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© 2010-11 ASC Signal Corporation All Rights Reserved. No part of this document may be photocopied, reproduced, stored in a retrieval system, or transmitted, in any form or by any means whether electronic, mechanical, or otherwise without the prior written permission of ASC Signal Corporation. ASC Signal Corporation reserves the right to change details in this publication without notice. Trademark Notices Any and all products and companies named herein are the trademarks of their respective creators and/or owners. Open Source Software Notice This product makes extensive use of Open Source Software (OSS), including but not limited to the operating system, network agents, user interface shells, and tools used to develop the software. This software gives you, the customer, the benefit of a large base of well-tested and feature-rich system software while lowering the expense of providing these features to you. It also carries certain obligations. Some of this software is licensed by the GNU General Public License (GPL), which requires that all modifications or additions to the source code be kept public, and that the licensee continues to make the source code covered public. None of this source code has been modified for use in this product. If you are a user of this product who desires a copy of any source code covered by the GPL, contact our technical support and we will provide this free of charge through an agreeable medium. We expect all source code archives will be posted to public FTP servers. At the time of this writing the exact address is not known. Be advised that this is a large archive. We may recommend you obtain it from the source we obtained it from, as the source may be using more recent versions. We will always supply it ourselves if you prefer. Some of this software is licensed by the GNU Lesser General Public License (LGPL), which requires that modifications be kept public but does not require proprietary source code linked to LGPL'ed libraries be made public. None of this code has been modified for use in this product. All of the required source code will be conveyed along with the code covered by the GPL above. Some of this software is licensed by variations of the Berkeley Software Distribution (BSD) license, which do not require us to pass on source code. Some of this software has been modified for use in this product. However, in the spirit of open source, the original code will be supplied in the same manner as the code covered by the GPL on request. Please be advised that you will incur the same responsibilities we have incurred if you choose to redistribute any or all of the source codes obtained through this method. Please read the included license documents carefully. If you have any questions about our interpretation of our obligations under OSS licenses, do not hesitate to contact us. Our intent is to comply fully with all licensing obligations.

©ASC Signal Corporation www.ascsignal.com


Table of Contents

INTRODUCTION: How to Use This Manual 4 I.I Purpose & Overview 4

I.II Description 4

I.III Miscellaneous Notices 5

I.IV Warning Symbols 5

I.V Safety Terms Summary 5

I.VI Summary of Safety Precautions 6

I.VII Things to Never Do 7

I.VIII Parts Verification 7

1.0 Recommended Tools & Foundation Preparation 8 1.1 Recommended Tools 8

1.2 A-325 Tensioning Procedure 9

1.3 Foundation Preparation 10

1.4 7.6m Assembly & Installation Reference Drawings 10

2.0 Mount & Antenna Assembly Procedures 11 2.1 Assembly Sequence & Helpful Tips 11 2.2 General Subreflector Alignment Guidelines 12

3.0 Operation 13 3.1 Acquiring Satellites 13 3.2 Subreflector Adjustment 16

4.0 Preventive Maintenance 17 4.1 General Cleaning 17

4.1.1 Electrical Parts 17 4.1.2 Mechanical parts 17

4.2 Inspections 17 4.2.1 Local Control/Motor Drive Controller Inspection 18 4.2.2 Antenna Inspection 18 4.2.3 Drive System Voltage & Current Checks 19

4.3 Preservation & Lubrication of Component Parts 19

4.3.1 Preservation of Aluminum Parts 19

4.3.2 Preservation of Galvanized Surfaces 20 4.3.3 Lubrication 20

4.3.4 Lubrication of Jackscrews/Motors 20

4.3.5 Lubrication of Gear Motor/Housing Fill Drain Requirements 20

4.4 Site Acceptance Test Procedure 24

5.0 Corrective Maintenance & Troubleshooting 25 5.1 Top 5 ESA Maintenance & Troubleshooting FAQ 25 5.2 Corrective Painting Instructions 25

