G-450A G-650A Antenna Rotator & Controller User Manual
Contents
1. Insert the mast adjustment plate s between the mast and the clamps on the rotor Controller Front Rear Panel Controls and Switches Controller Front Panel YAESU G_450A Power switch POWER OVERLAP len OFF INDICATOR JNISION 6 CONTROLLER Indicator needle adjustment screw Left rotation switch Right rotation switch Controller Rear Panel Adjustment potentiometer selection switch Indicator needle adjustment potentiometer Overlap LED adjustment potentiometer Rotor control interconnection jack When replacing fuses be sure to use a fuse of the same type and current rating YAESU Fuse holder Rotator Unit Components and Dimensions Rotator Unit Flat washer a Spring washer C CAN N TN Hexagonal nut U bolts Clamps amp g C N e 186 ___ gt Rotator Attachment Plate Dimensions The tower plate onto which the rotator unit is mounted must be drilled with four holes of 9 mm diameter equally spaced on a circle of 119 mm diameter The center to center distance between any two adjacent mounting holes is 84 mm Which Antennas Can Be Attached The size and type of antenna s that can be attached to this r2. Spring washer M8 x 16 length 16 mm Figure 3 Less than 1 m Mast Bearing GS 065 option y More than 1 m oo Figure 7 Rotor 10 Thrust Bearing GS 065 option Figure 4 Antenna mast TS an Must be parallel ra Provide sufficient slack Figure 8 Important The installation of a rotatable antenna on a tower system is a dangerous and potentially life threatening task if due care is not taken A tower must never be installed in a position where it could fall across power distribution cables in the event of a catastrophic tower failure during a windstorm or earthquake The control cable attached to this rotator could in the event of a nearby or direct lightning strike carry lethal voltages down the cable and into your home Yaesu strongly recommends the installation of suitable lightning arrestors on all control cables and coaxial lead in cables from your antenna installation See your dealer for details of available lightning protection devices If an electrical storm should be reported in your area quickly unplug the control cable from the rear of the rotator s controller box and disconnect the AC cable from the wall outlet Disconnect the coaxial cable s from the antenna s as well Do this only if the lightning is not in your
3. 4 Solder the wires to the round plug pins noting the color of the wire and the number associated o0 O 10 with each pin for reference later Pin 7 of the round connector is not used Confirm that all solder joints are firm and cleanly made as this part of the cable will be difficult to access once the rotator is installed on top of the tower Do not slide the shell onto the connector at this time Crimp the supplied pin contacts onto the wires on the opposite end of the cable per the illustra tion on the next page Referring to your notes of the wire color at each pin of the round rotator end connector insert the pins into the rectangular plug at the opposite controller end of the cable Be sure that each wire from the round connector is routed to the corresponding pin number in the rectangular connector i e 1 to 1 2 to 2 etc Temporarily connect the round plug to the rotator and the rectangular plug to the controller Make sure that the POWER switch is set to the Off position then connect the AC plug to your station s AC power outlet Turn on the Power switch The pilot lamps on the controller should become illuminated and the meter needle on the controller may rotate so as to align itself with the current position of the rotator remember the two units have not been aligned with each other Press the Lert left rotation switch and confirm that the rotator when viewed from the top a
