Andrew 7.6-Meter ESA Operating instructions

Andrew Corporation
10500 West 153rd Street
Orland Park, IL U.S.A. 60462
Telephone [phone]
FAX (U.S.A.) 1-800-349-5444
Internet http //www.andrew.com
Customer Service, 24 hours U.S.A. • Canada • Mexico 1-800-255-1479
U.K. 0800 250055 • Republic of Ireland 1 800 535358
Other Europe [phone] September, 2006
Copyright © 2005 by Andrew Corporation
Installation, Operation and Maintenance Bulletin OM76
Type ES76( )
7.6-Meter ESA
7.6-Meter Earth Station Antenna
Revision E

Introduction
How to Use This Manual
Getting Started
Installation
Procedures
Operation
Preventive
Maintenance
Table of Contents
2
Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Proprietary Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Information and Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ontent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parts Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reporting Equipment Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reporting Visible Loss or Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reporting oncealed Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inventory Equipment Received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Foundation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A-325 Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tripod Ground Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Azimuth Beam Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Support Legs Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Panning Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Elevation Jackscrew Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Azimuth Jackscrew Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Reflector/Backstructure Installation Drawing (239501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reflector/Backstructure Installation Drawing (239908) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Theodolite & Alignment Installation Drawing (239611A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Subreflector and Subreflector Strut -Band Installation Drawing (239906) . . . . . . . . . . . . . . . . . . 50
Subreflector and Subreflector Strut Ku-Band Installation Drawing (239909) . . . . . . . . . . . . . . . . . 52
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Acquiring A Satellite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Subreflector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
General leaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Electrical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Mechanical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Local ontrol/Motor Drive ontroller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Drive System Voltage and urrent hecks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Preservation of omponent Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Aluminum Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Galvanized Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Jackscrews/Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Gear Motor/Housing Fill Drain Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Introduction Like all Andrew earth station antennas, the 7.6 Meter Earth Station Antenna provides
high gain and exceptional pattern characteristics. The electrical performance and excep
tional versatility provides the ability to configure the antenna with your choice of linearly
or circularly polarized 2 port or 4 port combining network. That versatility is provided at
the time of initial purchase, as well as in the future, as your satellite communication
requirements evolve.
The aluminum reflector is precision formed for accuracy and strength requiring minimal
assembly. The reflector assembly is 25 feet (7.6 meters) in diameter and segmented in
a sixteen piece configuration to reduce shipping volume and facilitate transport to
remote sites. Reflector panels are chromate converted and painted with a highly reflec
tive white paint.
The versatile tripod mount can be purchased with either manual or motorizable capabili
ties. The tripod mount features 180 degree azimuth coverage in three continuous 120
degree overlapping ranges and executes 90 degree continuous elevation adjustment.
This large adjustment range provides non critical foundation orientation and the ability to
view geostationary satellites from horizon to horizon, from any location worldwide.
The motorizable tripod mount features self aligning bearings for the elevation pivots,
resulting in "zero" backlash. This mount can be operated manually, but has the ability to
be upgraded for motorized operation, including steptracking/Smartrack™ applications.
The motorizable mount type is indicated by the ES76 or ES76HS letters within the
antenna type number. The addition of the letter "HS" within the antenna type number
indicates that the mount includes High Speed azimuth/elevation machine jackscrews,
instead of corresponding azimuth/elevation strut assemblies. The azimuth/elevation
jackscrews are equipped for integration with the optional motor drive systems. A cross
axis grounding kit is supplied with each mount to ensure electrical interconnectivity of
the complete structure.
The aluminum enclosure and hot dipped galvanized steel mount maintain pointing 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 motor drive systems
(with power interfaces addressing domestic and international standards), remote micro
processor antenna control for motor drive systems, pressurization equipment, and inter
connecting HELIAX®cables and waveguide.
3Introduction
.6-Meter Earth Station Antenna

Proprietary Data
Information and
Assistance
Notice
Technical
Assistance
The technical data contained herein is proprietary to Andrew Corporation. It is intended
for use in operation and maintenance of Andrew supplied equipment. This data shall not
be disclosed or duplicated in whole or in part without express written consent of Andrew
Corporation.
Andrew Corporation provides a world wide technical support network. Refer to the 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 © 2005, Andrew Corporation
4Introduction
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 [phone] [phone]
Any Location U. S. A. [phone] [phone]
(International)
Customer Ser ice 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 [phone] (toll free)
United Kingdom 00 800 0 255 1479 (toll free) 00 800 0 349 5444 (toll free)
Australia 0011 800 0 255 1479 (toll free) 0011 800 0 349 5444 (toll free)
China 00 800 0 255 1479 (toll free) 00 800 0 349 5444 (toll free)
New Zealand 00 800 0 255 1479 (toll free) 00 800 0 349 5444 (toll free)
Hong Kong 001 800 0 255 1479 (toll free) 001 800 0 349 5444 (toll free)