5.2.1 Preparatory Cleaning of Aluminum Surfaces 25 5.2.2 Priming Cleaned Aluminum Surfaces 25 5.2.3 Painting Primed Aluminum Surfaces 25 5.2.4 Prepping & Painting Galvanized Surfaces 26 5.2.5 Priming & Painting Cleaned Jack Surfaces 26

5.3 Removing Backlash via Jack Adjustment 26 5.4 Maintenance Kits 27


APPENDIX: Equipment Issues & Technical Support 28

List of Figures Figure 1-1a: Bolts Shorter than 4 Diameters 9

Figure 1-1b: Bolts Longer than 4 Diameters 9

Figure 1-2: Scraping Foundation Pads 10

Figure 3-1: Pure Noise Signal on Spectrum Analyzer 13 Figure 3-2: Minimum Transponder Signal on Spectrum Analyzer 13 Figure 3-3: Antenna Radiation Pattern Topographical Diagram w/ Plan View 14 Figure 3-4: Polarization at 45 Degrees from Optimum Setting 15 Figure 3-5: Maximizing Odd Transponders 15 Figure 3-6: Optimum Polarization Settings 15

Figure 4-1: High-Speed Antenna Lubrication Points 22

Figure 4-2: Medium-Speed Antenna Lubrication Points 23

Figure 5-1: Jac/Jack Anti-Backlash Procedure 27

List of Tables Table 1.1: Recommended Tools 8

Table 1.2: 7.6m Assembly & Installation Drawings 10

Table 4.1: Lubrication Chart 21

Table 5.1: Cure Times 26

Table 5.2: Maintenance Kits 27

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1.2 A-325 Tensioning Procedure

Throughout the installation instructions set forth in this manual, there will be references to the A-325 hardware tensioning procedure. A-325 hardware must be properly tensioned to avoid slippage between bolted surfaces under high loads. Slippage can cause the corresponding assembly to move or slip, resulting in antenna misalignment. Use of A-325 hardware eliminates slippage between mating surfaces under high loading conditions as well as the need for future retightening.

NOTE: A-325 tensioning is for final connections ONLY. NEVER LOOSEN OR REUSE A-325 HARDWARE.

Points to Keep in Mind: “Snug tight” is defined as tightness when plies of joint are in firm contact Do not proceed with felt-tip marker or tightening unless connection is final and will not be loosened again If after tensioning procedure the bolts are loose, discard them and replace with new hardware Do NOT use A-325 tensioning unless specifically called for by installation instructions

Figure 1-1a: Figure 1-1b:

Bolts Shorter than 4 Diameters Bolts Longer than 4 Diameters

A-325 hardware should be tightened according to the following tensioning procedure:

Step 1. Lubricate the bolts with provided wax stick to reduce friction

Step 2. Insert the bolt and add flat washer (if required). DO NOT allow wax to get under flat washer

Step 3. Add the nut, and tighten with your fingers

Step 4. After all connections are complete, tighten the bolts until surfaces are joined and nuts are snug (for example, as achieved by the full effort of a SINGLE person using a standard spud wrench)

NOTE: If A-325 bolts are loosened after Steps 5 and/or 6, discard & replace with NEW hardware

Step 5. Using a Felt-Tip Marker, mark the nuts and ends of the bolts with a straight line as shown above in Figures 1-1a (Bolts shorter than 4 diameters) and 1-1b (Bolts longer than 4 diameters)

Step 6. Tighten nuts even further, using an Extra-Long-Handled Wrench, until the nuts are:

Moved 1/3 TURN (120°) as shown in Figure 1-1a, shorter than 4 diameters (“After Tensioning”) Or 1/2 TURN (180°) as shown in Figure 1-1b, longer than 4 diameters (“After Tensioning”)

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2.2 General Subreflector Alignment Guidelines

The primary goal of Subreflector alignment is for the Subreflector to be properly centered and for the height to be adjusted to the correct focal length for the antenna.

