0018110003100ma01 A 0

Installation, Operation and Maintenance Technical Manual for SAAR
20VV Model 12 Pedestal

Antenna Drive System SAAR 20VV
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3 A/0 8 A/0
4 A/0 9 A/0
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A/0 15/12/2009 All Initial edition
HOJA DE DISTRIBUCIÓN
Distribution sheet
Nº
Copia Empresa / Organismo Departamento Nombre y Apellidos
Copy Company / Organization Department Name and surname
no.
II Doc.Nº: 0018110003100MA01
Edic./Rev.: A/0
Fecha / Date: 15/12/2009
ÍNDICE GENERAL
Table of contents
Capítulo Descripción Página

Chapter Description Page
1. INTRODUCTION .......................................................................................................................... 1-1

2. PURPOSE .................................................................................................................................... 2-1
3. SCOPE ......................................................................................................................................... 3-1
4. DOCUMENTS ............................................................................................................................... 4-1
4.1 APPLICABLE DOCUMENTS ................................................................................................. 4-1
4.2 REFERENCE DOCUMENTS .................................................................................................. 4-1
5. DEFINITIONS AND ACRONYMS ................................................................................................ 5-1
5.1 DEFINITIONS .......................................................................................................................... 5-1
5.2 ACRONYMS ............................................................................................................................ 5-1
6. DESCRIPTION ............................................................................................................................. 6-1
6.1 FIXED BOX ............................................................................................................................. 6-3
6.1.1 Connector panel for the fixed part.................................................................................. 6-3
6.2 TURNTABLE ........................................................................................................................... 6-4
6.3 MOVEMENT TRANSMISSION SYSTEM ............................................................................... 6-6
6.3.1 Bearing ring ...................................................................................................................... 6-6
6.3.2 Energy Transmission Group (GTE) ................................................................................ 6-6
6.4 ANGULAR INFORMATION TRANSMISSION SYSTEM ....................................................... 6-9
6.4.1 Encoder ............................................................................................................................. 6-9
6.4.2 Angular information system cabling ............................................................................ 6-10
6.5 ROTARY JOINT .................................................................................................................... 6-10
6.6 SLIP RINGS .......................................................................................................................... 6-11
6.7 PEDESTAL CONNECTION PANEL ..................................................................................... 6-12
6.8 GREASING............................................................................................................................ 6-15
6.9 PEDESTAL AIR CONDITIONING......................................................................................... 6-15
6.10 ANTENNA BLOCK ............................................................................................................... 6-16
7. DRIVE SYSTEM INSTALLATION ............................................................................................... 7-1
7.1 MECHANICAL INSTALLATION OF THE PEDESTAL .......................................................... 7-1
7.1.1 Site requirements ............................................................................................................. 7-1
7.1.2 Pedestal anchoring and lift ............................................................................................. 7-1
Doc.Nº: 0018110003100MA01 III

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Fecha / Date: 15/12/2009
ÍNDICE GENERAL
Table of contents
Capítulo Descripción Página

