Andrew 7.6-Meter ESA Technical information

Andrew 7.6-Meter ESA Technical information
7.6m Earth Station
Assembly, Installation,
Operations, & Maintenance
Document# OM76 – Revision J
ASC Signal Corporation
606 Beech Street
Whitby, Ontario, Canada
L1N 7T8
OM76_Rev J
1120 Jupiter Rd.
Ste. 102
Plano, TX 75074
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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
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
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 OM76_Rev J
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Table of Contents
INTRODUCTION: How to Use This Manual
Purpose & Overview
Miscellaneous Notices
Warning Symbols
Safety Terms Summary
Summary of Safety Precautions
Things to Never Do
Parts Verification
1.0 Recommended Tools & Foundation Preparation
Recommended Tools
A-325 Tensioning Procedure
Foundation Preparation
7.6m Assembly & Installation Reference Drawings
2.0 Mount & Antenna Assembly Procedures
2.1 Assembly Sequence & Helpful Tips
2.2 General Subreflector Alignment Guidelines
3.0 Operation
3.1 Acquiring Satellites
3.2 Subreflector Adjustment
4.0 Preventive Maintenance
4.1 General Cleaning
4.1.1 Electrical Parts
4.1.2 Mechanical parts
4.2 Inspections
4.2.1 Local Control/Motor Drive Controller Inspection
4.2.2 Antenna Inspection
4.2.3 Drive System Voltage & Current Checks
4.3 Preservation & Lubrication of Component Parts
4.3.1 Preservation of Aluminum Parts
4.3.2 Preservation of Galvanized Surfaces
4.3.3 Lubrication
4.3.4 Lubrication of Jackscrews/Motors
4.3.5 Lubrication of Gear Motor/Housing Fill Drain Requirements
4.4 Site Acceptance Test Procedure
5.0 Corrective Maintenance & Troubleshooting
5.1 Top 5 ESA Maintenance & Troubleshooting FAQ
5.2 Corrective Painting Instructions
5.2.1 Preparatory Cleaning of Aluminum Surfaces
5.2.2 Priming Cleaned Aluminum Surfaces
5.2.3 Painting Primed Aluminum Surfaces
5.2.4 Prepping & Painting Galvanized Surfaces
5.2.5 Priming & Painting Cleaned Jack Surfaces
5.3 Removing Backlash via Jack Adjustment
5.4 Maintenance Kits
APPENDIX: Equipment Issues & Technical Support
List of Figures
Figure 1-1a: Bolts Shorter than 4 Diameters
Figure 1-1b: Bolts Longer than 4 Diameters
Figure 1-2: Scraping Foundation Pads
Pure Noise Signal on Spectrum Analyzer
Minimum Transponder Signal on Spectrum Analyzer
Antenna Radiation Pattern Topographical Diagram w/ Plan View
Polarization at 45 Degrees from Optimum Setting
Maximizing Odd Transponders
Optimum Polarization Settings
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Figure 4-1: High-Speed Antenna Lubrication Points
Figure 4-2: Medium-Speed Antenna Lubrication Points
Figure 5-1: Jac/Jack Anti-Backlash Procedure
List of Tables
Table 1.1: Recommended Tools
Table 1.2: 7.6m Assembly & Installation Drawings
Table 4.1: Lubrication Chart
Table 5.1: Cure Times
Table 5.2: Maintenance Kits
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INTRODUCTION: How to Use This Manual
I.I Purpose & Overview
The scope of this manual is intended to provide station personnel with the base installation, operation, and
maintenance requirements necessary for a 7.6-Meter C-, X- or 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.
Top Level Assembly Numbers are as follows:
7.6m ESA C-Band: ES76C-1
7.6m ESA K-Band: ES76K-1
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ OVERVIEW
The installation, operation, and maintenance of the 7.6-Meter Earth Station Antenna require qualified and
experienced personnel. ASC Signal installation, operation, and maintenance instructions are illustrated for
such personnel. Additionally, the antenna should be inspected by qualified personnel to verify proper
installation, maintenance, and condition of equipment as described in Preventive Maintenance. The basic
equipment and accessories are either manufactured or design controlled by ASC Signal 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.
I.II Description
The 7.6-Meter Earth Station Antenna provides high gain and exceptional pattern characteristics. The electrical
performance and exceptional versatility provides the ability to configure the antenna with your choice of
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 reflective white paint.
The versatile tripod mount can be purchased with either manual or motorizable capabilities. The tripod mount
features 180 degree azimuth coverage in three continuous 120 degree overlapping ranges and executes 90
degree continuous elevation adjustment. This large adjustment range provides non-critical foundation
orientation and the ability to view geostationary satellites from horizon-to-horizon, from any location worldwide.
