector Assembly Attach the angle clips P N 49187 around the reflector perimeter at the indicated posi tions using the appropriate hardware as noted in Figure 3 53c 3 8 x 2 1 4 Bolts Lockwashers and Nuts 4 Places Bolts Lockwashers and Nuts 16 Places Figure 3 53c Subreflector Assembly 65 Installation Procedures Step 4 Raise and attach the preassembled subreflector strut assemblies between the corre sponding angle clips using a tag line as shown in Figure 3 54a The angle clips should correspond with the holes in the reflector NOTE Ensure that one subreflector adjustment stud is located at the six o clock position Pa Figure 3 54a Subreflector Attachment 66 Installation Procedures Subreflector Struts Embedded Pipe Ground Mount Assembly Step 1 Loosely preassemble the 300056 Subreflector Struts using supplied 222888 strut sup ports and the 9963 127 3 8 inch by 2 1 4 inch bolts 9974 63 lockwashers
53. nches 1 1 16 Inch 1 1 1 4 Inch 1 Screw Driver Standard 1 Phillips 1 Allen Wrench 7164 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 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 ship ment If you find that there are missing components please refer to page 9 for step by step instructions on how to properly report the equipment loss When you have received your order verify that all parts contained in the shipment corre spond 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
54. nd 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 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 foun dation 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 satel lite 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 17 Installation Procedures Step 5 Step 6 Step 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 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 3 4 Dia 19 mm 10 UNC Galvanized Threaded Steel Rod ASTM A 193 Grade B7 with Heavy Hex Nuts 3 4 19 mm Typ 8 places Flat washers Supplied with Anchor Bolt Kit and m ae Supplied wih Antenna Antenna Base Plate Supplied with Antenna 12 305 mm
55. nd mount assembly 54 Installation Procedures Reflector to Mount The reflector can be installed on the mount manually or by using a crane However Assembly Andrew recommends that this procedure be performed using a crane Using a Crane The following steps provide the procedure for installing the reflector to the mount using a crane Step 1 Route a sling through the upper holes in the reflector torsion box assembly and connect the ends using a 5 8 inch shackle as shown in Figure 3 42 NOTE If using a steel sling install foam pad protection in the upper reflector torsion box holes under the sling to avoid disfiguration of the reflector Rear View Figure 3 42 Sling Placement Step 2 Route two rope tag lines through two consecutive holes in the torsion box assembly to be used as guides when the reflector is lifted with a crane Figure 3 43 Safety Rope Tag Lines Installation Procedures Figure 3 44a Crane Lift Step 3 Verify that all hoist assembly hardware is fully in tact before lifting the reflector to avoid personal injury or damage to the reflector Step 4 Route the crane s cable and hook from the hoist over the slings and attach the shack le s hook to the crane s hook for raising the reflector Step 5 Position a person at the end of each tag line to guide the reflector as it is being lifted and position another person on the mount to crank the hoist NOTE The crane s hook must be perfectly aligned with t
56. nding hardware in a dry area for future use Remove the remaining clamp segments with the corresponding hardware After the antenna is pointed at the satellite tighten all azimuth and elevation setscrews to 35 foot pounds If you are assembling a motorizable pedestal mount P N 208800 follow the directions for ground mount assembly before beginning this section The following steps provide the procedure for assembling the motorizable pedestal ground mount Bolt the azimuth pivot assembly top and bottom brackets to the ground mount assem bly using 5 8 inch hardware hex bolt flatwasher and hex nut as shown in Figure 3 23 33 Installation Procedures Step 2 Bolt one jack to the azimuth pivot assembly using 5 8 inch hardware hex bolt flatwash er and hex nut as shown in Figure 3 24 Figure 3 24 Jack Attachment Step 3 Unscrew the jack using a spud wrench until it meets with the front azimuth strut weld ment as shown in Figure 3 25a Figure 3 25a Jack Unscrew Procedure 34 Installation Procedures Step 4 Place pivot blocks P N 205876 on both sides of the jackscrew ends bolting with lubri cated 1 2 inch hex bolt flatwasher and hex nut as shown in Figure 3 25b EPA AAA Figure 3 25b Azimuth Jack Attachment Step 5 Tighten the hardware using the A 325 tensioning procedure Step 6 Lubricate the jackscrews according to the maintenance instructions Step 7 Pull the protective boot over the jackscrew and c