Chapter Description Page
7.1.3 Location of the pedestal in its position .......................................................................... 7-2
7.1.4 Screws and coupling torque ........................................................................................... 7-2
8. REPARING AND REPLACEMENT OF SYSTEM ELEMENTS ................................................... 8-1
8.1 REPLACEABLE ELEMENTS ................................................................................................. 8-1
8.1.1 Energy Transmission Group (GTE) ................................................................................ 8-1
8.1.2 Rotary joint ........................................................................................................................ 8-3
8.1.3 Encoders ........................................................................................................................... 8-6
8.1.4 Fans.................................................................................................................................... 8-8
8.1.5 Thermostats .................................................................................................................... 8-10
9. PREVENTIVE MAINTENANCE.................................................................................................... 9-1
9.1 BEARING RING MAINTENANCE........................................................................................... 9-1
9.2 MAINTENANCE OF THE ENCODER MECHANICS .............................................................. 9-6
9.3 MAINTENANCE OF THE MOTOR/GEARBOX ...................................................................... 9-7
9.4 VIBRATIONS ........................................................................................................................... 9-8
9.5 SYSTEM MAINTENANCE PLAN.......................................................................................... 9-10
IV Doc.Nº: 0018110003100MA01
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ÍNDICE TABLAS
Tables index
Descripción Página
Description Page
Table 7.1.1-1 Dynamic forces ............................................................................................................................... 7-1
Table 8.1.5-1 Thermostat terminals .................................................................................................................... 8-11
Table 9.5-1 Maintenance plan ............................................................................................................................ 9-10
Doc.Nº: 0018110003100MA01 V
Edic./Rev.: A/0
Fecha / Date: 15/12/2009
ÍNDICE FIGURAS
Figures index
Description Page
Figure 6-1 Pedestal ............................................................................................................................................... 6-1
Figure 6-2 Pedestal Interior ................................................................................................................................... 6-2
Figure 6-3 Mechanical Interfaces .......................................................................................................................... 6-2
Figure 6.1-1 Fixed Box .......................................................................................................................................... 6-3
Figure 6.1.1-1 Connector panel in pedestal base.................................................................................................. 6-4
Figure 6.2-1 Turntable ........................................................................................................................................... 6-5
Figure 6.2-2 Turntable connectors panel .............................................................................................................. 6-5
Figure 6.3.1-1 Bearing ring.................................................................................................................................... 6-6
Figure 6.3.2.2-1 Installation position and detail of exhaust valve and level plug ................................................... 6-7
Figure 6.3.2.2-2 Anchoring of the Motor/Gearbox set to the Fixed Box ................................................................ 6-8
Figure 6.3.2.3-1 Pinion .......................................................................................................................................... 6-8
Figure 6.4-1 Location of the encoder mechanics .................................................................................................. 6-9
Figure 6.4.2-1 Angular information system cabling ............................................................................................. 6-10
Figure 6.5-1 Rotary joint ...................................................................................................................................... 6-11
Figure 6.5-2 Installed rotary joint ......................................................................................................................... 6-11
Figure 6.6-1 Rings installed in the Turntable ....................................................................................................... 6-12
Figure 6.7-1 Pedestal connection panel with thermostats ................................................................................... 6-13
Figure 6.7-2 Pedestal interior diagram ................................................................................................................ 6-14
Figure 6.8-1 Automatic lubricator support ........................................................................................................... 6-15
Figure 6.9-1 Pedestal air conditioning elements ................................................................................................. 6-16
Figure 6.10-1 Antenna block interface piece/Risk to get caught ......................................................................... 6-17
Figure 7.1.2-1 Lifting of the Pedestal/Location layout of the lifting points .............................................................. 7-2
Figure 8.1.1-1 Disassembly of the set ................................................................................................................... 8-2
Figure 8.1.1-2 Detail of the Motor-Gearbox fixing screws ..................................................................................... 8-2
Figure 8.1.2-1 ½” RF wires.................................................................................................................................... 8-4
Figure 8.1.2-2 Screws that fix the joint to the flange ............................................................................................. 8-4
Figure 8.1.2-3 Position of the wires that go to the rotary joint ............................................................................... 8-5
Figure 8.1.2-4 Notch to install the stub of the rotary joint ...................................................................................... 8-6
Figure 8.1.2-5 Applying the screw-fixer ................................................................................................................. 8-6
Figure 8.1.3-1 Detail of the encoder to disassemble ............................................................................................. 8-7
Figure 8.1.4-1 Connector for fans ......................................................................................................................... 8-8
VI Doc.Nº: 0018110003100MA01
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Fecha / Date: 15/12/2009
ÍNDICE FIGURAS
Figures index
Description Page
Figure 8.1.4-2 Connection with Faston terminals in the fan .................................................................................. 8-8
Figure 8.1.4-3 Fan fixing screws ........................................................................................................................... 8-9
Figure 8.1.4-4 Fan (Air direction) .......................................................................................................................... 8-9
Figure 8.1.5-1 Connection panel with thermostat................................................................................................ 8-10
Figure 8.1.5-2 Thermostat cabling ...................................................................................................................... 8-11
Figure 9.1-1 Manually greaser details ................................................................................................................... 9-2
Figure 9.1-2 Automatic lubricator .......................................................................................................................... 9-3
Figure 9.1-3 Register lid of the mobile housing ..................................................................................................... 9-4
Figure 9.1-4 Automatic lubrication of the bearing ring teeth .................................................................................. 9-4
Figure 9.1-5 Greasing of the internal and external labyrinth ................................................................................. 9-5
Figure 9.1-6 Detail of the external labyrinth greasing point ................................................................................... 9-5
Figure 9.2-1 Detail of the greasing points of bearings and gears .......................................................................... 9-6
Figure 9.3-1 Gearbox oil plugs .............................................................................................................................. 9-8
Figure 9.4-1 Pedestal vibration reading reference ................................................................................................ 9-9
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VIII Doc.Nº: 0018110003100MA01

Edic./Rev.: A/0
Fecha / Date: 15/12/2009
1. INTRODUCTION
SAAR 20VV Model 12 Pedestal provides movement to the Antenna Drive System and angular information
to the radar in order to place the antenna position.
Doc.Nº: 0018110003100MA01 Capítulo / Chapter 1

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Capítulo / Chapter 1 Doc.Nº: 0018110003100MA01

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2. PURPOSE
This manual provides information for the installation, operation and maintenance of the Pedestal with
two motors.
In the pedestal there are the following functional groups:
1. Movement transmission group (motors and reducers).
2. Angular information transmission group.
3. Rotary joint.

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3. SCOPE
This document establishes and defines the information required for the installation, operation, and
maintenance of the Pedestal with two motors, P/N 0018110003100, belonging to the SAAR-20VV
Antenna Drive System, model 12, P/N 0018100001100.

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4. DOCUMENTS
The following documents, in their latest approved edition/revision are applicable to the extension
indicated in this document, except otherwise indicated.
4.1 APPLICABLE DOCUMENTS
REF. DESCRIPTION CODE / REV.
Product specification for the SAAR 20VV MOD12 Radar Antenna Drive 0018100000700AT01_Ed.1/Rev.0
[1]
System P/N: 0018100000700
Factory Acceptance Test for the SAAR 20VV MOD12 Radar Antenna 0018100000700AT01_Ed.1/Rev.0
[2]
Drive System P/N: 0018100000700
4.2 REFERENCE DOCUMENTS
REF. DESCRIPTION CODE / REV.
Reliability, Maintainability and Availability analysis for Antenna Drive

[3] 0018100000700IF01_Ed.1/Rev.0
System SAAR 20VV Mod.12
[4] Recommended Spare List for Antenna Drive System SAAR 20VV Mod.12 0018100000700IF02_Ed.1/Rev.0
Description, Installation, Operation and Maintenance Manual for SAAR

[5] 0018129011900MA00_Ed.A/Rev.0
20VV Mode 12 Control Box. P/N: 0018129011900
Control de Interfaces del Sistema de Arrastre de Antena Radar SAAR

[6] 0018100000700IC01_Ed.A/Rev.0
20VV Modelo 12. P/N: 0018100000700

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5. DEFINITIONS AND ACRONYMS
5.1 DEFINITIONS
N/A
5.2 ACRONYMS
A Amps
AC Alternating Current
ACP Azimuth Count Pulses
AITS Angular Information Transmission System
ARP Azimuth Reference Pulses
DC Direct Current
GTE Energy Transmission Group (Grupo de Transmisión de Energía)
Km/h Kilometers/hours
Kn Kilo-Newton
KW KiloWatts
LRU Line Replaceable Unit
MTBCF Mean Time Between Critical Failures
MTBDE Mean Time Between Downing Events
OFF Switched Off
ON Switched On
PC Personal Computer
PCB Panel Control Box
PTC Positive Temperature Coefficient
RF Radio Frequency
rpm revolutions per minute
SAAR Radar Antenna Drive System (Sistema de Arrastre de Antena Radar)
V Volts
VAC Volts of Alternating Current
VDC Volts of Direct Current

