Installation, Operation and Maintenance Bulletin OM40 Rev C 4.0 Meter Earth Station Antenna Type ES40C-1, ES40K-1, ES40CM-1 and ES40KM-1 One Company. A World of Solutions. Andrew Corporation 3 Westbrook Corporate Center Suite 900 Westchester, Illinois 60154 USA Customer Support Center From North America Telephone: 1-800-255-1479 Fax: 1-800-349-5444 satcom@andrew.com International Telephone: +1-708-873-2307 Fax: +1- 708-349-5444 Internet: www.andrew.com Printed in U.S.A.
Table of Contents Introduction Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proprietary Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Information and Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction Like all Andrew earth station antennas, the 4.0 meter earth station antenna provides high gain and exceptional pattern characteristics. The electrical performance and exceptional versatility provides the ability to configure the antenna with your choice of transmit/receive as well as receive-only, and for either linearly- or circularly-polarized C-band and linearly-polarized operation. A pedestal mount version is available for addition of motorization.
Introduction Proprietary Data Information and Assistance Notice The technical data contained herein is proprietary to Andrew Corporation. It is intended for use in installation, operation, and maintenance of Andrew equipment. This data shall not be disclosed or duplicated in whole or in part without express written consent of Andrew Corporation. Andrew corporation provides a world-wide technical support network.
How to Use This Manual Overview The scope of this manual is intended to provide station personnel with the base installation (ie: mount, reflector and enclosure), operation and maintenance requirements necessary for a 4.0 Meter Earth Station Antenna. Note: All antenna option instructions are included in the individual kit shipped with the part.
Getting Started Overview The installation, operation and maintenance of the 4.0 Meter Earth Station Antenna requires qualified personnel. Andrew installation, operation and maintenance instructions are illustrated for such personnel. Additionally, the antenna should be inspected by qualified personnel to verify proper installation, maintenance and condition of equipment as described in Preventative Maintenance.
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 sample to the right. 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.
Getting Started Recommended Tools Andrew recommends that the following tools be used for a proper installation of the Earth Station Antenna. Table 1. Recommended Tools Tool Size Open End Wrench 13 mm 3/8” 1/2” 9/16” 1 1/8” 1.
Tool and Hardware Conversion Chart Bolts and Wrenches Chart, Possible US to Metric Substitution During 4.0 Meter ESA Installation** Bolt Location BOM Item No. Base Diam. Open Wrench Length Qty. Material inches Metric Bolt (Gr 8.8 DIN 933) Base Diam. Standard Length Material 2 7 3/8-16 1.5 8 SS 9/16 2 8 3/8-16 1.125 4 SS 9/16 2 12 3/8-16 6 3 SS 9/16 Reflector 3 111 5/16-18 1.25 40 SS 1/2 3 117 3/8-16 1.5 15 SS 9/16 3 121 1/4-20 1.25 24 SS /8 3 125 M6 1 250 SS 5 mm Allen 3 126 3/8 SHLDR 0.
Getting Started Parts Verification Upon receipt of your order, the shipment should be verified to ensure that all parts have reached your site. This process should occur before the installation process begins. Andrew Corporation thoroughly inspects and carefully packs all equipment before shipment. If you find that there are missing components, please refer to step-by-step instructions on how to properly report the equipment loss.
Getting Started Installation Sequence Checklist Site Preparation Pedestal Ground Mount Assembly ES40 Main Reflector Assembly ES40K-1 The 4.0 Meter Earth Station Antenna requires the installation team to perform the assembly in the sequence presented below. Moreover, this sequence should be reviewed beforehand to ensure a smooth installation. Use the following checklist to verify and/or determine the installation sequence. Throughout the checklist certain part numbers will be used.
Getting Started Site Preparation ES40CM-1 or ES40KM-1 Pedestal Ground Mount Assembly ES40CM-1 or ES40KM-1 Refer to Foundation Specifications for guidance in preparing the location and the installation of the 4.0 Meter Earth Station Antenna foundation.
Installation Procedures Overview This section provides installation procedures for the 4.0 Meter Andrew Earth Station Antenna. The installation procedures include instructions on the following antenna components. • Mount • Reflector • Back Structure • Reflector To Mount Assembly • Subreflector • Feed System Note: All installation instructions for the antenna options are contained in the parts kit included in the shipment.