57. nstructions packaged with the individual feed systems 13 Getting Started Installation Procedures Overview This section provides installation procedures for the 3 7 Meter Andrew Earth Station Antenna The installation procedures include instructions on the following antenna com ponents Mount Reflector Enclosure Reflector to Mount Assembly Subreflector Feed System Refer to installation instructions packaged with the individual feed systems Foundation Before beginning the installation process on the ground mount assembly ensure that Preparation 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 ship ment 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 Figure 3 1 ANDREW 14 Installation Procedures A 325 Tensioning Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 During the installation process there are several references to the A 325 hardware ten sioning procedure The A 325 hardware must be properly tensioned to avoid slippage between bolted surfaces under high loads Slippage can cause the corresponding assembly to move causing a
58. nt ssas arsa A ae ee ee a ecw ee ee 9 Installation Sequence Checklist 000 cece 10 Site Preparations eo vive ii a hd ob Sr be SD DL lo AR eg dase BOS 10 Ground Mount Assembly imi rotae wode a ee Sn SB ae Sg 0 3 Gia Rog gee alae ee ek a 10 For MPK Types Only 5200 cod wists aot at A A hae A ad Sa ees dow eae pares ties 10 For MPIK Types Only 0000 d w a a wie des 1 Main Reflector Assembly iroot ieren a A he Eee ee 11 Enclosure Assembl yy orrei nasze w Pa w Zo W O AA NO AP a WA GP ena 12 Reflector To Mount Assembly oooooccocccccn aan aaa EEE E REE E E A 12 S breflector s oe ci a A AAA 13 Feed System nn csi A O ALE a laa IA PA adan 13 Installation A AN Rare ack ates dona panes A aiw afk A A AA ONA GLEN Bes 14 Procedures Foundation Preparati0D o oooooccccccraan enn eee eee eee eee eee eee 14 A 325 TENSIONING iire n wio aE TRA na de RE E ee Bs Rais Re es Ee 15 MOUNT A a tena BA DA END dE ES A BA 16 Unpacking ooo O ge he bee he A A Pa a be a GC 16 Assembly Using 2 Crane ssi sii a man a A a ia 16 Assembly Without a Crane auuaaaaaaaa anawa ee 19 Motorizable Pedestal Ground Mount Assembly ooooocoocccnncca eee e eee eeeee 22 Manual Pedestal Ground Mount ASSemMbly ooooooconccan zacina 24 Manual Actuator Assembly 0 asarre a a eens 32 Manual Actuator Assembly Removal 0000 eee n enna 33 Motorizable Pedestal Ground Mount Assembly 0 0 cece eee e
59. ntenna misalignment When designated the A 325 hard ware 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 hard ware 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 Use Felt Marker Use Felt Marker f s O AS 4 Before After Before After Tensioning Tensioning Tensioning Tensioning Figure 3 1a A 325 Tensioning Procedure Figure 3 1b A 325 Tensioning For bolts less than 4 diameters For bolts over four diameters 15
60. olt and Nut Figure 3 8b Ground Mount Assembly Tiller Arm Hardware EL SPT Angle Assembly 3 4 x 2 Bolt and Flat Washer 2 Washers per Bolt one each on Reflector and Mount Side AZ Tiller Arm Weldment Figure 3 8c Ground Mount Assembly Elevation Support Angle 22 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 Left Position Center Position 90 To 30 60 To 60 Right Position 30 To 90 Figure 3 8e Ground Mount Assembly Tiller Arm Hardware 23 Installation Procedures Manual Pedestal Ground Mount Assembly Step 1 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 z EM Figure 3 9 Hardware Separation Step 2 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 ANDREW 24 Installation Procedures Step 3 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
61. on der signals are maximized ATTEN 1028 RL 10 Od3m CENTER 3 S500GH SPAN S10 DMHz RBW 1 OMHz V5w B OMHzZ Swe SD Ome ATTEN 2098 RL 10 OdBm CENTER B SS00GH SPAN 510 OMR RBW 1 OMH vBw 3 DMHz SWP SO Dms Figure 4 6 Optimum Polarization Setting 75 Operation Manual Actuator Assembly Removal Step 1 Step 2 Step 3 Embedded Pipe Ground Mount Elevation Adjustment Step 1 Step 2 Azimuth Adjustment Step 1 Conclusion After you have successfully acquired the satellite and all adjustments have been made the manual actuator should be removed The following steps provide the procedure for the prop er removal of the manual actuator assembly Remove the manual actuator assembly by first removing the hardware securing the actuator to the base angle NOTE The adjustment kit assembly should be removed after the antenna has been adjust ed Store the manual actuator assembly and the corresponding hardware in a dry area for future use Remove the remaining clamp segments with the corresponding hardware After the antenna is pointed at the satellite tighten all azimuth and elevation setscrews to 35 foot pounds Loosen the M20 elevation hinge bolts slightly If coarse adjustment i e more than 7 5 is required then loosen the three square head bolts and u bolt to threaded rod make adjustment then re tighten U bolt Fine adjustment is performed by working brass nuts on either sid