The motorizable tripod mount features self-aligning bearings for the elevation pivots, resulting in "zero"
backlash. This mount can be operated manually, but has the ability to be upgraded for motorized operation,
including step-tracking or 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 accuracy and ensures
durability and reliability. The antenna and standard manual mount with enclosure will survive 125 mph (200
km/h) wind, in any position of operation, without damage or permanent deformation in moderate
coastal/industrial areas. Severe conditions require additional protection.
ASC Signal Corporation provides complete system engineering if required.
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I.III Miscellaneous Notices
Proprietary Information
The technical data contained herein is proprietary to ASC Signal Corporation. It is intended for use in the
installation, operation, and maintenance of ASC Signal equipment. This data shall not be disclosed or
duplicated, in whole or in part, without the expressed written consent of ASC Signal Corporation.
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ Installation Notice
Installation, maintenance, or removal of the hardware described in this manual requires qualified and
experienced personnel. ASC Signal installation instructions are written for such personnel. Qualified
personnel MUST perform proper installation and maintenance of the equipment, and MUST verify the
condition of the equipment at initial installation and periodically thereafter.
NOTE: ASC Signal is NOT liable or responsible for results of improper or unsafe installation and maintenance practices.
All designs, specifications, and availability of products are subject to change without notice.
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ IMPORTANT: What to Know When You See OPTION:
Any time you see OPTION: this means that the information following it is related to an optional element (in
either hardware or software) that may or may not apply to the arrangement of your particular NGC Unit. Please
note that if you see an option that you do not have but would like to purchase, please contact ASC Signal.
I.IV Warning Symbols
Various components of this System may display safety symbols. Be sure to use extreme caution when
operating components with any of the following safety symbols:
Certains éléments du système montreront peut-être des symboles de sécurité. Faites très attention à faire
marcher tous les éléments qui tiennent les symboles de sécurité suivants:
I.V Safety Terms Summary
The following safety terms may appear on the product:
Les termes de sécurité suivants peuvent apparaître sur le produit:
DANGER—Indicates an immediately accessible injury hazard is present as you read the marking, and failure to take
precautions could result in loss of life
DANGER—Cette indication signale un risque de blessure immédiat et qui peut être mortel.
WARNING—Indicates a nearby injury hazard that is not immediately accessible as you read the markings, and failure to
take precautions could result in personal injury and/or loss of life
AVERTISSEMENT—Cette indication signale un risque de blessure non immédiat mais qui peut être mortel.
CAUTION—Indicates a potential hazard to property, including the product
PRUDENCE—Indique un risque pour l’environ du produit, le produit inclus.
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The following safety symbols and terms may be used in this manual:
Les symbols et les termes suivants de sûreté peuvant être employés en ce manuel:
WARNING!/CAUTION! Statements identify conditions & practices that could result in injury or loss of life.
AVERTISSEMENT! Les rapports d’avertissement identifient les conditions ou les pratiques qui pourraient avoir comme
conséquence les dommages ou la perte de la vie.
I.VI Summary of Safety Precautions
The following safety precautions are not related to any specific procedure, and so will not appear elsewhere in this
manual. Ensure all personnel understand & apply these precautions in all phases of installation, operation, &
maintenance. Failure to do so may result in loss of life.
KEEP AWAY FROM LIVE CIRCUITS: Personnel must observe all applicable safety regulations at all times.
Ensure power is disconnected or removed from the unit before replacing any components. Potential hazards may exist
even though the power control switch is in OFF position. Capacitors retain electrical charges. Always remove power &
use test equipment to confirm a circuit is at ground potential before touching it. Never reach into or enter an enclosure to
service or adjust the equipment until the absence of power has been confirmed.
DO NOT SERVICE OR ADJUST ALONE: Under NO circumstances should ANY person reach into or enter the
enclosure for the purpose of servicing or adjusting the equipment except in the presence of someone who is capable
of rendering aid in case of an accident/emergency.
RESUSCITATION: Personnel working with or near high voltage should be familiar with resuscitation methods
(CPR and/or AED). CPR info may be obtained from medical personnel. For AED (Automated External Defibrillator)
information, contact supervisor or hosting administration for details on the availability and/or location of an AED unit at
your worksite.
This equipment contains electrostatic discharge (ESD) sensitive devices. ESD sensitive equipment handling methods
must be used to prevent equipment damage during handling and servicing.
Refer to document “P/N 240117—Essential Health and Safety Requirements”.