Installation Procedures A-325 Tensioning During the installation process there are several references to the A-325 hardware tensioning procedure. The A-325 hardware must be properly tensioned to avoid slippage between bolted surfaces under high loads. Slippage can cause the corresponding assembly to move, causing antenna misalignment. When designated, the A-325 hardware should be tightened according to the following tensioning procedure.
Installation Procedures Mount Assembly 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 you can use Andrew Manual Lifting Kit or similar options The elevation/azimuth low cost manual mount design simplifies installation, minimizes foundation requirements, and enables horizon-to-horizon coverage from any worldwide location.
Installation Procedures Step 3 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 6. Figure 6 Figure 7 Step 4 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 7. Step 5 Set Azimuth Tube Weldment (7542711) on the ground near the pedestal.
Installation Procedures Step 6 Install Two Universal Brackets (7542460) using (8) x 3/4-10 hardware. Tighten bolts per ASTM A325 procedures. Figure 8-B Universal Bracket Universal Bracket Note: Insure that frontal faces of the universal brackets and tube weldment are in plane and leveled.
Installation Procedures Step 7 Install Reflector Support Tube (7542474) to the previous installed universal brackets using front access slots and (8) x 3/4-10 hardware. Tighten bolts per ASTM A325 procedures. Figure 9-A Figure 9-B Figure 9-C Step 8 Install Two Universal Brackets (7542460) using (8) x 3/4-10 hardware. Tighten bolts per ASTM A325 procedures.
Installation Procedures Step 9 IInstall fine azimuth adjustment rod using two spherical rod ends (7542639) and 3/4-16 nuts. Level the rod using 3/4-16 adjustments nuts. Hand tighten the hardware. Figure 10-A Figure 10-B Step 10 Install Elevation Pivot Bracket (7542693) using 3/4-10 hardware. Hand tighten hardware.
Installation Procedures Pedestal Mount The elevation/azimuth mount design simplifies installation, minimizes foundation requirements, and enables horizon-to-horizon coverage from any worldwide location. The ground mount assembly enables 180 degree positioning for selected azimuth viewing. Azimuth range coverage is plus or minus 90 degrees, divided into three 120 degree continuous ranges with a 30 degree overlap. Elevation adjustment is continuous from 0 degrees to 90 degrees.
Installation Procedures Step 1 Carefully remove the ground mount assembly (P/N 208800 - motorizable or P/N 202680-2 manual) from the packing crate. Leave the steel strapping intact to avoid disengagement of the panning frame from the square-tube weldment during the ground mount installation. Step 2 Securely attach the crane to the ground mount assembly using a sling, and carefully raise the entire ground mount as shown in Figure 12.
Installation Procedures Step 5 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. 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. Step 6 Remove the steel strapping from the ground mount assembly. Step 7 Tighten the foundation hardware using the A-325 tensioning procedure.
Installation Procedures Assembly (Without a Crane) 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. Step 1 Carefully remove the ground mount assembly (P/N 208800-motorizable or P/N 2026802- manual) from the packing crate.
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 15 and Figure 16. Figure 16 Figure 15 Be very cautious when lowering the mount. Do not lower the mount onto your feet.
Installation Procedures Step 4 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. 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. 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.
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 19. Figure 19 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 20.
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 21. NOTE: The ground mount assembly enables 180 degrees positioning for selected azimuth viewing.
Installation Procedures An illustration of the final azimuth tiller arm is shown in Figure 22. Figure 22 Step 5 Locate the elevation and azimuth struts (P/N 202951-2-manual) as shown in Figure 23. NOTE: The azimuth strut is the strut pictured on the bottom and the elevation strut is on the top in the illustration below.
Installation Procedures 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 24. 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.
Installation Procedures 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 16. Spacer blocks (P/N 205874) and 5/8 inch hardware (hex bolt, flatwasher, hex nut) should be inserted as shown in Figure 26. 3/4 inch 5/8” Hardware Flat Washer Spacer Blocks Figure 26 Step 9 Mount the azimuth strut to each bracket on the ground mount assembly as shown in Figure 27a and Figure 27b.
Installation Procedures The front and rear brackets should be aligned as shown in Figure 28. Figure 28 illustrates a final azimuth strut assembly mounted to the ground mount assembly. Figure 28 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 29.
Installation Procedures Step 13 The elevation strut tube assembly should now be bolted to the elevation strut bracket as shown in Figure 31 and Figure 32.
Installation Procedures Manual Actuator Assembly The manual actuator assembly (P/N 207882) is used to adjust the elevation and azimuth angles of the 4.0-meter antenna. The following steps provide the procedureused to assemble and install the manual actuator assembly. NOTE: This assembly should be conducted upon completion of the antenna assembly (after feed assembly). Refer to “Acquiring A Satellite”.