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6. DESCRIPTION
It is composed of a light-alloy turntable (mobile part of Pedestal) in angular plane, mounted on a

bearing and all supported in its base by a casting light-alloy cylinder (fixed part of Pedestal).
The pedestal supports the antenna and provides the clockwise rotating movement between 7.5 y 15
r.p.m.
Each of these subsets is displayed in Figure 6-1 (Pedestal) and Figure 6-2 (Pedestal Interior).
Figure 6-1 Pedestal

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Figure 6-2 Pedestal Interior
In Figure 6-3, Mechanical Interfaces, the user will find the mechanical system interfaces defined.
Figure 6-3 Mechanical Interfaces

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6.1 FIXED BOX
This cylinder contains the movement transmission system (motors and reducing boxes, pinion and
bearing ring), the angular information transmission systems and the rotary joint.
The pedestal base is equipped with 16 drill holes of Ø30 that enable to install it on a foundation
platform or supporting tower. There are two doors that enable to access to the interior part for
inspections, controls and maintenance (see Figure 6.1-1).
Figure 6.1-1 Fixed Box
6.1.1 Connector panel for the fixed part
The lower part of the pedestal has a plate which is used as a support for the power supply connectors
for the different groups and for the security-related devices: Figure 6.1.1-1, Fixed Box connector
panel:
RF connectors (J25, J26, J27).
Power supply connectors for the motors lines (J3 and J4).
Signals and angular information connectors (J1 and J2).
Service and control connector (J5).
Hatch interlock (optional).
Acoustic/light pilot (start-up warning).

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Antenna block bar (stow pin) with bracket and end stop with pedestal disconnection when no
bar is detected.
Figure 6.1.1-1 Connector panel in pedestal base
6.2 TURNTABLE
The rotating base is equipped with 12 holes M16, 30º equidistant, that are used as anchoring points
for the Antenna plus Antenna Interface set.
It has a register for repair and maintenance tasks located at a side that matches the motor group, and
another one as a register for screws of the external ring of the bearing ring (Figure 6.2-1, Turntable).
On the centre of the upper side is located a group of connectors used as the register for slip rings, the
flexible joint and radiofrequency wires (Figure 6.2-1, Turntable).
It is important to locate the antenna in such a way that it allows to access to the different registers.
Their handling is possible even when the Antenna plus Interface set are supported on the base.

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Figure 6.2-1 Turntable
The connectors group of the mobile part hosts the RF connectors (J28, J29, J30) and the connector
for the beacon power supply J6 (Figure 6.2-2, Connector panel of the turntable).
Figure 6.2-2 Turntable connectors panel

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6.3 MOVEMENT TRANSMISSION SYSTEM
The movement transmission system is composed of an inner carved gearing bear (bearing ring) that
transmits movement to turntable, a pinion located in the outer part of motor/gearbox assembly that
transmits movement to bearing ring, and two 4 KW motor/gearbox assemblies, controlled by pedestal
control box frequency inverters.
6.3.1 Bearing ring
It is a bearing with 150-tooth rolling that joins the fixed part of the structure to the mobile part.
Figure 6.3.1-1, (Bearing ring). Both the fixed and the mobile part are joined by 24 M12 screws. It is in
charge of transmission forces to the mobile part and, therefore to rotate the antenna.
Figure 6.3.1-1 Bearing ring
6.3.2 Energy Transmission Group (GTE)
6.3.2.1 Motors
The pedestal contains two drives type 230/400 VAC; 8.7/15.2 A; 50Hz three-phase with a power of 4
KW, squirrel-cage type.
By means of frequency inverter, the rotation speed is variable, between 7.5 and 15 rpm (once the
corresponding reductions had been applied).

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The motor has a thermal probe to control its temperature. The signal from this thermal probe is sent to
the frequency inverter in order to communicate a failure warning in case of over-heating.
6.3.2.2 Gearbox
The system has a gearbox made up of a system of two helicoidal gear trains lubricated with oil and
with a reduction between the output axle and the input axle of 12.33.
The gearbox includes a gas-expansion valve, three plugs for oil level (maximum, minimum and reference)
and drainage or emptying plug (Figure 6.3.2.2-1, Installation position and detail of exhaust valve and level
plug).
Figure 6.3.2.2-1 Installation position and detail of exhaust valve and level plug
Every motor is fixed to the casting part by 8 hexagonal-head screws M12 INOX DIN933 (Figure
6.3.2.2-2, Anchoring of the Motor/Gearbox set to the Fixed Box).

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Figure 6.3.2.2-2 Anchoring of the Motor/Gearbox set to the Fixed Box
6.3.2.3 Pinion gear
It is an element located at the gearbox axle output that drives the bearing ring to transmit the
movement to the mobile part of the pedestal. It has 16 teeth, which involves a reducing relation with
the bearing ring of 9.375:1 (Figure 6.3.2.3-1, Pinion).
Figure 6.3.2.3-1 Pinion

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6.4 ANGULAR INFORMATION TRANSMISSION SYSTEM
The angular information transmission system is located on the upper part of the fixed box. It is in
charge of the transmission of the azimuth information that will further reach the Secondary Radar
Interrogator. All its elements are duplicated to ensure the redundancy.
Two encoders are the main elements of the system measuring angular position of the antenna.
The system is made up of a frame that supports, besides the bearings, a central axle that fits two
satellite axles with a 1/1 relation.
Each of the satellite axles transmits the movement to an encoder, through an elastic coupling and its
signals are sent to the pedestal control box.
In Figure 6.4-1 appears the assembly of Encoder Mechanics and its location in the upper site of the
Fixed Box.
Figure 6.4-1 Location of the encoder mechanics
6.4.1 Encoder
Encoders, P/N: 1247500210000, offer digital outputs to a remote supply that indicate the rotating
speed and the rotor position. The movement of the encoder axis is activated by the mechanics of the
encoder already explained.
The encoder, by means of an electro-optical procedure, generates two digital outputs (1 and 0), which
consist of a train of 16384 pulses, and a zero-reference pulse, for each turn of the encoder. The power
supply range of these devices is between 12 to 26 VDC.

