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Installation, Operation and Maintenance

C/Ku band 4.5-Meter Earth Station Antenna

Shaanxi Probecom Microwave Technology Co.,Ltd


Add: Floor 12, Lugang Mansion, Xi'an International Trade and Logistic Park,

Xi'an, Shaanxi, PRC Z ip: 710026

Tel: +86-29-88451625 88451755

Fax:+86-29-88860260

E-mail:sales@probecom.cn
Shaanxi Probecom Microwave Technology Co., Ltd.
Tel: 0086-29-884 51625 Fax: 0086-29-88860260 http://:www.probecom.cn

Table of Contents
1.General…........................................................................................................................................4
2. Technical Specifications.................................................................................................................4
2.1 Electrical Specifications .......................................................................................................4
2.2 Mechanical Specifications.....................................................................................................5
3. Antenna Structure...........................................................................................................................6
3.1 Main Reflector........................................................................................................................7
3.2 Pedestal Structure...................................................................................................................8
3.3 Antenna Sub-reflector Assembly ..........................................................................................9
3.4 Feed System...........................................................................................................................9
4. Foundation Requirements..............................................................................................................9
5. Installation Preparation................................................................................................................10
5.1 Recommended Tools............................................................................................................10
5.2 Equipment Check………………………………………………………………………….11
5.3 Installation Cautions ...........................................................................................................11
5.4 Block Diagram of Installation Procedure………………………………………………….12
6. Installation Steps..........................................................................................................................13
6.1Foundation Preparation.........................................................................................................13
6.2 Installation Preparation….……………...…………………………………………………13
6.3 Pedestal Installation.............................................................................................................13
6.4 Az Drive Base Assembly…………………………………………………………………..13
6.5 Hub Assembly ………………...…………………………...………………….…………..14
6.6 Back Structure Installation ……………………………..…………………………………15
6.7 Panel Installation…………………………………………………………………………..16
6.8 Feed System Installation…………………………………………………………………..17
6.9 Sub-reflector Assembly……………………………………..…………………………..…18
6.10 Adjust Installation Dimension……………………………………………………..……..18
7. Antenna Operation ……………………………..........................................................................19
7.1 Antenna Pointing Adjustment..............................................................................................19
7.2 Antenna Polarization Adjustment.........................................................................................19
7.3 Installation Caution………………………………………………………………………..19
8. Satellite Search of Antenna System……………………………………………………..……...19
9. Antenna Maintenance….………………………..........................................................................20

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9.1 Notice in Using the Antenna…............................................................................................20
9.2 Fasteners’ Maintenance ……...............................................................................................20
9.3 Surface Coating Maintenance…………………………………………………………..…20
9.4 Rotary System Lubricating Oil Maintenance……………………………………………...21

9.5 Antenna Facility Maintenance……………………………………………………………..21

9.6 Notice for antenna maintenance…………………………………………………………...21


10. Antenna Packing List….……………………............................................................................22
11. Antenna Foundation Drawing……............................................................................................23

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Tel: 0086-29-884 51625 Fax: 0086-29-88860260 http://:www.probecom.cn

1. General
4.5-meter C/Ku earth station antenna, which uses a shaped parabolic reflector,
provides high gain and exceptional pattern characteristics as well as low VSWR. Its
electric performance meets the FCC regulation 25.209, IESS (Intelsat), or ITU-RS
Recommendation 580 sidelobe specification (domestic and international standards).

2. Technical Specification

2.1 Electrical Specifications

2.1.1 Frequency Range (GHz):

Rx(GHz) Tx(GHz)

C-band 3.625-4.2 5.85-6.425

Ku-band 10.95-12.75 13.75-14.5

2.1.2 Polarization:Linear、Circular、Linear and Circular switchable


2.1.3 Gain(dBi)
Rx(GHz) Tx(GHz)

C-band 43.3+20lg(F/4) 46.8+20lg(F/6)

Ku-band 52.8+20lg(F/12) 54.1+20lg(F/14)

2.1.4 Antenna Sidelobe Level


First Sidelobe:≤-14dB
Sidelobe:Meet CCIR-580-4 requirements
29-25Logθ(dBi) 1°<θ≤20°