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I.VII Things to Never Do
 NEVER touch circuits or reach into an enclosure until the disconnection of power and absence of charge has
been confirmed
 NEVER service or adjust equipment alone. Electric shock can lead to cardiac arrest. Presence of immediate
aid gives you a 90% chance of survival, but this drops by 10% with every passing minute. After 5
minutes resuscitation without permanent heart and/or brain damage is nearly impossible. Consider
this: Without the immediate aid of CPR or an AED, what are the odds you will be found and
successfully revived in less than 5 minutes?
 NEVER ignore warning symbols or fail to read safety signs
 NEVER skip steps in a sequence, unless specifically instructed to do so by the manual, software, and/or
authorized ASC Signal Tech Support Personnel. Aside from risking harm to yourself, you risk doing
permanent damage to the equipment
 NEVER touch or stand near any potentially moving parts (even if they are not in motion at the time) when the
unit is in operation or powered on, as they may move without warning
 NEVER stand underneath any object while it is being lifted
 NEVER stand in front of, inside of, or near the antenna or feed while the antenna is in operation, as severe
eye damage and/or bodily injury may result from exposure to Radio Frequency (RF) radiation.
 NEVER begin any task without first donning the proper safety equipment for the situation (hardhats, gloves,
goggles, etc.)
 NEVER remove, disable, or exceed the unit’s safety, software, security, or movement limits, unless
specifically instructed to do so by the manual, software, and/or authorized ASC Tech Support Personnel. The
careless disabling of such safeguards is one of the most common causes of serious equipment damage
during installation and operation
I.VIII 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. ASC Signal Corporation thoroughly inspects and
carefully packs all equipment before shipment. If you find that there are missing or damaged components,
please refer to the step-by-step instructions (located in back of this manual) on how to properly report
equipment loss or damage. When you have received your order, verify that all parts contained in the shipment
correspond to the parts listed on your packing slip/inventory.
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1.0 Recommended Tools & Foundation Preparation
The following sections will offer you with information related to preparing to assemble and install the 7.6m ESA,
such as recommended tools (Section 1.1) and foundation preparation (Section 1.3). The details of the A-325
tensioning procedure required for the tightening of all A-325 hardware will also be explained (Section 1.2).
1.1 Recommended Tools
ASC Signal supplies all appropriate hardware/parts required for installation of the 7.6M ESA. All tools needed
for the installation process, however, should be provided by the installation crew.
ASC Signal recommends the following tools, as shown in Table 1.1, be used for a proper installation of the
7.6M ESA.
Table 1.1: Recommended Tools
Open End or Combination Wrench
Nylon Web Slings (2000lb breaking strength)
Rope or Cord (2000lb breaking strength)
Drive Sockets
Breaker Bar
Spud Wrenches
Allen Wrench
Tape Measure (or other/similar measuring
Felt-tip Marker (or other/similar marking
Rubber Mallet
Pry Bar
Tin Snips
Safety Gloves
Wax Stick
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5/16 Inch
7/16 Inch
9/16 Inch
7/8 Inch
3/4 Inch
1/2 Inch
1-1/4 Inch
15 Ton Minimum Capacity,
extended end
3 Inch X 14 Foot
50 feet
5/8 Inch
10 Foot Extension Ladder
1/16 Inch
9/16 Inch
7/8 Inch
3/4 Inch
1-1/4 Inch
1/2 Inch
1-1/16 Inch
1-1/4 Inch
Standard / Flathead
7/64 Inch
3/16 Inch
1/4 Inch
1 (supplied)
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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:
Bolts Shorter than 4 Diameters
Figure 1-1b:
Bolts Longer than 4 Diameters
A-325 hardware should be tightened according to the following tensioning procedure:
Step 1.
Step 2.
Step 3.
Step 4.
Lubricate the bolts with provided wax stick to reduce friction
Insert the bolt and add flat washer (if required). DO NOT allow wax to get under flat washer
Add the nut, and tighten with your fingers
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”)
 1/2 TURN (180°) as shown in Figure 1-1b, longer than 4 diameters (“After Tensioning”)
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1.3 Foundation Preparation
Before beginning the installation process on the ground mount assembly, ensure that the foundation has been
prepared. Foundation specifications are provided by ASC Signal and may be used as a reference by civil
engineering personnel when preparing the foundation for local soil conditions. These specifications are
available before the shipment arrives by contacting the Customer Service Center or your Account Manager.
Foundation should be dimensioned as detailed in Mount Assembly Instructions (237151C, see Table 1.2)
Sweep foundation clear of any dirt or debris
To ensure smooth surface for mount, scrape foundation pads as shown in Figure 1-2
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
Figure 1-2: Scraping Foundation Pads
1.4 7.6m Assembly & Installation Reference Drawings
This section provides the ASC Signal document numbers of all the necessary instructions, drawings, and
schematics for the assembly of the 7.6m Antenna Reflector. As the procedures explained in this manual are
performed, be sure to refer to the appropriate drawing.