Keep the following guidelines in mind during Subreflector alignment: A tape measure is generally used in order to center the Subreflector Measure from a repeatable location, running the tape measure from the 4 locations where the strut ends

meet the main reflector to the inside edge of the Subreflector For centering measurements, a zero delta between all is ideal Focal length is measured from the antenna vertex to the edge of the Subreflector at the three Adjustment

Rod locations on the Subreflector Target focal length distance is determined by antenna type Normally, the process of centering the Subreflector then the Subreflector height is repeated until both

centering and height are “nuts on” precise

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Page 13

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Step 2 of 9: With the antenna positioned in Azimuth, with the transponder signal maximized, follow the same procedure as in Step 1, only this time using the Elevation direction (scanning up-and-down). Once again, do this until the transponder signal has been maximized.

Step 3 of 9: Repeat this procedure, alternating between the Azimuth and Elevation excursions of the antenna, until you have peaked the antenna transponder amplitude. Transponder signal amplitude of 30 dB or greater from peak to average noise signal indicates that the

antenna is receiving the signal on the main beam. Transponder signal amplitude of less than 30 dB indicates the antenna is peaking on a side lobe of the main

beam.

Step 4 of 9: If the antenna is peaked on a side lobe in Az or El, move the antenna Azimuth while observing the Spectrum Analyzer screen, as illustrated below in Figure 3-3.

Figure 3-3: Antenna Radiation Pattern Topographical Diagram w/ Plan View

Step 5 of 9: If the signal amplitude diminishes and does not increase (position B) to the level that was noted when the antenna was peaked on a side lobe, then this means that the antenna is moving away from the main beam. Reverse the direction of antenna movement. From the original side lobe position (Position A), the signal amplitude should now diminish to a null point at

Position C (minimum amplitude showing only signal noise) and then symmetrically increase again to the same level at Position D as noted at Position A

At the null point (Position C), the antenna is aligned with the alternate (El) axis. If antenna was peaked on a side lobe in Azimuth, it was appropriately aligned with the El axis (go to Step 6).

If the antenna was peaked on a side lobe in Elevation, it was appropriately aligned with the Az axis (go to Step 6, moving the antenna in Azimuth rather than Elevation).

Step 6 of 9: Move the antenna in Elevation while observing the Spectrum Analyzer screen. If the signal amplitude increases, then decreases, and then increases again (but to a lesser value than the first increase), this means the antenna is moving in the wrong direction. Reverse direction of antenna movement. From the original null point, the signal level should increase and decrease alternately, but with increasing

amplitude until the transponder signal increases to a level of at least 30 dB, at which time it will be on the main beam. Continue to manually peak the signal to a maximum level, using Azimuth and Elevation adjustments.

Step 7 of 9: If antenna is aligned in Azimuth and Elevation (signal maximized) and a total of 24 transponder signals of relatively equal amplitude are NOT noted (12 horizontal + 12 vertical = 24), 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.

Step 8 of 9: Rotate the feed assembly clockwise until 24 transponder signals are noted and of approximately equal amplitude.


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

Figure 3-4: Polarization at 45 Degrees from Optimum Setting

Step 9 of 9: With all 24 transponder signals of approximately equal amplitude appearing on the Spectrum Analyzer screen, determine the specific antenna system and satellite parameters. Rotate the feed assembly as required until the appropriate (odd or even) transponder signals have been maximized.

Figure 3-5: Maximizing Odd Transponders

Figure 3-6: Optimum Polarization Settings


3.2 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 antenna. The following procedures should be followed if a subreflector adjustment is required to maximize optimum performance. NOTE: All INTELSAT Type Approved antennas do not require subreflector adjustment.

Before proceeding, the Azimuth and Elevation patterns should be conducted to determine any adjustments that need to be made. The goal is to achieve a high peak on the main lobe and even distances between the main lobe and sidelobes as shown in Figure 3-6. NOTE: No adjustments should be made in the receive band.

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

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

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

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 side lobes and top of main lobe) as shown in Figure 3-6.