2.1.5 Cross Polarization Isolation


On Axis: ≥35dB, Within 1dB beamwidth: ≥33dB
2.1.6 VSWR
Rx: ≤1.25 Tx: ≤1.25
2.1.7 Feed insertion Loss

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Rx(GHz) Tx(GHz)
C-band ≤0.25dB ≤0.20dB
Ku-band ≤0.30dB ≤0.20dB

2.1.8 Port to Port Isolation(Tx/Rx):


≥85dB
2.1.9 Antenna Noise Temperature :
C-band:≤30 K ,Ku-band:≤50 K
20°Elevation (in clear sky and soft wind)
2.1.10 Feed Power Handling Capacity :

C: ≤5KW Ku: ≤ 2KW


2.1.11 Feed Interfaces
Rx:CPR-229F Rx:WR-75
C: Ku:
Tx:CPR-137F Tx:WR-75

2 .2 Mechanical Specifications
2.2.1 Antenna Diameter:
4500mm
2.2.2 Drive Mode:
Manual or Motorized
2.2.3 Antenna Pointing Range
Az:±85°
El:5° ~ +90°
2.2.4 Polarization adjustment:
±90° Manual
2.2.5 Surface Accuracy(RMS)
Main reflector: σ≤ 0.5mm (r.m.s)
Sub reflector: σ≤ 0.15mm(r.m.s)
2.2.6 Environmental Specification
a. Wind Resistance Capacity
b. Operational Wind:20m/s Gusting to 27m/s

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c.Survival Wind:56m/s
d.Temperature:-25℃+55℃
e. Rain:100mm/hr
f. Relative Humidity:100%
g. Ice:15mm work normally
30mm (Survival)
h. Seismic: 0.3G’s horizontal 0.15G’s vertical

3. Antenna Structure
4.5M antenna system mainly consists of the antenna main reflector; pedestal, sub
reflector assembly, feed system, Az drive mechanism and El drive mechanism, as
shown in Fig.1.

To make it clear for the customer, the series number of the antenna has been marked
on the kingpost, the hub, the panels and the struts. The positioning numbers for the
panels corresponding to the long strut and the short strut as well as the hub are also
marked on each part. So there is only one way of connection between the panels and
the struts, the panels and the hub, the struts and the hub.

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Fig.1

3.1 Main Reflector


The main reflector consists of a hub, 12 individual panels and 12 back structures. The
antenna is a complete structure system on which 12 panels are circumferentially
connected by bolts and then connected with hub and backup support struts. The
structure is so designed that the rigidity and strength as well as high accuracy of
surface can be obtained.

3.1.1 Hub
The hub is a welded cylinder(diameter φ725×675mm) made of steel. It is not only the

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main load-bearing of the reflector, but also the parts which are connected with the
pedestal and feed system. The flange provided on the upper part of the hub, is not
only used for installing the feed system, but also used as a reference surface for
installing and measuring the accuracy of the reflector. An available space provided in
the inner cavity of the hub is used for installing the feed system and RF outdoor unit.
The lower flange of the hub is used for connecting with the pedestal and installing the
rear cover. Close the cover after installing the electric equipment so as to seal the
cavity.
3.1.2 Individual Panel
The panels are the critical parts of the reflector, which the ribs and envelop are
stretch-formed and riveted on the precise mould. The envelope is made of 1.5mm
thick aluminum plate, and the rib is made of angle aluminum 50×25×3. Such a
structure has the characteristics of higher accuracy and strong rigidity after individual
panels are stretch-formed.
3.1.3 Back Struts
Back structures are used to support and position reflectors through hub, and it is
welded by truss structure made of cylinder. One end of the support strut is connected
with the hub and the other is connected with the panel, which provides a stable
support structure for the reflector so that the antenna can safely and reliably operate
under the required environment.