NOTE: It is important to match up the appropriate drawings listed in the below table to the antenna’s specific reflector type
(ES76C-1 = C-Band; ES76K-1 = Ku-Band). Refer to the Introduction, Section I.I, for Top Level Assembly Numbers if
Table 1.2: 7.6m Assembly & Installation Drawings/Instructions
7.6m Foundation Specifications
7.6m Theodolite Alignment Instructions
Reflector & Back Structure Installation
Medium Modular Mount Assembly
Feed Support Installation Instructions
Feed Rotation Drive Installation Instructions
Subreflector & Strut Installation Instructions
Azimuth Strut Arm Installation
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2.0 Mount & Antenna Assembly Procedures
These sections provide the basic sequence and tips for the assembly of various elements of the 7.6m ESA.
Appropriate drawings and schematics references for assembly of the antenna are also provided, when
applicable. Refer to the drawings, instructions, and schematics for the specific system being installed, per the
information provided in Table 1.2.
2.1 Assembly Sequence & Helpful Tips
ASC Signal recommends following these helpful tips regarding the sequence of assembly:
 Always use the correct provided hardware and use the appropriate sequence for tightening/torque, as per
the instructions provided with the part or kit being assembled and/or installed (as listed in Table 1.2).
 As a rule, never fully tighten A-325 type hardware (see Section 1.2) unless instructed to do so by
instructions. Once tightened, A-325 cannot be loosened. If loosened, it must be replaced with new A-325
 Assemble the Mount per the instruction up to Section 6.6 in 237151C, then move on to reflector assembly
before continuing on to Section 7.0 in 237151C.
 The Mount should be assembled at ground level before beginning any hoisting with crane.
 The Reflector & Back Structure should be assembled at ground level before beginning any hoisting with
 Theodolite Alignment is included in the below sequence, but is required for the ES76K-1 only. If
assembling/installing an ES76C-1 type antenna, do not proceed with Theodolite Alignment.
 Theodolite Alignment should be performed at ground level level before beginning any hoisting with
 During assembly of the Azimuth Jackscrew, ensure that the Azimuth Jackscrew assembly is in the fully
retracted position.
 During Panning Frame assembly, insert bolts from the inside of the Panning Frame.
 During hoisting (with crane) of the Motor/Jack Assembly, do NOT attach any ropes to the Small Motor.
 Always attach hoisting ropes in such a way that moving parts will not drop/rotate when lifted.
 Realignment of the Panning Frame/Pivot Assembly may be necessary to ensure proper alignment of the
Azimuth Jackscrew pin. Make snug the Panning Frame/Pivot Assembly hardware and fully extend the
Azimuth Jackscrew so that binding does not occur along the full range of the Azimuth Pivot.
The following steps represent the recommended (but not required) basic sequence of assembly for this
NOTE: More steps may be required, in addition to those listed below, depending on the antenna type and/or the presence
of particular options. Refer to Table 1.2 to locate document numbers for the system being installed. Such documents will
be provided in the shipment of each part, kit, and/or option.
1. Mount Assembly: Refer to instructions per document 237151C
2. Reflector & Back Structure Assembly: Refer to instructions per document 239501 (ES76C-1) or 239908
3. Feed Support Installation: Refer to instructions per document 240159
4. Theodolite & Alignment: Refer to instructions per document 239611A (for ES76K-1 antennas ONLY)
5. Feed Rotation Drive Installation: Refer to instructions per document 239954
6. Subreflector Assembly & Installation: Refer to instructions per document 239906 (ES76C-1) or 239909
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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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3.0 Operation
After completing the assembly of the antenna, the 7.6m ESA is ready to become operational. To operate the
7.6m ESA, it is necessary to direct it to the desired satellite and adjust both Elevation and Azimuth angles
appropriately. These procedures provide details on how to correctly position the antenna on a desired satellite.
NOTE: If intending to use an ASC Signal NGC Indoor Unit (NGC-IDU) or NGC Outdoor Unit (NGC-ODU) in order to
control antenna, it is best to refer to the appropriate manuals of the NGC Documentation Package received with that unit. 3.1 Acquiring Satellites
There are a number of possible procedures for acquiring a satellite. ASC Signal recommends that a Spectrum
Analyzer of some type be used, regardless of your chosen procedure.
While viewing any Spectrum Analyzer screen, a pure noise signal will likely be observed, as shown below in
Figure 3-1. Additionally, some transponder signals may be observed above the noise signal, as shown below
in Figure 3-2.