Overview
Content
The scope of this manual is intended to provide station personnel with the base installa
tion, operation, and maintenance requirements necessary for a 7.6 Meter C , X or Ku
Band Earth Station Antenna. This manual provides a convenient reference for autho
rized operator/service personnel requiring technical information on general system or
specific subsystem equipment.
The tables and figures presented in this manual are used as communication aids for the
installation, operation, and maintenance of the 7.6 Meter Earth Station Antenna. These
tables and figures instantly convey messages, as well as make the procedures easier to
understand. This manual uses tables and figures for the following references:
•Tables The tables allow you to locate information quickly and easily.
•Drawings The drawings supplement the installation instructions by using a combi
nation of graphics and verbage to assist you in simplifying complex pro
cedures and clarifying components.
•Photographs The photographs compliment the installation instructions by providing
actual examples of the steps being performed, which allow you to view
the installation in concrete form.
The manual is divided into five distinct sections, each dealing with a specific technical
topic relating to either system or component subsystem information. The sections 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 7.6
Meter Earth Station Antenna.
•Getting Provides the preliminary information needed to perform a successful
Started installation. This section should be reviewed prior to the installation. The
warnings, recommended tools, parts verification, instructions on report
ing lost or damaged equipment, and installation checklist are located in
this section.
•Installation Provides the procedures for the different phases of a 7.6 Meter Earth
Procedures Station Antenna base installation. This section will help you easily find
requirements for an individual task, as well as displays the sequence for
each task execution.
•Operation Describes the controls, functions, and general operating procedures
required for proper operation of the 7.6 Meter Andrew Earth Station
Antenna.
•Pre enti e Describes preventive maintenance procedures that are required to
Maintenance maintain proper functional operation of your new Andrew Earth Station
Antenna.
5How to Use This Manual
How to Use This Manual

Overview
Warnings
The installation, operation, and maintenance of the 7.6 Meter Earth Station Antenna
requires qualified and experienced personnel. Andrew installation, operation, and 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 7.6 Meter Earth Station Antenna can be
found in this section. Furthermore, this section should be reviewed BEFORE performing
the installation, operation, or maintenance. Warnings, recommended tools, and the
antenna parts can be verified and/or determined with such a review.
When installing the 7.6 Meter Earth Station Antenna, be conscious of the warnings 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. Installation of antennas may require persons to work at elevated work stations.
Whenever persons are working at eight or more feet above the ground and not on a
guarded platform, they should wear safety belts with at least one (preferably two) 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 exposure to radio frequency (RF) energy. The antenna must be
turned off before entering the area in front of the reflector and near the feed.
6Getting Started
Getting Started

Recommended
Tools
NOTE: Failure to follow an installation procedure could result in damage to equipment
or personal injury.
Additional warnings will be displayed throughout this manual for your awareness. These
warnings can be identified in warning boxes as shown in the following sample.
Andrew disclaims any liability or responsibility for the results of improper or unsafe
installation, operation, or maintenance practices.
Andrew supplies all appropriate hardware/parts required for the installation of your 7.6
Meter Earth Station Antenna. All tools necessary for the installation process should be
provided by the installation crew. Andrew recommends the following tools to be used for
a proper installation of the 7.6 Meter Earth Station Antenna.
Tool Size Quantity
Open End or Combination Wrenches 5/16 Inch 2
7/16 Inch 2
9/16 Inch 2
7/8 Inch 2
3/4 Inch 2
1/2 Inch 2
1 1/4 Inch 1
Crane 15 Ton Minimum Capacity, extended end 1
Nylon Web Slings (2000 pound breaking strength) 3 Inch by 14 Foot 2
Rope or Cord (2000 pound breaking strength) 50 Foot 1
Shackles 5/8 Inch 2
Ladder 10 Foot Extension 1
Drive Sockets 1/16 Inch 1
9/16 Inch 1
7/8 Inch 1
3/4 Inch 1
1 1/4 Inch 1
Breaker Bar 1/2 Inch 1
Spud Wrenches 1 1/16 Inch 1
1 1/4 Inch 1
Screw Driver Standard 1
Phillips 1
Allen Wrench 7/64 Inch 1
3/16 Inch 1
1/4 Inch 1
Tape Measure (or other measuring device) Standard 1
Felt tip Marker (or other marking device) Standard 1
Hammer Standard 1
Rubber Mallet Standard 1
Pry Bar Standard 1
Tin Snips Standard 1
Safety Gloves (each installer) Standard 1
Table 2-1. Recommended Tools
7Getting 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 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.
8Getting 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 Material Authorization
(RMA) number, as well as an address to forward the material to.
Tag or identify the defective equipment, noting the defect or circumstances. Also, be
sure to write the RMA number on the tag. It would be helpful to reference the sales
order and purchase order, as well as the date the equipment was received.
Pack the equipment in its original container with protective packing material. If the 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
• RMA Number
• Problem Description
• Contact Name
NOTE: Absence of the RMA number will cause a delay in processing your equipment
for repair. Be sure to include the RMA number on all correspondence.
Ship the equipment to Andrew Corporation using UPS, U.S. Postal Service, or other
appropriate carrier; freight prepaid and insured. The material should be forwarded to the
address given by the Andrew contact in Step 1.
9Getting Started

Overview
Foundation
Preparation
10 Installation Procedures
This section provides installation procedures for the 7.6 Meter Andrew Earth Station
Antenna. The installation procedures include instructions on the following antenna com
ponents:
•Mount •Reflector to Mount Assembly
•Reflector •Subreflector
•Enclosure •Feed System (C , X and Ku band)
Before beginning the installation process on the ground mount assembly, ensure that
the foundation has been prepared. Foundation specifications are provided by Andrew
and may be used as a reference by civil engineering personnel when preparing the
foundation for local soil conditions. These specifications are available before the ship
ment arrives by contacting the Customer Service Center or your Account Manager.
•Foundation should be dimensioned as detailed in Figure 1.
•Sweep foundation clear of any dirt or debris.
•To ensure smooth surface for mount, scrape foundation pads as shown in Figure 2.
•Studs should extend 3 in. above the ground and are 7/8 in. in diameter
•Apply stick wax to stud threads to ease later connections.
Installation Procedures
Figure 1
Figure 2