4. Indicator Needle Adjustment Potentiometer Fig 2 so that the indicator needle points exactly to 0 8 After aligning the needle to 0 set the Adjustment Potentiometer Selection Switch back to the left position 9 Hold down the Ricut switch again and continue rotation to the right You should observe the OVERLAP LED becoming illuminated as rotation passes the 360 point If the OverLap LED does not light up at the 360 position the Overlap LED Adjustment Poten tiometer may be used to align the illumination threshold to the 360 point 10 Check to verify that rotation automatically stops at approximately 90 East representing a total rotation range of 450 from the original starting point 11 Press the Lerr and Ricut rotation switches a few more times verifying that rotation appears to be normal If so press the LEFT switch to return the rotator to the fully counter clockwise 0 position 12 At this time you must determine whether you wish to leave the Left Stop position at North or whether you wish to set it to South to allow uninterrupted rotation from southeast to north east to northwest to southwest for example If you wish to leave the Stop at North the checkout process is complete If you wish to set the Stop to South again loosen the needle adjustment screw on the face of the controller and rotate the needle to the South position Be certain that the rotator is fully rotated to t
5. immediate area as you could be killed instantly if lightning should strike while you are holding a cable If you have any doubts about your ability to install this rotator safely enlist the services of a professional antenna installation company 11 NOTE 12 YAESU leading the way Copyright 1998 Yaesu Musen Co Ltd All rights reserved No portion of this manual may by reproduced without the permission of Yaesu Musen Co Ltd
6. less than 48 50 mm nearly centered rotation can be achieved using the optional GL 33 mast adjustment plate per the illustrations below Mast Diameter 32 to 38 Use two plates Mast Diameter 39 to 47 Use one plate Mast Diameter 48 to 50 Do not use a plate e The use of a mast of outside diameter greater than 51 mm 2 01 will result in off center rotation The amount of offset increases with increasing mast diameter A mast of 60 mm outside diameter will result in rotation offset from the center by approximately 8 mm Note that commonly available steel water pipe is A usually specified in terms of inside diameter and B designed for holding in liquid under pressure it is not particularly designed to resist bending Consult with your dealer or a professional tower antenna installer for assistance in procuring a mast of specifications adequate for your antenna system Center line The rotation becomes off centered for masts 1 in lh eee with a diameter of less than 48 i l Mast adjustment plate Option Pa i Dm Use two plates for mast diameters between 32 and 38 AI a 1 Use one plate for mast diameters between 39 and 47 Do not use a plate for mast diameters between 48 and 50
7. 8 m 0 3 X 0 8 0 24 lt 0 25 and B if the mast weight plus the antenna weight is less than 10 kg However if the mast is 1 meter long the specifica tion will be exceeded 0 3 x 1 0 3 gt 0 25 Less than 0 8m EN lt Mast Clamp GC 038B option Example of a 50MHz Band 5 Element Yagi Antenna Table 1 Wind Loading Areas for Common Antennas Typical Elements Elements Elements 2 element 3 element 4 element l element w loading coils i 4 element i 5 element 2 element w loading coils 5 element i 6 element 3 element w loading coils 2 element Swiss Quad 2 element Swiss Quad 3 element 3 element trapped 10 element 4 element 9 4 element trapped E 10 element stacked 5 element 3 element trapped K 10 element x 4 3 element ti 4 element trapped i 10 element x 4 x 2 4 element 3 3 element trapped 12 element 5 element 4 element trapped g 12 element stacked 6 element 2 14 21 28 3 element trapped 12 element x 4 2 element Swiss Quad i 14 21 28 4 element trapped 7 12 element x 4 x 2 These are approximate values Wind Loading Area will vary significantly depending on element and boom diameters 4 Tower Mounted Antennas In the preferred tower mounting configuration the antenna Wind Loading Area must be less than 1 m G 450A or 2 m G 650A and the K factor see below must not exceed 100 G 450A or 180 G 650A where K Anten
8. YAESU G 450A G 650A Antenna Rotator amp Controller User Manual YAESU MUSEN CO LTD 1 20 2 Shimomaruko Ota Ku Tokyo 146 8649 Japan YAESU U S A 17210 Edwards Rd Cerritos CA 90703 U S A YAESU EUROPE B V Snipweg 3 1118DN Schiphol The Netherlands YAESU UK LTD Unit 12 Sun Valley Business Park Winnall Trading Estate Winchester Hampshire SO23 OLB U K YAESU GERMANY GmbH Am Kronberger Hang 2 D 65824 Schwalbach Germany YAESU HK LTD 11th Floor Tsim Sha Tsui Centre 66 Mody Rd Tsim Sha Tsui East Kowloon Hong Kong Packing List Check Before Installing Rotator Rotor Controller U bolts M8 x16 Bolts Hex Nuts 7 pin Round Plug 6 pin Rectanglar Plug Rubber Boot User Manual Available Options GA 2500 Shock Absorber Plate GS 680U Universal Bearing GS 050 Thrust Bearing 50 mm mast GS 065 Thrust Bearing 65 mm mast GC 038B Mast Clamp C 25MWP_ Control Cable 25 m C 40MWP_ Control Cable 40 m GL 33 Mast Adjustment Plate Specifications G 450A G 650A Rotation Torque 600 kgf cm 43 ft lbs Braking Torque 3000 kgf cm 217 ft lbs 5000 kgf cm 362 ft lbs Maximum Vertical load Continuous load 100 kg or less Instantaneous load 300 kg Mast Outside Diameter 32 to p63 center protrudes by 48 to 52 Rotation Range 450 360 Rotation Time 63 seconds at 50 Hz 51 seconds at 60 Hz Braking Type Mechanical stopper Mechanical and electrical stoppers Ante