Figure 3-1: Pure Noise Signal on Spectrum Analyzer
Figure 3-2: Minimum Transponder Signal on Spectrum Analyzer
Use the following steps in order to acquire a satellite:
Step 1 of 9: Manually move the antenna in the Azimuth direction (scanning back-and-forth) to achieve a
maximum transponder signal with the greatest amplitude
 Scan in one direction until amplitude continues to diminish, and then scan in opposite direction until the same
 Return to the position yielding the greatest amplitude
 The maximum Azimuth excursion from the original setting should not exceed +/- 1.5 Degrees, or the antenna
may begin to access a different satellite than the one desired.
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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
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
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.
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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
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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. OM76_Rev J
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4.0 Preventive Maintenance
These sections contain periodic preventative maintenance instructions for the 7.6m Earth Station Antenna.
Included are instructions for performing inspections, preventative maintenance procedures, and cleaning.
NOTE: Refer to applicable vendor manuals for any repair procedures that are not included in this manual.
These sections describe cleaning, inspections, and preventative maintenance procedures. Regularly replacing
normally functioning assemblies or components as a preventative measure is not required. Malfunctions of this
ESA can normally be traced to components and/or parts through the use of troubleshooting procedures.
4.1 General Cleaning
To prevent excessive accumulation of dust and dirt, as well as to ensure the removal of various contaminants,
the equipment needs to be thoroughly cleaned. It is recommended that you clean the antenna every time you
conduct a visual inspection of the components. No special cleaning procedures are required. However, to
ensure trouble-free operation you will need to clean in accordance with procedures in Sections 4.1.1 & 4.1.2.
­ ­ ­ ­ 4.1.1 Electrical Parts
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ CAUTION: Confirm ALL ELECTRICAL POWER IS REMOVED BEFORE proceeding.
Minor cleaning, such as the removal of dust and loose foreign particles, can be accomplished by one or all
of the following methods:
 Vacuuming
 Using a soft-bristle brush or lint-free cloth
 Using an air compressor, with dry air at a LOW PRESSURE (between 5 and 25 psi), to blow out dust
and dirt
NOTE: When using air to clear contaminants, take extreme care when blowing air stream on or near ANY delicate parts.
To remove imbedded dirt, grease, and/or oil from electrical parts:
 Use a 50% solution of Isopropyl “rubbing” alcohol
 Apply to surface with a soft-bristle brush
NOTE: At times, it may be necessary to brush some parts vigorously with a stiff bristle brush in order to remove imbedded
or hardened dirt particles.
NOTE: After cleaning, ALLOW CLEANED PARTS TO DRY FOR 10-15 MINUTES before restoring power and/or
returning equipment to operation.
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ 4.1.2 Mechanical parts
Cleaning of mechanical parts begins by removing dust, dirt, and other loose contaminants with a scraper,
stiff-bristle brush (or wire brush in cases of rust or corrosion removal), lint-free cloth, or compressed air
(pressure between 25 and 40 psi). Any accumulation of imbedded dirt, corrosion, grease, or oil deposits
which require more cleaning may be removed with a stiff-bristle or wire brush, along with a cleaning solvent
such as trichloroethylene (or equivalent).
NOTE: After cleaning, ALLOW CLEANED PARTS TO DRY FOR 10-15 MINUTES before restoring power and/or
returning equipment to operation.
4.2 Inspections
The frequency of inspection is contingent upon the user’s individual standards and the operational environment
in which the earth station antenna is located. However, a visual inspection of the components should be
performed at least semi-annually. Where there are no established wear limits, perform a visual inspection to
locate worn or damaged parts that could result in a malfunction of the earth station antenna. It is recommended
that the mechanical and electrical inspections be performed on the assembled or partially disassembled
equipment to determine the extent of disassembly required prior to completely disassembling a component or
module that is suspected of malfunctioning.
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.
OM76_Rev J
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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)
 IF APPLICABLE, check that drain holes in bottom of the enclosure and pedestal are not obstructed, and
there is no evidence of water accumulation. Check enclosure doors for proper closure. Verify door seals
are intact and free of tears, abrasions, and/or other damage. Check that all other seals are intact, and
repair with coating of RTV-108 silicone rubber sealant as needed to seal exposed electrical fittings, bolt
holes, and/or any other points of possible water entry to electrical components to maintain a waterproof
condition. If enclosure has a vent fan, inspect fan blade for freedom of operation. Fan bearings are
permanently lubricated. However, any binding, abnormal noises, and/or vibration means replacement of
the fan assembly is needed. Check fan filter element and, dirty or obstructed with dust, replace it.