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6.4.2 Angular information system cabling
Figure 6.4.2-1 Angular information system cabling
6.5 ROTARY JOINT
The rotary joint used is a three-channel P/N: 1242200110100 (Figure 6.5-1, Rotary joint), which
enables the RF passage between the rotating base and the fixed part of the pedestal. The rotary joint
is installed on the lower part of the angular information transmission group and it is tracked by means
of the GTIA (Figure 6.5-2, Installed rotary joint).

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Figure 6.5-1 Rotary joint
Figure 6.5-2 Installed rotary joint
6.6 SLIP RINGS
In order to feed the obstruction lights located on the antenna, which rotate simultaneously with it, it is
necessary to wire 230 VAC and 10 A from the fixed part to the mobile part; for this purpose a six
sliding ring compact module is installed, with multi-thread brushes protected by housing. Out of the six
circuits that make up the set, two are used for the phase, two for neutral and two for ground, therefore
providing the corresponding circuit redundancy.
Ring are placed, by means of customized mechanical arrangement, in the Turntable; one of the parts
does not rotate (it is fixed to the fix housing), and the other rotates along with the Turntable (Figure
6.6-1, Rings installed in the Turntable).

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Figure 6.6-1 Rings installed in the Turntable
6.7 PEDESTAL CONNECTION PANEL
This is the point where the signals coming from the pedestal control box are distributed to the
elements inside the pedestal, i.e., fans and heating elements, plug, interlock circuit and motors PTC.
With this panel, a quick connection is made to enable the replacement of elements (Figure 6.7-1,
Pedestal connection panel with thermostats).

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Figure 6.7-1 Pedestal connection panel with thermostats
The control and service signals reach the pedestal by means of connector J5. To avoid coming out
directly from that connector to each element, this connection panel is introduced as an interface.
Through its terminals, manipulation is simplified, as well as the replacement or addition of elements
inside the pedestal. Only the signal from the slip rings does not go through this panel.
Besides, two thermostats are installed on the panel; they control the heater and doors fans, their
function is to avoid extreme temperatures and condensation inside the pedestal.
The heater thermostat is adjusted to a temperature of 10ºC, and that of the fans (extractors) to a
temperature of 30ºC.
See the layout thermostat of the pedestal interior (Figure 6.7-2, Pedestal interior diagram):

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Figure 6.7-2 Pedestal interior diagram

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6.8 GREASING
To the greasing of the bearing ring, as well as the gears between the pinion and the bearing ring, an
automatic dispenser lubrication system is used. In order to activate those dispensers, the lubricator
activation screw must be threaded. As it is an electro-chemical reaction, a gas generator drops into
the electrolytic liquid, creating a pressure of up to 4 bar, which moves the piston forward, pressing the
lubricant at the lubrication point. The duration of each greasing is 12 months. The greasing installation
is displayed on 6.8-1. Automatic lubricator support:
Figure 6.8-1 Automatic lubricator support
6.9 PEDESTAL AIR CONDITIONING
The pedestal is equipped with a series of fans located at the doors, it has four fans: two for air
removal, located on the upper part, and two to input air, located on the lower part, so that natural
convection currents are enabled. Fans are driven by the high-temperature thermostat which is
regulated at 30º (Figure 6.9-1, Pedestal air conditioning elements).
To avoid condensation inside, a ceramic heater is provided. It is activated by the low-temperature
thermostat.

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Figure 6.9-1 Pedestal air conditioning elements
6.10 ANTENNA BLOCK
For the maintenance tasks at the area of influence of the antenna, there is a rigid block of the antenna.
The block is performed by means of a bar located on the connector panel, placing it between the
mobile base and the fixed part of the pedestal.
For safety reasons, in order to avoid getting caught at the previous installation phases, the
blocking piece of the fixed part shall be fixed when the antenna is installed in its final position
(Figure 6.10-1, Antenna block interface piece/Risk to get caught).

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Figure 6.10-1 Antenna block interface piece/Risk to get caught

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7. DRIVE SYSTEM INSTALLATION
The installation of the drive system is divided into two differentiated parts: the mechanical installation
of the pedestal, and the installation of the pedestal control box.
In the following paragraphs the mechanical installation of the pedestal is described. For installation of
the pedestal control box see document Ref. 3.
7.1 MECHANICAL INSTALLATION OF THE PEDESTAL
Consists of the installation of the pedestal on the tower, where it will be placed finally. This is one of
the most important and delicate tasks.
It is very important to pay attention to the way of installing the pedestal to lift it, to avoid an irreparable
damage to the bearing ring.
7.1.1 Site requirements
The anchoring surface of the drive system SAAR 20VV MOD. 12 and ANTENNA Indra CSL-M has to
offer enough capacity to support both static and dynamic forces. For the dynamic forces, the following
requirements apply:
Table 7.1.1-1 Dynamic forces
Max transmited loads pedestal base (V = 200 Km/h)
Shear load 56 Kn
Axial load 16 Kn
Overturning moment 195 Kn · m
7.1.2 Pedestal anchoring and lift
The installation begins with the pedestal on the floor or on pallet. Two eyebolts must be placed on the
pedestal base (M16), one in front of the other. Next, another pair of eyebolts is placed on the mobile
housing. In each eyebolt of the fixed housing a sling is put through. With this action we avoid the
pedestal tumbling down. It is appropriate to highlight that the pedestal must be lifted attached to the
fixed housing (Figure 7.1.2-1, Lifting of the pedestal/location layout of the lifting points).