62. ong bolts 100526 57 nuts and 100522 57 lockwashers in three places Tighten these three to 38 Nem M20 x 50 Bolt Lockwasher and Nut Elevation Fine Adjustment M20 x 50 Bolt Flatwasher Lockwasher and Nut Figure 3 50b Reflector to Mount You have now completed the attachment of the reflector to the ground mount assembly Proceed to the instructions on assembling and attaching the subreflector to the reflector ANDREW 62 Installation Procedures Subreflector Once the reflector has been assembled to the mount the subreflector must be installed Figure 3 51 presents a final subreflector assembly Figure 3 51 Installed Subreflector The following steps provide the procedure for assembling the subreflector Step 1 Loosely preassemble the subreflector strut weldment P N 202775 using the supplied strut angles P N 202776 and the 3 8 inch by 2 1 4 inch bolts lock washers and nuts as shown Figures 3 52a and 3 52b 3 8 x 2 1 4 BOLTS LOCKWASHERS AND NUTS 8 PLACES Figure 3 52a Subreflector Strut Assembly Installation Procedures Figure 3 52b Subreflector Strut Assembly Step 2 Position and attach the subreflector mounting ring part of 205929 subreflector assem bly to the corresponding mounting holes in the strut support plates using 3 8 inch by 1 inch bolts oversized flat washers lock washers and nuts as shown in Figure 3 53a and Figure 3 53b NOTE Ensure that one subreflector adjustment stud is
63. orqued within the limits specified Tighten the jam nuts 83 Preventive Maintenance Preservation of Component Parts Aluminum Parts Galvanized Surfaces Lubrication When preserving the component parts refer to the following paragraphs in this section 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 trichlorethyl ene 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 dif ficult 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 thin ner 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 subrefl
64. otor 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 stand point 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 man ufacturer 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 agr
65. res Step 8 Mount the front P N 202790 and back hub mounting ring P N 49965 to the reflector with the appropriate hardware as shown in Figures 3 35a and b NOTE These components are included as part of P N 206319 Feed Hardware Kit For K Band Antennas these components are included as part of P N 301544 Feed Hardware Kit 2 Port or P N 301515 Feed Hardware Kit 4 Port 1 4 20 x 1 1 2 Bolts Flatwashers and Nuts 12 places Front Hub A ITITI HUR Mounting Ring Back Hub gt Mounting Ring Flatwashers ao Lockwashers gt Nuts Reflector Side View he Figure 3 35a Mounting and Center Rings Figure 3 35b Mounting and Center Rings For equipment enclosure versions only apply a smooth continuous bead of RTV sealant to the inside of the reflector mounting ring to seal the reflector and the mounting ring seam as shown in Figure 3 36 Step 9 4 Figure 3 36 Mounting Ring Sealant Equipment Enclosure Versions Only 50 Installation Procedures Alignment Test Step 1 Step 2 Step 3 Step 4 As a final test of proper reflector alignment Andrew recommends that a string test be performed The following steps provide the procedure for the string test Attach a string at the twelve o clock position of the reflector stretching to the six o clock position of the reflector Attach a second string at the three o clock position stretching to the nine o clock position Verify its
66. ressure compensation Lube points 2 and 4 shown in Table 5 1 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 cor rectly gauge the appropriate amount of oil in the gear housings 85 Preventive Maintenance Lube Service Lube Quantity Andrew Point Parts to be Lubricated Action Frequency Type Type Points Number 1 Elevation jackscrew housing Lubricate Every 3 Pressure SHC32 1 49208 months Fitting 2 Elevation gear motor housing Inspect Monthly Pipe Plugs SHC624 10 ounces 47497 SARE tikand drain z Roa li A O R AZ E YW OSA OWCZE GRA Change Every 3 months 3 Azimuth jackscrew housing Lubricate Every 3 Pressure SHC32 2 49208 months Fitting 4 Azimuth jackscrew gear Inspect Monthly Pipe Plugs SHC624 10 ounces 47497 housing fill and drain months 5 Panning frame tube assembly Lubricate Every 3 Brush Lightning Surface 207912 and thrust pads months On Lubricant Coverage Table 5 1 Antenna Lubrication Chart 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 lea
67. 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 necessi tates 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 e 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 81 Preventive Maintenance Drive System Voltage and Current Checks Step 1 Step 2 Step 3 Check security of antenna mounting and interconnecting assembly hardware Be cer 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 an
68. sure 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 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 WARNING Additional warning information will be located in this type of format 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 7 Meter Earth Station Antenna All tools necessary for the installation process should be provided by the installation crew Andrew recommends the following tools to be used for a proper installation of the 3 7 Meter Earth Station Antenna Recommended Tools Tool Size Quantity Open End or Combination Wrenches 5116 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 Wre