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

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

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

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

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Page 17

Earth Statiures, and cleis manual.

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In the absence of any special inspection requirements, operational tests are the most effective means in isolating parts and assemblies requiring further inspection. During inspection, any noted damage and/or problematic condition which could preclude the continuation of proper operation (prior to the next scheduled inspection) should be recorded. These discrepancies should be immediately corrected (either by repair or replacement, as required), or dealt with immediately after the inspection procedure has been completed.

CAUTION: Allowing the antenna to continue to operate after damage or discrepancies have been noted during inspection may result in property damage (especially to your earth station antenna), as well as increase the risk of creating dangerous situations for personnel, causing personal injury and/or loss of life.

‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ 4.2.1 Local Control/Motor Drive Controller Inspection For details on inspections for the Local Control/Motor Drive Controller, refer to the appropriate antenna control documentation.

‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ 4.2.2 Antenna Inspection Inspection of the antenna generally conforms 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 as noted:

Inspect all wiring and cables, particularly the network-to-enclosure and enclosure-to-mount interfaces, for discolored and/or burned insulation, entry of water/moisture, corrosion, dirt, breaks, secure connections, and any other signs of damage or deterioration. Examine connections for dirt, corrosion, and mechanical defects. Check for loose or broken lacing, as well as cuts, braiding, dry rot, or cracks in insulation

Inspect all connectors for corrosion, broken inserts, and stripped threads. Inspect connector shells, checking for distortion and dents. Inspect contact pins for bends, misalignment, and/or other deformities. Check connector inserts for carbon tracking, burns, or charring, indicating arc-over

Check all electrical components for dirt, cracks, chips, breaks, discoloration, and any other signs of damage or deterioration. Discoloration, blistering, or burns are evidence of overload(s). Measure the actual value(s) of any suspect electrical components (as with a digital multimeter) and compare against value(s) in the product’s specifications

Operate the Azimuth and Elevation drives, as well as the feed rotation (if applicable) in both the plus and minus direction from the local control/motor drive controller at least once every three (3) months during antenna down time. Check to make sure the mechanical Hard Limit switches stop the antenna and feed movement, and limit travel to prevent structural interference and damage. Check the mechanical Hard Limit switches for corrosion and water entry. Check the arm on the feed limit switch for free movement, with no binding or interference. Be certain both of the feed rotation limit switch arms are not distorted and ride centrally on the actuating cam to open their corresponding Hard Limit switch

Inspect the Azimuth and Elevation Jackscrew boots for security of attachment at both ends, checking for abrasions, tears, cuts, dry rot, and other damage that might expose the jackscrew to environmental conditions (rain/water/ice, dust, etc.). Minor repairs can be made by resealing compromised areas with RTV-108 silicone rubber sealant

Visually inspect the feed window for dirt. Check the feed, feed supports, feed window, and reflector for distortion, foreign object damage, and environmental deterioration (due to snow/ice, rain, hail, high winds, etc.). Environmental deterioration can result in damage and/or deformation of both the electrical components and the structure

Check the cable attachment to the resolvers, to the LNA/LNB, and the enclosure-to-mount interface for security. Check the cable routing for secure hanger attachment. Check cable insulation for cuts, cracks, abrasions, and other signs of damage or deterioration. Check LNA/LNB and resolvers for secure mechanical attachments. Ensure there is proper torque in setscrews of Polarization drive gear box, and proper tensioning of corresponding drive chain assembly (if applicable)

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Page 19

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4.3.2 Preservation of Galvanized Surfaces 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 using fine grit sandpaper. Wipe the surface to be painted with a soft rag dampened with a small amount of acetone, 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. Acetone will dissolve paint if applied heavily and rubbed vigorously. Do not use bleach, soap solutions, or kerosene as it is difficult to remove the residue. Allow the clean surface to dry thoroughly before painting.

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

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

The following is a list of the lubricant characteristics: Lubrication Engineers (LE) 4622: LE4622 is Lithium complex grease. Operating temperature range is -

40 degrees to 400+ degrees Fahrenheit (-40 degrees to 204+ degrees Celsius).