Installation Procedures Step 4 Remove the two indicated strut-support setscrews, and attach the base angle to the corresponding strut support using the supplied 1/2 inch clamping nuts and the previously removed strut-support setscrews as shown in Figure 34. WARNING: Azimuth brakes have been factory set. Do not readjust brakes to facilitate the use of actuators. Step 5 Securely tighten the remaining mounting hardware to achieve the clamping force. Step 6 Follow directions for “Acquiring a Satellite”.
Installation Procedures Step 2 Bolt one jack to the azimuth pivot assembly using 5/8 inch hardware (hex bolt, flatwasher and hex nut) as shown in Figure 36.
Installation Procedures Step 4 Place pivot blocks (P/N 205876) on both sides of the jackscrew ends, bolting with lubricated 1/2 inch hex bolt, flatwasher and hex nut as shown in Figure 38 Figure 38 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 clamp at the end as shown in Figure 39. Note: Position condensation drain holes downward.
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 40. Figure 40 Step 9 Bolt the jack to the elevation pivot assembly using 5/8 inch hardware (hex bolts, flat washers and nuts) as shown in Figure 41a and b.
Installation Procedures 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 42. Figure 42 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.
Note: Use bottom holes only Elevation Pivot Bracket Figure 43 4.
Installation Procedures ES40C-1 Reflector Assembly Step 1 Reflector should be assembled on a clear, flat area in front of the foundation pad. Clear debris from area. Unscrew the sides and the front of the container. Each panel is fastened to the crate braces on top and the bottom by joint plates Figure 45a Figure 45b Carefully unscrew each panel from the crate one by one during installation.
Installation Procedures Step 2 Place plastic sheeting from packing crate as shown in Figure 12. Cut and build center standoff from the cutting marks on the Andrew crate or use custom 34 in brace (standoff) to support center of reflector. Cut from the marks on the Andrew crate outer ring wood supports or use custom 3 in supports for the outer rim of the reflector (3 supports per panel piece). It is desirable that supports will be leveled to allow faster and easier reflector assembly.
Installation Procedures Step 3 Identify and orgnaize antenna parts as shown in the following illustrations and photos. Note: All reflector segments are identified individually by one or two letter designation (A, B, C, D, E, F; A-B, B-C, C-D, D-E, E-F). Locate the markings on the reflector segments in order to assemble the reflector in the proper sequence. See Figure 14 for parts with stamped I.D.
Installation Procedures The common parts without any identification are as follows: Figure 49 1 Feed Mount Ring (7545392) Following is the reflector hardware kit: Figure 50-A Figure 50-B Reflector Hardware Kit Outer Ring Hardware (3/8 -16) Reflector Panel Hardware (Special Shoulder Bolt) 42 Figure 50-C
Installation Procedures Step 4 Place the center of the first panel (7541278) on the 34 inch standoff and outer rim of panel on supporting blocks with concave side down. Place the center of the second panel on the center brace insure that the match-markings are correct. (Ex: A to A, B to B…… ) as shown in Figures below. Figure 51 Step 5 Insert and hand tighten special hardware shoulder bolts to the first joint plate connection.
Installation Procedures Step 6 Insert and hand tighten 2 x 5/16 bolts inside the torsion panel at each joint plate connection.
Installation Procedures Step 8 Place the correct match-marked rib (7544097) on the seam and insert and hand tighten all rib hardware (special shoulder bolt). Insert capscrews from concave side of reflector panels. Figure 55 Step 9 Install remaining panels and ribs per the previous instructions Note: Leave one panel and rib unassembled until ring is in place and assembled.
Installation Procedures Step 11 A B A B A Gusset On Left Side A F B F F C C F E E C C D D E E D D Back View Step 12 B Figure 57-B Install the remaining panel and last rib.
Installation Procedures Step 13 Start snug tighten all hardware following steps below: 1. All shoulder bolts on all joint plates 2. All inside torsion panels 5/16 bolts on all joint plates 3. All exterior 5/16 bolts on all joint plates 4. Tighten 8 rib bolts (4 at each side) high at a time going around the reflector 5.
Installation Procedures Step 14 Install all 3/8-16 hardware between mount ring and ribs, thumb tighten it. Figure 61 Step 15 After all other hardware is snug tightened - snug tighten 3/8-16 rib to mount ring bolts.