OM76_Rev J
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 Visually inspect all mechanical parts for freedom of operation with no misalignment, binding, or
interference. Check all cabling for sufficient slack in order to prevent cable strain while still providing
enough restraint to adequately prevent abrasions and/or chaffing during antenna and feed movement
 Check antenna mounting and interconnecting assembly hardware for security. Verify that all electrical
grounding connections (including cross-axis grounding straps) are intact and secure, free of corrosion or
breaks. Use a wire brush to thoroughly clean any noticeably corroded portions of grounding cables, the
un-plated portion of universal terminals, and corresponding mounting surfaces. ANY LOOSE A-325
installation and, once loosened, will not maintain the required high strength friction connection. All other
(not A-325) assembly and installation hardware should be tightened to its original torqued condition.
When installing new structural hardware, do not use a wrench with a lever arm longer than two (2) feet
 Examine all painted aluminum or galvanized surfaces for chips, cracks, or deep gouges, and touch-up
spots as needed
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ 4.2.3 Drive System Voltage & Current Checks
For details on Drive System Voltage and Current Checks, refer to the appropriate antenna control
4.3 Preservation & Lubrication of Component Parts
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ 4.3.1 Preservation of Aluminum Parts
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 using fine grit sandpaper. Wipe the surface to be painted with a soft rag
dampened in trichloroethylene, lacquer thinner or equal. Be certain to remove all loose paint, corrosion,
imbedded dirt, grease, and oil deposits or the paint will not adhere to the surface. Lacquer thinner will
dissolve paint if applied heavily and rubbed vigorously. The reflector may be washed with plain water if
necessary. Do not use bleach, soap solutions, or kerosene as it is difficult to remove the residue. Allow the
cleaned surface to dry thoroughly before priming.
Prime the cleaned surface by applying zinc chromate primer. The primer can be applied with a brush,
roller, or pressurized spray. If necessary, thin the primer with lacquer thinner to the proper consistency.
Feather the primer onto the adjacent painted surfaces. Allow primer to thoroughly dry before applying the
finish paint coat.
Paint all RF surfaces, such as the inside of the main reflector and subreflector with highly-reflective white
paint. This type of paint disperses light rays, reducing the focusing effect of the sun’s radiation, thereby
reducing heat build-up caused by the focused sunrays on the feed system. Rear surfaces of the reflector
and subreflector may be painted with 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.
­ ­ ­ ­ ­ ­ ­ ­ 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 in trichloroethylene, lacquer thinner, or equal. Be certain to remove all loose paint,
corrosion, imbedded dirt, grease, and oil deposits or the paint will not adhere to the surface. Lacquer
thinner will dissolve paint if applied heavily and rubbed vigorously. Do not use bleach, soap solutions, or
kerosene as it is difficult to remove the residue. Allow the clean surface to dry thoroughly before painting.
Paint the cleaned surface with a 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.
OM76_Rev J
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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.
OM76_Rev J
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Table 4.1: Lubrication Chart
Pt. #
Components to be Lubricated
2 [*1]
3 [*2]
7 [*1]
8 [*2]
El Jackscrew Housing
El Jackscrew Gear Housing Fill & Drain
El Drive Intermediate Gearbox
El Jackscrew Pivot Pin, upper
Az Jackscrew Pivot Pin, front
Az Jackscrew Housing
Az Jackscrew Gear Housing Fill & Drain
Az Drive Intermediate Gearbox
Pol Drive Gear
Feed Rotation Worm Gear Pillow
X = Lubricate
I = Inspect
I*/*** C**
Type of
#/Qty of
Pressure Fitting
Pipe Plugs
Pressure Fitting
10 Oz
34 Oz
4 Oz
34 Oz
Min. Surface
Pressure Fitting
Pressure Fitting
Pressure Fitting
Pipe Plugs
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
** 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
OM76_Rev J
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Figure 4-1: High-Speed Antenna Lubrication Points
OM76_Rev J
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Figure 4-2: Medium-Speed Antenna Lubrication Points
OM76_Rev J
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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.
5.0 Corrective Maintenance & Troubleshooting
The following sections will offer information, instructions, and guidelines regarding issues of corrective
maintenance such as painting, backlash adjustment, and maintenance kits.
5.1 Top 5 ESA Maintenance & Troubleshooting FAQ
1. What should be done about chips, cracks, scratches, etc., in the paint of the reflector and/or other
ESA surfaces?
Priming and/or painting certain surfaces of the ESA is permitted and advisable under specific conditions such
as gouges, scratches, etc. in the surface of the reflector paint (refer to Section 5.2 for detailed instructions).