9. e GS 065 does not allow the elimination of the mast weight from the K factor calculations above Control Cable Installation Before installing the rotator mast and antenna prepare the rotator control cable and test rotator system performance on the ground Potential alignment cabling or other problems can quickly be resolved on the ground once a rotator is mounted however troubleshooting may require that the tower be climbed and or the rotator be removed and lowered to the ground Control Cable Preparation The control cable to be used should have six stranded conductors of at least 0 5 mm 20 AWG diameter if the cable is shorter than 40 m in length 125 if the cable is longer than 40 m use conductors with a diameter of 0 75 mm 18 AWG or larger 1 2 3 Disassemble the supplied round plug slide off the rubber boot remove the setscrew from the shell using a small screwdriver then unscrew the shell from the plug Save the setscrew in a safe place until step 10 so you don t lose it Slide the rubber boot and the round shell over the rotator end of the cable Leave enough cable protruding to allow easy dressing the end of the cable Using special care to avoid nicking the insulation of the individual wires strip back 15 mm about 5 8 of the outer jacket of the cable from both ends Now strip 5 mm about 3 16 of insulation from each wire being careful not to nick the conductors 15 mm 5 mm lt
10. he Lert position in either case The position of the Left Stop can be set to whatever position you like North South East or West Just remember where you have set it because the antenna must initially be aimed in the same direction when it is installed on the mast see next section 13 Turn the Power switch Orr This completes the ground based testing of the rotator and controller 8 Installation of Rotator and Antenna on Tower The procedure for installing the rotator depends on the type of tower used The following instruc tions are generally applicable to most guyed crank up or roof towers 1 Attach the rotator to the tower s rotator mounting plate using the supplied M8X16 bolts and spring washers It is recommended that the tips of the bolts be lightly dipped in lubricating grease to ease disassembly in the future 2 If a thrust bearing such as the optional Yaesu model GS 065 is to be utilized mount it on the top of the tower see Figure 4 using the supplied hardware 3 Using a gin pole or other raising fixture insert the antenna mast through the bearing from above and set the mast in the rotator s mast clamps Do not tighten the mast clamps at this time just secure the U bolts to the point where the mast is held in place but is allowed to rotate freely 4 Partly tighten the thrust bearing s mast bolts so as to center the mast in the thrust bearing When you are satisfied that the mast
11. is centered back off slightly on each of the thrust bearing s mast bolts and if possible lift the mast by a very small amount approximately 5 mm or 3 16 just enough to lift the bottom of the mast slightly off the top of the rotator Now re tighten the thrust bearing s mast bolts to secure the mast in place This procedure takes all the weight of the mast and antennas off of the rotator all weight is being carried by the thrust bearing If no thrust bearing is used the mast should be allowed to rest on the top of the rotator 5 Verify that the mast rotates freely in the mast clamps and that the mast is properly centered in the clamps Now tighten the nuts on the U bolts of the mast clamp Do not over tighten the nuts on the mast clamps They should be tightened until the spring washer becomes flat then tightened further by 1 2 to one turn maximum 6 Install the rotator control cable s round plug into the jack on the side of the rotator s base and tighten the connector ring to secure the connector Slide the rubber boot over the connector while putting a slight amount of inward pressure on the rubber boot use electrical tape to secure the back end of the rubber boot to the cable This slight inward pressure on the rubber boot will enhance the weatherproofing of the installation Secure the control cable to the tower in several places using electrical tape and or UV resistant cable ties zA Install the antenna s on the ma