3.2 Pedestal Structure


Antenna pedestal is made of kingpost and Az. rotating support, which is used to bear
and adjust all reflectors. El. adjustment is obtained by the Jackscrew on the El drive
base which is located on upper part of the kingpost; and Az. adjustment is obtained by
the Jackscrew on lower part of the kingpost.
3.2.1 Kingpost
The kingpost is made of steel tube (6mmφ325 thick).The upper part is welded by steel
plate with hub structure; the kingpost body is welded and assembled with the kingpost
support connection structure and Az. rotating base.

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3.2.2 Kingpost support

Two kingpost supports are welded by steel tubeφ89×4.5 and copper plate, and are
used to support the kingpost.
3.2.3 Az. Drive Base

Az. drive base is used to install Az. adjustment Jackscrew, and it is steel welded part
and is fixed with foundation directly when installing.

3.3 Antenna Sub-reflector Assembly

Antenna sub-reflector assembly is made of four sub-reflector supports, sub-reflector


bracket, sub-reflector and four adjustment Jackscrews.
3.3.1 Sub-reflector Support

Sub-reflector support is used to support sub-reflector bracket and sub-reflector by


reflector and is made of steel tubeφ30, which is pressed into ellipse.
3.3.2 Sub-reflector Bracket

Sub-reflector bracket is welded by steel tubeφ30×2 and steel plate and is used to
install antenna sub-reflector.
3.3.3 Sub-reflector

Sub-reflector is made by casting aluminum finish turning. Sub-reflector accuracy


requirement(σ≤0.15mm)will affect the performance directly, so protect sub-reflector
from damage.
3.3.4 Adjustment Screw

Four adjustment Jackscrews is used to connect sub-reflector, and adjust sub-reflector


height size by M12.

3.4 Feed System

The feed system of 4.5m antenna is made of corrugated horn, circular waveguide,
movable flange, and OMT.

4 Foundation Requirements
The foundation should be prepared ready for 12-15 days before installing antenna. A
foundation must be constructed according to the foundation drawing ensuring that the
antenna can be safely operated under the required environment.

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The customer must specially pay attention to the anchor bolts during construction.
Coat the grease on the exposed part of bolts and wrap them up till the antenna is
installed in order to prevent them from damage before installation.

A Foundation template B1、B2 Foundation template C Foundation template


1:5 1:5 1:5

Table for foundation bearing force

Wind speed(m/s) A pull pressure(Kgf) B1,B2 pull pressure(Kgf) C shear(Kgf)

E-E 10 Grade(28.5) 3086 2077 1240

1:2 12 Grade(32.6) 3929 2768 1760

14 Grade(42) 6290 4703 2800

17 Grade(56.1) 10914 8491 4450


C
Steel mesh reinforcement

设 计
校 核 Foundation Drawing PROBECOM
审 核
工 艺
4.5M ESA
标准化 阶段标记 重量 比例
CAD

批 准

5. Installation Preparation
Table 5-1 Recommended Tools

Tool Qty. Name Qty.


5.5×7 double-head wrench 2 12″adjustable wrench 1
10×12 double-head wrench 2 5M tape measure 1
14×17 double-head wrench 2 Screwdriver “-” 1
17×19 double-head wrench 2 0.22kg Hammer 1
Common stipulations before installation
Š If the components distorted, it should be rectified before installation, the
components can not be beaten, cut or punched when the temperature is lower than
-20℃.
Š Any components with rotation joints should go through rotation test until the
components rotate limberly, smoothly and without any abnormal sounds prior to
installation.

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Š When you hoist the main reflector, don’t give a force to the reflector lest the
reflector deforms.
Š You should know their weight before hoisting the components. The crane should
have enough carrying capability and arm length and try several times before hoisting
to make sure the balance.
Š Clean the flange surface before installation.
Š Please check the screws and components to ensure the installation to go well.
Š Polarization and integration components have been tested and adjusted precisely
in the factory, any adjustment is forbidden during installation.
Š If due to the structure features, some of the integration components must be
dismantled and installed, the components should be marked before installation to
ensure the right order of them.
Š During the process of installing the feed system, you should take strictly
precautions against the screws, nuts or some other things fall into the wave-guide.