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Besides these slings, other slings must be attached in parallel to two eyebolts located on the mobile
housing. Take into account that these slings must not support any weight, they are there just for
security purposes and to make the positioning maneuver to its final position.
The pedestal shall be lifted to the top of the tower and it shall be left there in the interface prepared for
that purpose, but not located at its final position. Take into account that the connector panel of the
fixed housing must match the position of the site wires.
Figure 7.1.2-1 Lifting of the Pedestal/Location layout of the lifting points
7.1.3 Location of the pedestal in its position
Once the pedestal is placed on the interface, the bolts from the pedestal base are removed. To place
it in its final position, the pedestal must be slightly lifted by means of the slings that are attached to the
mobile housing and the pedestal is placed so that the interface holes of the pedestal and the
connector panel match the site wires.
The pedestal is leveled by means of a bubble leveling device or a similar tool on the upper part of the
mobile housing by moving the level radial and adjusting its base if necessary with wedges until a
perfect level is achieved.
7.1.4 Screws and coupling torque
The pedestal is fixed to the tower by means of 16 inox steel hexagonal-head M24 screws. The screws
shall be fixed below the interface with a flat washer, a grower washer and a nut. To tighten the screws
is used a torque wrench calibrated. The maximum torque shall be 711N·m.

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8. REPARING AND REPLACEMENT OF SYSTEM ELEMENTS
As any mechanical element, the pedestal has elements than can suffer from degradation due to an
uninterrupted operation and under extreme conditions, it could be necessary to replace it or repair it.
Before performing any type of operation inside the pedestal, it is important to know that:
There are dangerous voltages inside the pedestal.
There are mobile mechanical components inside the pedestal that could be accidentally
activated, and they could produce personal injuries.
8.1 REPLACEABLE ELEMENTS
Next is a description of the replacement procedure for LRU elements.
8.1.1 Energy Transmission Group (GTE)
The Energy Transmission Group is one of the basic elements of the system and probably the one that
stands the highest forces. Because of this, it is important to know how to replace it in case of failure.
The process to apply in order to replace it is the following:
1. The system is stopped from the lower area with the antenna control of the interrogator and all
the protections on the control box are disconnected. Then the emergency stop is pressed in
the upper area to ensure that the antenna rotation cannot be activated accidentally from the
lower area.
2. The pedestal access lid is opened.
3. The RF wires are disconnected and the rotary joint is disassembled to facilitate the work and
avoid accidental shocks against it. If necessary, the ½’’ wires from the connector panel are
disconnected.
4. Motor disconnection: The position of the phases and PTC connections are written down for
further connection.
5. Disassembly process of the set:
- A hydraulic jack is installed on the floor where the pedestal is installed, and it is fixed to
the lower part of the motor. Slings passing through the eyebolts placed on the roof of
the fixed housing can be used to fix the motor through their eyebolts and avoid a
possible tumbling down of the set while disassembling it (Figure 8.1.1-1, Disassembly
of the set).
- The 8 screws of the gearbox to the fixed housing are loosened in a crossed
configuration, i.e., a screw and its contrary from a quarter turn to a quarter turn (Figure
8.1.1-2, Detail of the Motor-Gearbox fixing screws).
- The set is removed from the interior of the pedestal.
Figure 8.1.1-12, shows the detail o the fixing screws of the motor-reducer group to the fixed housing.

Fecha / Date: 15/12/2009
Figure 8.1.1-1 Disassembly of the set
Figure 8.1.1-2 Detail of the Motor-Gearbox fixing screws

Fecha / Date: 15/12/2009
6. Assembly process for the new set:

- The set is installed in the hydraulic jack assembly and lifted until the gearbox is in its
position. The gearbox is presented and the fixing screws are installed tightening them
one quarter of a turn in a cross pattern.
- The motor is connected to the power supply taking into account the position of the
phases and the connections to the PCB.
- Before closing the lid of the pedestal the power supply is connected and switched on to
verify the rotation direction of the antenna. Once verified, the motor lid is closed.
8.1.2 Rotary joint
The rotary joint is an element that usually shows no operation problems, but as explained in the
previous section; just in case it is necessary to replace the motor, the joint must be removed to ease
the work and avoid damages. The precaution to take consists of ensuring that the wires are well
connected when assembling it again and that they do not produce any VSWR. The disassembly
process is the following:
1. The system is stopped from the lower area with the interrogator antenna control and all the
protections are disconnected at the control box. The emergency stop is pressed at the upper
area to ensure that the antenna cannot be rotated accidentally from the lower area.
2. The pedestal access lid is opened.
3. The ½’’ wires are removed from the rotary joint, ensuring that the installation place is indicated
(Figure 8.1.2-1, ½’’ RF wires).
4. The screws used to fix the rotary joint to the encoder mechanics are loosened in a cross
patter, i.e. a screw and its opposite one (Figure 8.1.2-2, Screws that fix the joint to the flange).
5. Once the screws had been loosened, the wires are released from the upper part of the rotary
joint. The wire position must be marked if it is not already (Figure 8.1.2-3, Position of the wires
that go to the rotary joint).