2. How can I remove Backlash?
Backlash is removed by performing anti-backlash Jack Adjustment (for detailed instructions, see Section 5.3)
3. Are there any particular kits available for purposes of maintenance?
A number of maintenance kits are available for this particular antenna. A list of these kits may be found in
Table 5.1 (refer to Section 5.4).
4. Are there any particular precautions that can be taken to avoid damaging the feed window?
All ASC Signal ESA feed windows are rated at .5 psi. This means placing any pressure on the feed window of
more than .5 psi is likely to cause permanent damage to feed window, which will require replacement.
5. What is the proper stow procedure for the 7.6m antenna?
In order to move the antenna to stow position, point the antenna to an Elevation angle of 35° (± 3°). The
Azimuth jackscrew should be placed in the center of its travel. In preparation for extreme winds, such as the
approach of a hurricane, antenna should be moved to this position. Stow positioning must be performed
before wind speeds reach 45mph.
5.2 Corrective Painting Instructions
The following sections offer detailed instructions for corrective painting of particular surfaces on the Earth
Station Antenna. Please keep in mind that only qualified personnel should be allowed to perform these
procedures. Also, be certain to read all of the following sections thoroughly BEFORE proceeding.
­ ­ ­ ­ ­ ­ ­ ­ ­ 5.2.1 Preparatory Cleaning of Aluminum Surfaces
­ ­ ­ ­ ­ Remove all loose paint and/or rust from the surface to be painted using a scraper, wire brush, or steel
wool. If steel wool is used, take care to ensure that none of it is left on the reflector or feed horn window
after cleaning (steel wool tends to leave behind particles). Wipe the surface to be painted with lacquer
thinner using a soft rag. However, keep in mind that the lacquer thinner will also dissolve the surrounding
paint if used too heavily and/or rubbed too hard. Paint edges can be blended to the metal using very fine
grit sandpaper. If necessary, the surface of the reflector may be washed clean using plain water.
IMPORTANT NOTE: Do NOT use bleach, soap, cleaning solutions, or kerosene, as these substances leave behind
residue that is difficult to remove.
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ 5.2.2 Priming Cleaned Aluminum Surfaces
Apply a thin coat (approximately .5 to 1 mil) of primer and feather paint it onto the adjacent painted areas.
Allow the primer to dry thoroughly (4-5 hours, depending on environmental conditions) before applying a
finish coat of primer.
Allow the finish coat of primer to dry thoroughly (8-12 hours) before proceeding.
5.2.3 Painting Primed Aluminum Surfaces
OM76_Rev J
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For antenna surfaces, such as the front or back of the main reflector or subreflector, high-reflectivity white
paint should be used. This type of paint disperses light rays. The paint may be applied to the prepared area
using a brush, roller, or sprayer. If a sprayer is used, be sure to first thin the paint to a proper consistency
with paint thinner (10-15% thinner).
Thoroughly cover all previously primed areas with paint and blend the paint with any preexisting painted
5.2.4 Prepping & Painting Galvanized Surfaces
 Remove all loose paint or rust using a scraper, wire brush, or sanding.
 Wipe clean the surface to be painted with a soft cloth rag and lacquer thinner.
 Allow the lacquer thinner to dry thoroughly before applying the finish coat of primer.
 Apply a zinc-rich paint as the final finish, thoroughly covering any previously primed surfaces.
­ ­ ­ ­ ­ ­ ­ ­ ­ 5.2.5 Priming & Painting Cleaned Jack Surfaces
­ ­ ­ ­ ­ Be sure to read ALL of the following instructions/guidelines BEFORE proceeding:
Surface Preparation – Use lacquer thinner and a soft cloth rag to remove all grease from the surface to be
Mixing – Use a power mixer to bring the paint to a uniform consistency before using.
Thinning – In the case of Jack Surfaces, thinning the paint is not normally required for most brush, roller,
or sprayer applications.
Using a Brush or Roller – Using a foam brush, apply paint to surface with full, single strokes. Avoid any
re-brushing. Using a medium nap roller apply paint to surface in long, single rolls. Avoid rerolling. The
recommended dry film thickness per coat is 2 mils (50 micron).
Allow Each Coat to Dry Thoroughly – Use the below chart (Table 5.1) to determine drying times. These
times are based on a 2 mil (50 micron) dry film thickness. Conditions such as higher film thickness,
insufficient ventilation, and/or cooler temperatures will likely require cure times to be extended. Allow the
primer to dry thoroughly before applying the topcoat. Application of the topcoat should be done based on
the above instructions.