5.2 Equipment Check


Prior to installation, check whether the containers/ packing case are damaged or not.
Open each case and check the packed parts according to the packing list. After that,
assemble the parts step by step

5.3 Installation Cautions


a. Make sure that the parts for installation are the same series number of the antenna.
b. All the spare parts should be protected carefully and taken or put them down gently
so as to keep them from the damage;

c. When entering the reflector for installation, the persons should wear soft bottom
shoes and stand on the places under which there are backup support struts and ribs of
the panel. Lay some liners such as soft foam and Kraft paper in the hub. Don’t step in
the envelope carelessly in order to avoid deformation of panels and damage on their
surface.
d. When installing the feed system, be careful to protect the horn cover against
scuffing and entering water. Replace it if damaged.

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e. If any pin is found to enter any hole of the shafts not easily, clean the hole as well
as the pin with sand paper 80#.
5.4 Block Diagram of Installation Procedure
The main installation procedures are given in Fig.

Start

Open and check the case

Contact PROBECOM

Clear and check the foundation


Wait for reply

Install the pedestal

Install Az. rotary combination

Install the El. jackscrew

Install the back structure

Install the reflector

Install the feed support structure

Install the feed and determine the polarization

Adjust Az./El. angles to the satellite position Repeat until the signal is
optimum

Clear up the site

End

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6 Installation Steps

6.1 Foundation Preparation


Refer to 4.5M foundation drawing to make foundation. It will take 12 to 15 days to
make the concrete dry, then it can be used.
6.2 Installation Preparation
Firstly clean any substance on the foundation surface and remove the wrappage on
the anchor bolts. Screw on 1*M24 nut on each anchor bolt, assure all the anchor bolts
on the same level, and then put 1*φ24 flat washer so as to assure the length of screw
thread between 50mm and 60mm.
6.3 Pedestal Installation
Hoist the kingpost(200Kg) on the foundation by the crane or by manual hoist
equipment. Pay attention to the direction of the kingpost, enable the azimuth axis to
be in the receiving direction of the antenna. Aim the center base of kingpost at anchor
bolts, fix, and then connect two kingpost supports with support lugs by M16×60,
adjust the two kingpost supports and assure the center of the kingpost and ground
vertical, push the kingpost by hand so as that the kingpost can rotate flexibly, and
finally fasten anchor bolts.
As the crane is hoisting, all persons should keep away from the hoisting scope, and
fast installation must be done when the sub-reflector is hanged in the right position.

6.4 Az. Drive base assembly


Connect Az drive base and Az base, and connect Jackscrew head with the lug on the
bottom of kingpost by special pin. As shown Fig.2

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Az Drive Base

Special Pin

Fig.2 Illustrated diagram for Az Drive Assembly Installation

6.5 Hub assembly


After finishing the pedestal installation, hoist the hub (If possible, after finishing the
back structure and panel’s installation, the customer can do the overall hoist). Aim the
three lugs on hub at the ones on the kingpost, then connect them by pin.

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6.6 Back Structure Installation (as shown Fig.3, 5)


There are 4 varieties of brace on back structure, outer brace marked no.1-12 , middle
brace marked No.1-12, bottom brace , oblique brace. And bottom brace and oblique
brace has not been sealed with No.1-12.
6.6.1 There are 12pcs back structures which is marked by 1-12 No., and also on the
hub there are 1-12 steel sealed numbers. Connect the back structure with hub
correspondingly by self-made taper pin and bolt M12×25.
6.6.2 Connect one end of the outer braces Marked with No. 1-12 No., with the back
structure marked with No.1-12 correspondingly in order by bolt M8×25.
6.6.3 The middle brace connection can be made per the outer brace connection
method. , except the bottom brace and oblique brace can be connected randomly.

Self-made Taper Pin

Bolt M12×25

Fig.3 Illustrated Diagram for Back Structure

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Outer brace

Position Pin
Middle brace

Position Pin
Oblique brace
Bottom brace

Fig.5 Illustrated Diagram for Outer Brace Connection

6.7 Panel Installation


There are 1-12 Nos. on the top right of each panel. Connect each panel with back
structure in corresponding order by bolt M8×25, and fasten them.