Fecha / Date: 15/12/2009
Figure 8.1.2-1 ½” RF wires
Figure 8.1.2-2 Screws that fix the joint to the flange

Fecha / Date: 15/12/2009
Figure 8.1.2-3 Position of the wires that go to the rotary joint
In order to install the same or other joint, the process to carry out would be the following:
1. Be sure to install the wires that go to the mobile housing in their connectors and to thread
them completely.
2. Before the joint is fixed with the screws, it must be taken into account that the stub that carries
the mobile part matches the mechanical part of the encoder that will make it turn. Be sure that
the connectors are oriented towards the ½’’ wires (Figure 8.1.2-4, Notch to install the stub of
the rotary joint).
3. The screws are tightened in a cross pattern applying the screw-fixer before (Figure 8.1.2-5,
Applying the screw-fixer).
4. The ½’’ wires are connected in their position and the system VSWR is measured to check that
the connections have been correct.
5. Take into account that the system phase will have changed and must be adjusted again.

Fecha / Date: 15/12/2009
Figure 8.1.2-4 Notch to install the stub of the rotary joint
Figure 8.1.2-5 Applying the screw-fixer
8.1.3 Encoders
Encoders are some of the most delicate elements of the system and therefore it is possible that,
during the useful life of the pedestal, it has to be replaced some time. The replacement process is the
following:
1. The system is stopped from the lower area with the interrogator antenna control and CB1 is
disconnected on the control box. Pedestal emergency stop is pressed to be sure that the
antenna rotation cannot be accidentally activated from the lower area.

Fecha / Date: 15/12/2009
2. The antenna block is set.

3. The side access lid to the interior of the pedestal is opened.
4. The wire of the encoder to replace is disconnected.
5. The screws of the encoder fixing elements are loosened with a 2.5 Allen key (Figure 8.1.3-1,
Detail of the encoder to disassemble)
6. Gently pull from the encoder to remove the encoder axle from its coupling.
7. The case 1 + elastic coupling + case 2 set is removed with the same 2.5 Allen key (Figure
8.1.3-1).
Figure 8.1.3-1 Detail of the encoder to disassemble
To install an encoder:
1. Place the case 1 + elastic coupling + case 2 set on the encoder tightening the grub screws.
2. Enter the encoder trying to align the encoder neck with case 3. This operation must be
performed very carefully to avoid damaging the coupling.
3. Tighten the encoder fixings.
4. Install the connector.

Fecha / Date: 15/12/2009
8.1.4 Fans
Fans located on the pedestal door keep constant air circulation inside the pedestal to avoid
condensation in the elements inside the pedestal. These fans are controlled by a thermostat which
activates them when the temperature defined is exceeded. However, the environmental conditions can
keep them ON for hours, which represent a wear out that could produce a break down at a given
moment.
Fans must be checked every year and replaced if it is necessary.
The disassembly process is the following:
1. Disconnect all the control box protections. Pedestal emergency stop is pressed to ensure that
cannot be activated accidental the draft of the antenna.
2. The pedestal access lid is opened and the fans are removed (Figure 8.1.4-1, Connector for
fans).
3. Wires for the fan to replace are released (Figure 8.1.4-2, Connection with Faston terminals in
the fan).
4. The nuts that fix the fan to the pass-through screw are released with a key and the fan is
removed from its housing.
Figure 8.1.4-1 Connector for fans
Figure 8.1.4-2 Connection with Faston terminals in the fan

Fecha / Date: 15/12/2009
Figure 8.1.4-3 Fan fixing screws
The assembly process of a new fan is the following:

1. Be sure of the function each fan should perform. Each upper fan in both doors is in charge of
taking the air out from the interior of the pedestal, while each lower fan takes the air into the
pedestal. The air direction is indicated by an arrow on the fan side (Figure 8.1.4-4, Fan air
direction).
2. The fan is installed with the screws and the nuts are tightened with a fix num. 8 wrench.
3. Fasten terminals are connected on the fans, respecting their positions.
4. Fans are connected and all the protections are connected in the control box. If the
temperature is not high enough to trigger the thermostat, its threshold can be lowered
temporally to make sure that the new fan operates correctly.
Figure 8.1.4-4 Fan (Air direction)

Fecha / Date: 15/12/2009
8.1.5 Thermostats
The correct operation of fans and heater depend on the status of the regulating thermostats, which
means that if they do not operate correctly, temperature cannot be maintained inside the pedestal
between acceptable values.
The disassembly process is the following:
1. The system is stopped from the control box or local management system. Interrogator radar
key is disconnected as well as all the protections in the control box. Then the emergency stop
is pressed in the pedestal to make sure that the antenna rotation cannot accidentally be
activated.
2. The thermostat to replace is identified, i.e., if it is serving the fans or heater (Figure 8.1.5-1,
Connection panel with thermostat).
3. The thermostat is opened using a star screwdriver for that purpose.
4. The thermostat cabling is written down before replacing it. Wires are disconnected and taken
out of the box pulling from the box to the left (Figure 8.1.5-2, Thermostat cabling).
Figure 8.1.5-1 Connection panel with thermostat

Fecha / Date: 15/12/2009
Figure 8.1.5-2 Thermostat cabling
To install a new thermostat:

1. The thermostat is installed on its support, on the connection panel.
2. The thermostat is wired in the mode previously described.
3. The housing is installed and screwed using a star screwdriver.
4. All the control box protections are connected, and it is must be checked that the thermostat
operates correctly and that the element it is connected to operates properly.
Table 8.1.5-1 Thermostat terminals
Terminal Cable Funtion
Signal CBL FLEX 3x1.5 mm2 0.6/1KV blue Thermostat signal temperature high/low
Phase CBL FLEX 3x1.5 mm2 0.6/1KV black Phase aux circuits
Ground CBL FLEX 3x1.5 mm2 0.6/1KV yellow/green Ground