Table 5.1: Cure Times
75° F (24° C)
75° F (24° C)
4 hours (Primer)
5 Hours (Topcoat)
12 hours
24 hours
8 hours
5.3 Removing Backlash via Jack Adjustment
The backlash removal feature is a factory setting and does not normally require any additional adjustment.
However, as time and extended use can lead to the development of wear, it may eventually become necessary
to perform a Jac/Jack Anti-Backlash Adjustment in order to reduce/remove backlash.
Use the following procedure for Jac/Jack Anti-Backlash Adjustment:
1. Loosen the Locknut (item b in Figure 5-1).
2. Loosen the Setscrews (item c in Figure 5-1).
3. In order to reduce backlash, rotate the Adjusting Cap (item a in Figure 5-1) in a clockwise direction until
able to feel resistance.
NOTE: Do NOT over-tighten the Adjusting Cap.
4. Using a felt-tip marker (or equivalent), place a reference mark between the thread on the Adjusting Cap
and the Housing.
5. Rotate the Adjusting Cap (item a) in a counterclockwise direction, in an amount equal to Dimension A
(labeled “A” in Figure 5-1) on the o.d. of the threads (match Jac/Jack model type, using the chart provided
in Figure 5-1).
6. Tighten the Setscrews.
OM76_Rev J
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7. While holding the Adjusting Cap (item a) stationary, tighten the Locknut (item b).
8. Operate the Jack through the entire stroke, checking for tight spots.
NOTE: If Jac/Jack has been used over only a portion of its stroke, the backlash should be adjusted in the least worn
portion of the screw.
CAUTION: Take special care not to over-tighten the anti-backlash system. Doing so may result in binding and/or
lockup between the drive nut and the lifting screw. Over-tightening can also result in a destructive heat buildup and/or
operational failure.
Figure 5-1: Jac/Jack Anti-Backlash Procedure
5.4 Maintenance Kits
The below table provides descriptions of and ASC Signal part numbers for commonly used maintenance kits:
Table 5.2: Maintenance Kits
Part #
OM76_Rev J
Ku-Band Feed Window Kit
C-Band Feed Window Kit
Lubrication Kit (Medium Modular Mount)
For 5.6m – 9.3m sized ESAs
Page 26 of 28
APPENDIX: Equipment Issues & Technical Support
If you find equipment was damaged during the shipping process, file a claim with the carrier. Follow the “Reporting Visible
Loss or Damage” or “Reporting Concealed Damage” procedures to file a claim with a carrier.
Make a note of any loss or evidence of external damage on the freight bill or receipt, and have it signed by the carrier’s
agent. Failure to adequately describe such external evidence of loss or damage may result in the carrier refusing to honor
a damage claim. The form required to file such a claim will be supplied by the carrier.
Concealed damage means damage which does not become apparent until the unit has been unpacked. The contents
may be damaged in transit due to rough handling, even though the carton may not show external damage. If you discover
damage after unpacking the unit, make a written request for an inspection by the carrier’s agent, then file a claim with the
carrier since such damage is most likely the carrier’s responsibility.
After opening your shipment, you should take inventory of the parts immediately. Check each item received in your
shipment against the packing slip included with the shipment. If any items are missing, please notify ASC Signal
Corporation immediately by contacting Customer Service.
ASC Signal strives to ensure all items arrive safe and in working order. Despite these efforts, equipment is at times
received with damage or faults. When this occurs, it may be necessary to return some items to ASC Signal for either
repair or replacement. Returns can be expedited using the following procedure:
Step 1: Call the ASC Signal Technical Support and request a Return Material Authorization (RMA) number, as well as the
address to which you should forward the material(s)
Step 2: Tag or identify the defective equipment, noting the defect or circumstances. Also, be sure to write the RMA
number on the outside of the carton. It would be helpful to reference the ASC Signal sales order and purchase order
number, as well as the date the equipment was received
Step 3: Pack the equipment in the original container with protective packing material. If the original container and packing
material are no longer available, pack the equipment in a sturdy corrugated box and cushion it with appropriate packing
Step 4: Be sure to include the following information when returning the equipment:
• Company Name, Address (City, State and Zip Code), and Telephone Number
• RMA Number*
• Problem/Damage Description**
• Contact Name
* 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.
** All installation, adjustment and operational information must be strictly adhered to in order to achieve warranted
performance specifications.
Step 5: Ship the equipment to ASC Signal 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 ASC Signal Customer Service
For technical support, contact information, and/or technical documentation:
ASC Signal Corporate Website:
ASC Tech Support Phone: (214) 291-7659
ASC Tech Support Email: [email protected]
ASC Signal Corporation
1120 N Jupiter Road, Suite 102
Plano TX 75074
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