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6.8 Feed System Installation


6.8.1 Firstly connect the corrugated horn and circular waveguide, circular waveguide
and circular waveguide, circular waveguide and movable flange (For C-band antenna
connect them with the screw M6×35 and flat & spring washer φ6 and fasten; For
Ku-band antenna connect them with the screw M4×30 and flat & spring washer φ4
and fasten.)
Note: Protect the sealed cover of corrugated horn against scuffing and entering water.
Seal ring must be put in the connecting parts.
6.8.2 Cover the feed adjustment tube into the corrugated horn, and fasten by bolts
M4×16.
6.8.3 After finishing the above step, cover the whole finished body into feed tube;
fasten adjustment tube and the top end of feed tube by bolts M8×20.
6.8.4 Take the whole feed system on the center of reflector, connect the lower flange
of feed tube and the upper flange of hub and fasten by bolt M10×25, flat washerφ10
and spring washerφ10.
6.8.5Install waveguide clip from the back of hub with bolt M4×10 and flat washerφ4
so as to fix circular waveguide; and then install OMT.(Before leaving factory, except
OMT, other parts had been connected ready. )

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6.9 Sub-reflector Assembly (As shown Fig.6)


When entering the reflector for installing sub-reflector, at best two persons and the
persons should stand on the places under which there are backup support structures
and ribs of the panel, and also some liners are laid.
6.9.1 Take the four sub-reflector supports and the assembly parts on the center of
reflector.
6.9.2 Connect one end of four sub-reflector supports with flange and reflector by bolt
M6×30, nut M6 and flat washer φ6, and connect the other end of sub-reflector support
with sub-reflector bracket by bolt M6×30, nut M6, flat washerφ6 and taper pinφ4×20;
finally tighten all above fasteners.

Adjustment screw
Sub-reflector

Sub-reflector bracket
Sub-reflector support

Fig.6 Illustrated Diagram for Sub-reflector Assembly


Note: No. on the four sub-reflector supports, and No. on the back structure, and No.
on sub-reflector bracket, the three No. must be corresponding.

6.10 Adjust Installation Dimension


6.10.1 Sub-reflector height and the distance between sub-reflector and hub is obtained
by adjusting four sub-reflector screws. (Before leaving factory, it has been adjusted
ready, on site the customers only do the fine-adjustment.)

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6.10.2 The height of corrugated horn surface is obtained by adjusting the feed tube.
Fix it according to the theoretical dimension, when adjusting, fine-adjust it up and
down to get the best electric specification.

7. Antenna Operation
Antenna operation mainly means antenna pointing adjustment; assure antenna work
on the best state.
7.1 Antenna Pointing Adjustment
A Firstly the customer should adjust antenna El according to El parameter. When
adjusting, drive up or down the antenna El by rotating El handwheel. Refer to El dial,
adjust El coarsely.
B According to Az parameter, obtain antenna Az by rotating Az handwheel.
C According to electric requirements, adjust Az and El repeatedly so as to get the best
signals.
7.2 Antenna Polarization Adjustment
Adjust Polarization by adjusting the movable flange on the front of OMT, which
locates the hub inner cavity. When adjusting, firstly loosen fastened bolts on the
movable flange, rotate the movable flange so as to get the best signals, finally fasten
the bolts here.
7.3 Installation Caution
A Prohibit to adjust it beyond antenna adjustment travel range, or the parts will be
damaged.
B After finishing adjustment, fasten all adjustment fasteners.

8. Satellite search of antenna system


Working-out the azimuth angle and elevation angle according to the local latitude and
longitude as well as the satellitic angle.
Making the antenna aim at the elevation angle by using compass and antenna control
system.
Searching the satellite roughly trough the antenna azimuth rotated by the antenna
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control system.
Using spectrum or other test equipments, according to the strength and weakness of
the receiving signal, adjust the azimuth angel and elevation angle time after time to
search the satellite precisely.
Notice:When searching the satellite, the antenna beamwidth center must be
ensured to aim at the satellite but not the sidelobes. (The main lobe of the antenna is
14dB higher than its first sidelobe).