12. na Turning Radius m x Antenna Mast Weight kg Refer to the antenna manufacturer s specification sheet for determining the turning radius and weight of the antenna In this example a 14 MHz 3 element Yagi of Turning Radius 7 5 m Weight of 14 kg p and Surface area of 0 7 m is proposed for tower mounting below a 3 element 21 28 MHz trapped Yagi of Turning Radius 3 5 m Weight of 13 kg and Surface Area of 0 3 m The mast weight is 5 kg Note In such Christmas Tree installations compute the mast weight separately for each an tenna using the relative heights of the two antennas to apportion the mast weight The antenna system K factor then is the sum of the two antenna K factors K K factor of 14 MHz 3 element Yagi K Turning Radius 7 5 m X Weight 14 kg 2 5 kg 123 75 l Antenna Weight Mast Weight 5 kg 2 K K factor of 21 28 MHz 3 element trapped Yagi K Turning Radius 3 5 m X Weight 13 kg 2 5 kg 54 25 Antenna Weight Mast Weight 5 kg 2 K K K 123 75 54 25 178 The antenna system Wind Loading Area is 0 7 m 0 3 m 1 0 m The Wind Loading Area is within the specifications for both the G 450A and G 650A but the net K factor 178 can only be met by the G 650A Therefore the above antenna system should only be mounted using a G 650A or larger rotator Mast Bearing GS 065 option Note Installation of a Thrust Bearing such as th
13. nd the controller s needle turn counter clockwise together Stop rotation then press the Ricut right rotation switch and confirm that the rotator and indicator needle turn clockwise If rotation does not occur as indicated turn the Power switch off and re check your cable connections If the rotator and controller are working as described replace the plug shells setscrew and rubber boot removed in step 1 Assembly of 6 pin Plastic Connector Crimp with a pair of pliers lt Insert to the fullest extent Assembly of 7 pin Metal Connector pgri Wiring for the control cable identical numbers to be inte ge Le A alle oD Pin No 7 for the metal connector is not used Mounting the Rotator and Antenna Indoor Performance Check and Alignment 1 Temporarily connect the rotator unit and the controller using the connection cable prepared per the previous section 2 Check to be sure that the PoWER switch on the controller is set to Orr then plug the controller s AC cable into your station s AC outlet 3 Set the controller s Power switch to ON Verify that the controller s pilot lights have become illuminated 4 Hold down the Lert Left rotation switch and continue to hold it down until the rotator reaches the counter clockwise position where it automatically stops Left represents counter clock wise rotation when the rotator is viewed fr
14. nna K Coefficient 100 180 Wind Loading Area Pole type 0 5 m x 0 5m Tower type 1m 2 m Maximum Continuous Duty 3 minutes Operating Temperature Range 0 40 C Controller 20 40 C Rotor Rotor Dimensions and Weight 186 x 263 approx 3 5 kg Controller Dimensions and Weight 190 W x 125 H x 150 D approx 2 7 kg Power Supply Voltage AC 100 120 V 50 60 Hz Power Supply Current Consumption 0 5 A Installation Operation Precautions e Always use Metric M8x16 bolts when mounting the rotor to the tower or roof tripod mounting plate e Take care not to scratch the surface of the rotator or its mounting hardware If the protective coating is scratched the underlying metal may be subject to corrosion or rusting e During operation do not suddenly reverse the rotation during operation as this places a large load on the internal components of the rotor Let the antenna come to a complete stop before reversing the direction of rotation e Do not engage the rotor for more than three minutes of continuous rotation While this rotor can operate for up to five minutes continuously operation must thereafter be halted and the motor must be allowed to cool for at least 15 minutes afterwards e This rotator is designed to provide centered rotation of a mast with an outside diameter of between 48 mm and 50 mm 1 89 to 1 97 O D If it is necessary to use a mast of diameter