Fecha / Date: 15/12/2009


Fecha / Date: 15/12/2009
9. PREVENTIVE MAINTENANCE
As any mechanical element, the SAAR-20VV Pedestal requires a series of maintenance activities to
keep it operating and extend its life. This maintenance actions must be performed by the system
operator in accordance with the indications given next. The inspection is especially important here, it
will help to prevent possible problems that could appear.
9.1 BEARING RING MAINTENANCE
Bearing ring maintenance is mainly focused on grease application both to the rolling tracks and the
gears. It is very important to accomplish the inspection and greasing periods for the bearing ring since
it is the pedestal element that supports the greatest forces and suffers a constant contact on the attack
pinion.
• Bearings:
There are two greasing points: one is the lower point, which is lubricated by means of an automatic
dispenser; the other is the upper point, which is lubricated manually.
To grease manually the bearing, the following steps must be followed:
1. The system is stopped from the lower area with the interrogator antenna control, removing the
key to ensure that no one can start up the system accidentally.
2. Remove the register screw in the upper part of the turntable and turn manually the mobile part
until getting access to the greasing point placed in the bearing ring (Figure 9.1-1 Manually
greasing details).
3. Using a greasing gun a grease dose is entered in the greaser, right on the upper grease point
or the lower grease point.
4. The antenna is rotated manually for two or more turns so that grease is distributed along the
bearings. Another dose is entered at each of the points and the antenna is turned again.

Fecha / Date: 15/12/2009
Register screw Greasing point
Greasing gun Lower and upper greasing points
Figure 9.1-1 Manually greaser details
To grease automatically the bearing (Figure 9.1-2):

1. Remove the old automatic lubricator and install a new one in the same place.
2. To activate the automatic lubricator, the grey plastic screw must be screwed until the plastic
ring breaks.
The type of grease recommended is a Lithium base High pressure, P/N: 1803001700000. P/N of
automatic dispenser is 78521001300000.

Fecha / Date: 15/12/2009
Figure 9.1-2 Automatic lubricator
• Teeth:
Take the following steps to grease the teeth:
1. Stop the system from the lower area with the interrogator antenna control, removing the key
to ensure that no one can move the system accidentally. Then the emergency stop is pressed
make sure that the antenna rotation cannot accidentally be activated.
2. To access lid on the upper part of the mobile housing is opened (Figure 9.1-3, Register lid of
the mobile housing).
3. The grease is entered through the register lid and evenly distributed over the whole teeth of
the bearing ring moving the antenna manually.
4. The automatic lubricator, which permanently lubricates the gear teeth through a set of
elements, is changed (Figure 9.1-4, Automatic lubrication of the bearing ting teeth).
5. The access lid to the mobile housing is closed, making sure that the rubber joint is properly
placed to avoid the entrance of water inside the pedestal.
The type of grease recommended is a Lithium base High pressure, P/N: 1803001700000. P/N of
automatic dispenser is 78521001300000.

Fecha / Date: 15/12/2009
Figure 9.1-3 Register lid of the mobile housing
Figure 9.1-4 Automatic lubrication of the bearing ring teeth
• Labyrinth:
The grease that enters into the labyrinth avoids the entrance of dirt, dust, water, etc., into the rotor.
There are two watertight labyrinths (Figure 9.1-5, Greasing of the internal and external labyrinth).
Follow this procedure to carry out the lubrication:
1. Stop the system from the control box or local management system. Interrogator radar key is
disconnected as well as all the protections in the control box. Then the pedestal emergency
stop is pressed to make sure that the antenna rotation cannot accidentally be activated.
2. Using a greasing gun, enter a grease dose in each lubricator (Figure 9.1-6, Detail of the
external labyrinth greasing point).

Fecha / Date: 15/12/2009
3. Manually rotate the antenna to distribute the grease and enter a new grease dose with the
antenna located in a different position.
4. Clean the access of grease that could have overflow to the external surface.
The type of grease recommended is a Lithium base High pressure, P/N: 1803001700000.
Figure 9.1-5 Greasing of the internal and external labyrinth
Figure 9.1-6 Detail of the external labyrinth greasing point

Fecha / Date: 15/12/2009
9.2 MAINTENANCE OF THE ENCODER MECHANICS
The maintenance of the encoder mechanics is basically focused on greasing both the rolling tracks
and the gears.
• Bearings:
There are three greasing points for bearings in the encoder mechanics: one is located on the centre
axle while the other two are located on the corresponding satellites. On the rear part of Figure 9.2-1,
Detail of the greasing points of bearings and gears, you will find the evacuation point for the excess of
grease.
Figure 9.2-1 Detail of the greasing points of bearings and gears
To carry out greasing, follow the next procedure:

1. Stop the system from the antenna control, removing the key to ensure that no one can move
the system accidentally. Then the emergency stop is pressed to make sure that the antenna
rotation cannot accidentally be activated.
2. Using a greasing gun, a dose of grease is entered in each lubricator (Figure 9.2-1).
3. Then, manually rotate the antenna to distribute the grease and enter a new dose of grease
with the antenna in a different position.

Fecha / Date: 15/12/2009
4. Clean the excess of grease that could come out to the external surface through the rear
greasing point.
P/N of the grease recommended is 1803001700000.
• Teeth:
The lubrication of the gear wheels can be made through two points located on the frame base (Figure
9.2-1). When grease is applied to any of these points, it has to be distributed to lubricate both the
bearing rings located at the satellite axles and the one located at the central axle.
The following procedure is used to apply grease:
2. Using a greasing gun, enter a dose of grease through one of the lubricators that lubricate the
bearing rings (Figure 9.2-1).
3. Manually rotate the antenna to spread the grease and enter a new grease dose with the
antenna located in a different position.
The type of grease recommended is a Lithium base High pressure, P/N: 1803001700000.
9.3 MAINTENANCE OF THE MOTOR/GEARBOX
The maintenance procedure for the motor/gearbox is described next:
• Inspection and maintenance of the gearbox:

It is very important to take into account that synthetic and mineral lubricants must not be combined.
The gearbox is delivered with synthetic oil, P/N: 1803103100000. In special operating condition,
please ask the manufacturer.
To change the oil, the gearbox must be at work temperature so that the oil is fluid and facilitates
emptying, otherwise the viscosity shall be increased and it will not be able to evacuate all.
2. Wait until the gearbox cools down a little to avoid burnings. Next, a container is placed under
the oil drain plug.
3. The oil level plug is removed, the gas expansion valve and the oil drain plug too (Figure 9.3-1,
Filling in and emptying points and gearbox level). The gearbox shall be fully emptied.
4. The oil drain plug is installed and, through the gas expansion valve hole, 3.8 litres of new oil
are entered.
5. Check the fluid level through the level plug.
6. Install the level plug and the gas expansion valve.