Mobil SHC624: low temperature synthetic oil for worm gear reducers. Operating temperature range is -40 degrees to 125+ degrees Fahrenheit (-40 degrees to 52+ degrees Celsius).

Moly Grease: grease lubricant containing molybdenum disulfide. Operating temperature range is -85 degrees to 300+ degrees Fahrenheit (-29 degrees to 149+ degrees Celsius).

‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ 4.3.4 Lubrication of Jackscrews/Motors Periodically inspect lifting screws on jackscrew ballscrew assemblies to ensure adequate lubrication. Loosen Jackscrew ballscrew boot clamps to expose the lifting screw assembly. Fully extend jackscrew assembly being careful not to exceed preset mechanical limits. Brush thin coating of LE4622 grease on exposed lifting screw. Replace boot and attach corresponding boot clamps. If lifting screw is rusty, remove existing lubricant with solvent and wire brush rusted area. Rinse with solvent and apply fresh grease.

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

‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ 4.3.5 Lubrication of Gear Motor/Housing Fill Drain Requirements Lube points 2, 3, 7, & 8, as shown in the Lubrication Chart (Table 5.1), require removal of the indicated drain plugs and, by using a measuring cup, to collect and measure the amount of SHC624 oil that drains out. The specified amount of oil must be added to the gear motor/housing (after the drain plug has been reinstalled), using a supplied funnel to pour new oil into the fill/vent plug opening. The addition of oil requires the use of an appropriate filling utensil. Use of a modified level stick will NOT correctly gauge the appropriate amount of oil that is present in the gear housings.


Table 4.1: Lubrication Chart Lube Pt. #

Components to be Lubricated Frequency (Months)

1 3 6 12

Type of Service

Lube Type

#/Qty of Lube

Points 1 El Jackscrew Housing X Pressure Fitting LE4622 1 2 [*1] El Jackscrew Gear Housing Fill & Drain I* C** Pipe Plugs SHC624 10 Oz 3 [*2] El Drive Intermediate Gearbox I* C** I*/*** SHC624 34 Oz 4 El Jackscrew Pivot Pin, upper X Pressure Fitting LE4622 1 5 Az Jackscrew Pivot Pin, front X Pressure Fitting LE4622 1 6 Az Jackscrew Housing X Pressure Fitting LE4622 2 7 [*1] Az Jackscrew Gear Housing Fill & Drain I* C** Pipe Plugs SHC624 4 Oz 8 [*2] Az Drive Intermediate Gearbox I*/*** C** SHC624 34 Oz 9 Pol Drive Gear X Brush LE4622 Min. Surface

Coverage 10 Feed Rotation Worm Gear Pillow

Blocks X Pressure Fitting LE4622 2

X = Lubricate I = Inspect C = Change

* Inspection requires checking for visible signs of leakage. Drain, replace, and add oil to ensure appropriate level requirements. Excessively dirty oil requires replacement with fresh oil. In case of excessive oil leakage, refer to appropriate troubleshooting info. Periodic inspections can be less frequent after the second scheduled inspection is completed without problems. ** Initial oil change requirements include flushing gear boxes with a standard cleaning agent. *** For motors that have no visible drain or fill plugs no maintenance is required and just a general inspection for oil leakage *1. Type ‘HS’ & ‘STHS’ drives only: 10 Oz required for Gearbox on type ‘MS’ drives *2. Type ‘HS’ & ‘STHS’ drives only


Figure 4-1: High-Speed Antenna Lubrication Points


Figure 4-2: Medium-Speed Antenna Lubrication Points


4.4 Site Acceptance Test Procedure

Once the installation procedure has been completed, and prior to turning over the system to the station facility, some form of Site Acceptance Test procedure will need to be performed, checked off, and signed by the responsible personnel and/or representative.

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Page 25

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Page 26

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6 of 28

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Page 27

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7 of 28

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Page 28

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