9. Antenna Maintenance
9.1 Notice in Using the Antenna
When wind speed is getting to or exceed 216km/h, the antenna must be locked to the
sky (stow).
The operators should be trained before working.
Stop to check in case there are some abnormal sounds or abnormal instance, turn on
the machine after getting rid of the troubles.
9.2 Fasteners’ Maintenance
The connecting fasteners of the antenna system include blots, nuts, flat washers,
spring washers and taper pins. Checking the state of the fasteners regularly is an
important step of guaranteeing the normal working.
The interconnected parts of the entire structure system as follows:
Š The connecting of antenna back structures and the hub as well as the reflector.
Š The connecting of the sub-reflector and its brackets to the reflector.
Š Connecting of feed supports and the hub.
Š Connecting of antenna hub lower flange and the connecting frame.
Š Connecting of the antenna mount lower flange and the foundation bolt, etc.
The fasteners of all the above parts must be checked periodically. Tighten the loose
and replace the damaged fasteners as soon as you find it.
9.3 Surface Coating Maintenance
All the surface of antenna system exposed in the open air has been painted. In order to

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protect the appearance and guarantee the lifetime of the antenna system, the damaged
painted surface should be painted with the corresponding primer and surface paints.
Aluminum components should be coated with H06-42 zinc chrome primer, steel
components should be coated with CO6-1 red oxide primer, and the surface paints
adopt the corresponding color alkyd magnetism painting.

9.4 Rotary System Lubricating Oil Maintenance


The components need to be maintained as follows:
Š Azimuth axis, elevation axis, and rotation joints, before used, they should be
forced into the right amount of lubricating oil or coated with grease. Once or
twice a month under the normal temperature.
Š The reducers use lubricating oil. Force 30# HJ-30 oil into the oil hole. The quality
of the oil should be forced into for each reducer is 500ml. Once a year under the
normal temperature.
Š The jackscrews use lithium-based grease, once a season under the normal
temperature.
9.5 Antenna Facility Maintenance
The antenna system should be checked twice a year after its application. The main
checks are as follows:
Š If there is excursion for the sub-bearing, the rotation components should be
forced into lubricating oil.
Š Check if there are any destroy or water leaking existed in the ripple horn cover,
especially after hailing or heavy raining. Please replace the ripple horn cover in
time if it is leaking water, otherwise it will influence the normal work of the
system.
Š Prior to replace the ripple horn cover, the water and the abnormal things should
be cleaned first.
Š Don’t drop the small things such as blots in the horn.
9.6 Notice for antenna maintenance
1)Don’t let eyes aim at the horn mouth to look into.

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2)Never make yourself stand in the right front of the horn of transmitting signal.

10.Packing List
Item Name QTY Remark
Including 5* Az connection plate
1 Kingpost 1pcs &pin and 1 set El drive assembly
2 Hub 1pcs Including 3* lugs
3 Main Reflector 1pcs 12*main reflectors
Back Structure 12pcs
Back Struts Brace 48pcs
Sub-reflector Support 4pcs
Kingpost Support 2pcs
Az Drive Assembly 1set
Including feed and waveguide
4 Back Structure Feed System 1set tube
1*Kingpost support connector
1 set fasteners(including
24*self-made pin)
1 set sub-reflector(sub-reflector
Accessory Box 1pcs and sub-reflector bracket)
1* display transition panel
2*motor cover
1*OMT
1*User’s Manual
List for fasteners
Item Name Specification QTY. Remark
1 Bolt M6×30 28
2 Bolt M8×25 320
3 Bolt M10×30 8
4 Bolt M12×35 26
5 Bolt M16×60 10
6 Nut M6 28
7 Nut M8 320
8 Nut M10 50
9 Nut M12 26
10 Nut M16 10
11 Nut M24 16
12 Flat Washer φ6 56
13 Flat Washer φ8 640
14 Flat Washer φ10 50

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15 Flat Washer φ12 56
16 Flat Washer φ16 20
17 Flat Washer φ24 32
18 Taper pin 4×20 25
19 Taper pin 6×30 56
20 Self-made taper pin 24

11. Antenna Foundation Drawing

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Foundation Drawing

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