Fecha / Date: 15/12/2009
Symbol Meaning
Breather valve
Oil level plug
Oil drain plug
Figure 9.3-1 Gearbox oil plugs
9.4 VIBRATIONS
Inside the pedestal, two vibration cubes have been installed: one at the transmission line and another
at the upper side of the pedestal fixed housing. Two readings are taken at each cube, one lengthwise
and the other crosswise regarding the anchoring point: 4 points in total. Vibration data collection in two
orthogonal directions (axial and crosswise) supplies much more information than single-axial's for
different failure frequencies could be displayed with greater amplitude on the different axis.
Such readings are reference or starting points to compare them with later readings and so be able to
predict a wrong behavior of the pedestal from a vibration standpoint (for example: gear failure,
gearbox, pinion or bearing ring wear out...).

Fecha / Date: 15/12/2009
Figure 9.4-1 Pedestal vibration reading reference
Test points PT1 and PT4 are localized on the motors bodies (Figure 9.4-1, Pedestal vibration reading
reference).
Test points PT2 and PT3 are located on the upper part of the fixed table inside the pedestal (Figure
9.4-1).

Fecha / Date: 15/12/2009
9.5 SYSTEM MAINTENANCE PLAN
The following table shows the inspection and greasing periods of the SAAR-20VV antenna drive
system:
Table 9.5-1 Maintenance plan
Interval Element Checking
Bearing ring Greasing
Motor/Gearbox Check oil level

Yearly
Pedestal fan Check
Heater Check
Outside painted surfaces Check paint state and repaint if it is necessary
Paint and pedestal seals Check state and wear to substitute if it is necessary
Labyrinth Greasing
Every three years Motor/Gearbox Oil change and bearing grease substitution
Mechanical AITS Greasing
Pedestal fan Substitute if it is necessary
Heater Substitute if it is necessary
Every 6 years Motor/Gearbox Substitute if it is necessary
Rotary joint Substitute if it is necessary

Every 10 years
Bearing ring Substitute if it is necessary
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Installation, Operation and Maintenance Technical Manual for SAAR

20VV Model 12 Pedestal

REGISTRO DE EDICIONES Y REVISIONES DE PÁGINAS

REGISTRO DE CAMBIOS EN EL DOCUMENTO

Capítulo Descripción Página

1. INTRODUCTION .......................................................................................................................... 1-1

Doc.Nº: 0018110003100MA01 III

Capítulo Descripción Página

Doc.Nº: 0018110003100MA01 VII

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VIII Doc.Nº: 0018110003100MA01

Doc.Nº: 0018110003100MA01 Capítulo / Chapter 1

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Capítulo / Chapter 1 Doc.Nº: 0018110003100MA01

Doc.Nº: 0018110003100MA01 Capítulo / Chapter 2

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Capítulo / Chapter 2 Doc.Nº: 0018110003100MA01

Doc.Nº: 0018110003100MA01 Capítulo / Chapter 3

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Capítulo / Chapter 3 Doc.Nº: 0018110003100MA01

4.1 APPLICABLE DOCUMENTS

REF. DESCRIPTION CODE / REV.

4.2 REFERENCE DOCUMENTS

REF. DESCRIPTION CODE / REV.

Reliability, Maintainability and Availability analysis for Antenna Drive

Description, Installation, Operation and Maintenance Manual for SAAR

Control de Interfaces del Sistema de Arrastre de Antena Radar SAAR

Doc.Nº: 0018110003100MA01 Capítulo / Chapter 4

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Capítulo / Chapter 4 Doc.Nº: 0018110003100MA01

5. DEFINITIONS AND ACRONYMS

ACP Azimuth Count Pulses

AITS Angular Information Transmission System

ARP Azimuth Reference Pulses

GTE Energy Transmission Group (Grupo de Transmisión de Energía)

LRU Line Replaceable Unit

MTBCF Mean Time Between Critical Failures

MTBDE Mean Time Between Downing Events

OFF Switched Off

PCB Panel Control Box

PTC Positive Temperature Coefficient

rpm revolutions per minute

SAAR Radar Antenna Drive System (Sistema de Arrastre de Antena Radar)

VAC Volts of Alternating Current

VDC Volts of Direct Current

Doc.Nº: 0018110003100MA01 Capítulo / Chapter 5

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Capítulo / Chapter 5 Doc.Nº: 0018110003100MA01

It is composed of a light-alloy turntable (mobile part of Pedestal) in angular plane, mounted on a

Figure 6-1 Pedestal

Doc.Nº: 0018110003100MA01 Capítulo / Chapter 6

Figure 6-2 Pedestal Interior

Figure 6-3 Mechanical Interfaces

Capítulo / Chapter 6 Doc.Nº: 0018110003100MA01

6.1 FIXED BOX

Figure 6.1-1 Fixed Box

6.1.1 Connector panel for the fixed part

 RF connectors (J25, J26, J27).

 Signals and angular information connectors (J1 and J2).

 Service and control connector (J5).

 Hatch interlock (optional).

 Acoustic/light pilot (start-up warning).

Doc.Nº: 0018110003100MA01 Capítulo / Chapter 6

RF connectors (J25, J26, J27).

Signals and angular information connectors (J1 and J2).

Service and control connector (J5).

Hatch interlock (optional).

Acoustic/light pilot (start-up warning).