69. 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 posi tion 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 posi tion to return antenna control to the studio Then close and lock the outer local control motor drive controller door The bearing pad within the pedestal mount adjustment rods bolts require yearly adjust ment and verification of torque value With the antenna at zenith 90 degrees follow the procedures presented below Loosen jam nuts on all adjustment rods bolts Torque the upper adjustment rod evenly to 40 45 foot pounds Then torque the lower adjustment rod evenly to 40 45 foot pounds Torque the upper adjustment bolt evenly to 40 45 foot pounds Then torque the lower adjustment bolt evenly to 40 45 foot pounds Repeat steps 2 and 3 verifying all adjustment rods bolts are evenly t
70. 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 80 Preventive Maintenance Operate the azimuth and elevation drives as well as the feed rotation in both the plus and minus direction from the local control motor drive controller at least once every three months during antenna down time 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 cer tain both feed rotation limit switch arms are not distorted and ride centrally on the actu
71. ticles can be accom plished 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 bris tle 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 clean ing solvent on electrical insulation After cleaning allow the cleaned parts to dry for 10 to 15 minutes before placing the equipment into operation 78 Preventive Maintenance Mechanical Parts Inspection Local ControllMotor Drive Controller Clean mechanical parts by first removing dust dirt and other loose contaminants with a scraper stiff brush bristle or wire in the case of rust or other corrosion or cloth or com pressed air at 25 to 40 psi Any accumulated imbedded dirt corrosion grease or oil deposits that require further cleaning may be removed with a bristle or wire brush and a cleaning solvent such as trichlorethylene or equal 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
72. tual 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 con tained 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 report ing 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
73. undation OOP a Sa Base Hardware 21 Installation Procedures Motorizable Pedestal Ground Mount Assembly Step 1 Step 2 Step 3 Step 4 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 tension ing 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 A 325 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 3 4 Flat Flat Washer Washer 3 4 Threaded Pivot Block 3 4 x 1 3 4 B
74. ware hex bolt flatwasher and nut as shown in Figure 3 20 Fi cnr ae w Figure 3 20 Bracket Support Plates Top View 30 Installation Procedures Step 12 The elevation strut tube assembly should now be bolted to the elevation strut bracket as shown in Figure 3 21a and Figure 3 21b Figure 3 21b Elevation Strut Bracket 31 Installation Procedures Manual Actuator Assembly Step 1 Step 2 Step 3 The manual actuator assembly P N 207882 is used to adjust the elevation and azimuth angles of the 3 7 meter antenna The following steps provide the procedure used to assemble and install the manual actuator assembly Loosely attach the manual actuator assembly P N 207882 to the elevation strut as shown in Figure 3 22 using clamp segments 1 4 inch screw lockwasher and hex nut in each of the 12 connections NOTE The drain hole should be positioned downward for proper water drainage Attach the base angle to the actuator P N 202661 using 1 2 inch screws flatwashers and hex nuts as shown in Figure 3 22 AVOID EXCESSIVE TORQUE ON THE MOUNTING HARDWARE Ensure that the locking strut support setscrew is firmly tightened on the strut assembly as shown in Figure 3 22 m Figure 3 22a Manual Actuator Assembly If interference occurs with set screw and actuator bolt remove set screw After antenna adjustment and removal of actuator assembly replace the set screw 25 Hex Head Screw Lockwasher Flatwasher
75. wn 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 adjust ment 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 adjust ment 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 subre flector 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 adjust ments have been set it is very important that the null depth adjustment be carefully conduct ed Be careful not to alter any previous a
76. y 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 instal lation 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 sta tion facility an installation acceptance check off sheet was prepared and duly signed off if installed by Andrew crew Part of this check off included voltage readings retaken to determine if proper voltage was available Current readings were also taken as a refer ence for future comparison to serve as a troubleshooting aid in determining possible equipment degradation and shortened life Any current reading taken during the follow ing 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 m

Andrew 3.7-Meter Earth Station Antenna Stereo System User Manual

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