Installation Procedures Reflector to Mount Assembly Step 1 Installed last two universal brackets (7542460) on spacers (7545087) with 3/4-10 x 5.0” long hardware. Hand tightened the hardware. Figure 64 Universal Bracket Universal Bracket Spacer Spacer Figure 65 Step 2 Lift the reflector. Position the reflector’s universal brackets in place with the mount universal brackets. From the one side of the reflector and mount assembly, drive the 1”-8 bolt through the central hole.
Installation Procedures Step 3 Attached the U-bracket (7545088) on the jackscrew (7544729) with the preinstalled and drilled nut (7545089) using 1”-8 x 5” long bolt, washer and nut. Tighten bolts per ASTM A325 procedures. Attached U-bracket (7545088) to the top hole of the reflector mounting ring (7544098) using 3/4-10 hardware. Figure 67 Jackscrew U-bracket Figure 68 Step 4 Screw 2 x 1.5’ nuts and one washers to the opposite side of the jackscrew.
Installation Procedures Step 7 Snug tighten bolt rods jam nuts 3/4-16. Using azimuth 5/8 bolts and azimuth fine adjustment 3/4 screw find transmitting / receiving pick. Tighten azimuth fine adjustment screw to snug. Figure 70 Step 8 Tighten 4 x 5/8 azimuth bolts per ASTM A325 procedures.
Installation Procedures Feed Strut Assembly Step 1 First lay subreflector struts on the ground. Use 3/8-16 bolts, lock washers, nuts and four L-brackets to combine struts. Attach U-brackets to struts with bolts, lock washers and nuts. Figure 72 Step 2 Attached adjustment plate (303763) to the U-brackets. Hand tighten all bolts/nuts. Figure 73 Step 3 Attached remaining L-brackets to the ends of the struts with 3/8 long hardware and hand tighten.
Installation Procedures Subreflector Assembly Step 1 Screw 3 all-threaded rods to the subreflector as shown on Figure 4 below. Figure 4 Figure 75 Step 2 Place assembly inside the reflector (on the ground or on the mount) 90˚ elevation position. Figure 76 Step 3 Place backup plates behind the reflector and align as shown with holes in reflector. Assemble angle brackets to reflector with 3/8-16 bolts, lock washers, nuts and backup plates.
Installation Procedures Step 4 Attach Subreflector to Adjustment Plate as shown.Positioned subreflector as shown on Figure 78 below ( 48.16” from the top of the reflector skin to the bottom of the subreflector flat surface). this dimension represents most probable reflector apex distance (focal point). Note: Subreflector Adjustment Plate must be level. Subreflector 48.16 Figure 78 Figure 7 For Feed installation - see specific feed installation instruction.
Preventive Maintenance Overview This section contains periodic preventative maintenance instructions for the 4.0-Meter Earth Station Antenna. Included in this section are inspection and preventative maintenance procedures including cleaning and lubrication, painting and an operational voltage/ current checkout procedure deemed within the capabilities of the average station technician.
Preventive Maintenance Mechanical Parts Inspection Local Control/Motor 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 corrosion), or cloth or compressed air at 25 to 40 psi. Any accumulated imbedded dirt, corrosion, grease or oil deposits that require further cleaning may be removed with a bristle or wire brush and a cleaning solvent such as trichlorethylene or equal.
Preventive Maintenance • Check all electrical components for dirt, chips, cracks, breaks, discoloration or 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 where applicable. • Check transformer for an excessive wax deposit on the surface, discoloration or a pungent odor indicative of burning varnish denoting overheating or a total breakdown.
Preventive Maintenance • 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. • 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.
Preventive Maintenance • • Drive System Voltage and Current Checks Check security of antenna mounting and interconnecting assembly hardware. Be certain all electrical grounding connections (including cross-axis grounding straps) and 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 with a wire brush.
Preventive Maintenance Step 5 Turn the ELEVATION DOWN/UP switch to either position and while the antenna is rotating, carefully use a clamp-on ammeter in accordance with the ammeter manufacturer’s instructions to take current readings off each of the power conductors (phases) connected to the main terminal block at the bottom of the panel. Record the current draw in the equipment log and compare the readings to the reference values entered in the installation/ acceptance check-off.
Preventive Maintenance Preservation of Component Parts Aluminum Parts When preserving 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 a metal surface by using a fine grit sandpaper.
Preventive Maintenance 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.
Preventive Maintenance Table 1.