15. om the top 5 When the rotator has reached the left Stop position release the LEFT switch and check to see if the controller s indicator needle is pointing to 0 N North If the indicator needle is out of alignment slightly loosen the needle adjustment screw using a small Phillips screwdriver on the face of the indicator then turn the white needle adjustment knob so that the indicator needle points precisely to O 6 Just above the round connector jack on the rotator unit you will observe two raised calibration marks one each on the rotating bell and fixed base of the rotator These two marks should be directly aligned with each other If not place a small piece of masking tape on the rotating bell and the fixed base of the rotator unit and make a calibration mark on each piece of tape so as to mark the current position of the bell relative to the base This calibration mark will be used to verify the amount of rotation in the next step 7 Hold down the Ricut Right rotation switch and continue rotating to the right until the calibration marks from Step 6 are again precisely aligned Now check the indicator needle which should also have rotated fully 360 so as to be pointing exactly to 0 If the indicator needle is not pointing exactly to 0 go to the rear panel of the controller and set the Adjustment Potentiometer Selection Switch see Figure 2 to the right position Now use a small screwdriver to adjust the
16. otator will differ widely depending on the installation method local terrain and the maximum expected wind speeds at your location The following pages describe typical antennas which are acceptable for installation with the G 450A or G 650A The discussion below assumes maximum wind speeds of 30 meters per second 67 mph 108 kph and it is recommended that you include a safety margin of at least 30 to account for higher wind gusts or other factors which might potentially cause damage to your installation Pole Mounted Antennas Mounting of the rotator on a pole or mast results in a significant de rating of the size of the antenna which can be mounted due to the tremendous bending forces applied to the rotator s clamps For pole mounting the attached antenna must have a net mounted weight combined weight of antenna plus mast of 10 kg or less and the product of multiplying the Antenna Wind Load Area in m by the Height of the Antenna Mast in m must be 0 25 or less see Table 1 and Fig 1 Antenna Weight Mast Weight lt 10 kg Antenna Wind Load Area x Height of Antenna Mast lt 0 25 Refer to the antenna manufacturer s specification sheet for determining the weight and the surface area of the proposed antenna For a 50 MHz 5 element antenna of surface area of 0 3 m see Table 1 the above xample i 3 specifications for pole mounting will be met if A the antenna is mounted on a mast not longer than 0
17. st Use a compass to align the forward end of the beam toward North 0 or whichever direction to which you set the Left Stop in Step 12 of the previous section Co Provide sufficient slack in the coaxial cable such that the antenna can rotate over its full 450 range without putting any tension on the coax see Figure 8 Secure the coax to the tower using electrical tape and or UV resistant cable ties Ke Installation is now complete If you have scratched through the melamine coating of the rotator during installation you may wish to apply several coats of clear acrylic spray to help protect the bare metal from corrosion After installation is complete test the system by operating the rotator through the entire range of its rotation It is helpful to do so with the help of an observer so that rotation can be stopped if some obstruction binding or tension on the coaxial cable s turning loop should be encountered during the performance test Installation Note If using a roof tower with a long mast between the top of the tower and the antenna the use of a Guy Bearing is highly recommended The Yaesu GS 050 and GS 065 include guying ears which allow attachment of guy cables As installing a guying system may cause the center lines of the guy bearing and the rotator to become mis aligned be certain to check the roof tower attach ment and guy cable alignment to ensure that the mast is straight
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