Yaesu_G-450XL_user.pdf

YAESTJ Antenna Rotator Model G-450XL Antenna Rotator Model G-450XL m Thank you for your purchase of the Yaesu G-450XL Antenna Rotator. It has been designed to provide many years of trouble-free operation. Before using the rotator, read this manual thoroughly to learn about its installing and operation. 1. Description of Parts (dimensions in mm) Controller Front Panel 190 POWER Switch OVERLAP Indicator LED 1 I d Screw for LEFT Switcn R|GHT Switch Direction Indicator Needle Controller Rear Panel ADJ Rotator Control Potentiometer Cable Jack Jack Cover , e.eee. Power Cable Cable Clamp Rotator Unit (f, 8 Washer 3000Kgf-cm (217 ft-lbs)Braking Torque 110kg or less (normal) (242 Ibs) 300kg (momentarily) (660 Ibs) Max. Vertical Load Mast Outside Diameter048-050 Rotation Range450 360 Rotation Time51 sec at 60Hz (63 sec at 50Hz) Braking TypeDrum Brake Antenna K Coefficient (See page 4) 100 Wind Loading AreaUnsupported Mast: 0.5m2 (used with 0.5m mast) Tower Supported Mast: 1m2 Max. Continuous Duty5 minutes Station/Antenna Cable0.5mm (#24 AWG) 5-conductor cable (0.75mm (#22 AWG) when cable is 40m (131 ft) or longer) Rotator Dimensions0169x266 Rotator Weightapprox. 3.2kg (7.04 Ibs.) Voltage Requirement110-120 or 220-240 VAC Motor Voltage24VAC Optional Parts 6-Conductor Cable GS-050 Universal Thrust Bearing GC-038 Lower Mast Clamp 4. Cautions and Warnings Concerning Use 1) The G-450XL has been designed to rotate antenna masts measuring from 48 mm to 50mm in diameter. We recommend that only masts in that diameter range be used. 2) Do not reverse the antenna movement suddenly, as the internal mechanism will undergo excessive stress. 3) Operate the rotator no longer than five minutes continuously. While you can operate it for as long as ten minutes, make sure to let the motor rest for at least ten minutes after that. 4) The inside of the rotator is lubricated with a high-performance grease for long-term lubrication. Under normal operating conditions, this lubricant does not need to be changed. 5) Do not transmit near the controller unit with VHP hand-held transceivers, as controller needle malfunction may result. 5. Mounting Antenna IMPORTANT: The tolerance limits for mounting your antenna vary to a large extent, depending on the mounting method, geographical location, wind velocity, and antenna height. Take into consideration the special conditions of your area when mounting the antenna, making adjustments as necessary. PAGES Antenna Rotator Model G-450XL i 1) Pole Mounting (using with optional GC-038 Lower Mast Clamp) Use the following formula to calculate the height restrictions for installing the antenna: (Antenna Wind Loading Area) X (Height in meters) < 0.25 (Example: An antenna with a wind loading area of 0.4m2 and a mounted height of 0.6m is acceptable, as the product of the two is 0.24.) An antenna with a wind loading area of 0.4m2 can be used if the indicated height is less than 60cm (23.6 inches). IMPOTANT: Keep the weight of the mounted Height antenna under 10 kg (22 IDS) for pole mounting. 2) Tower Mounting Make sure that the antenna K coefficient and the wind loading area of the antenna to be installed do not exceed the specified ranges. IMPOTANT: You can more reliable operation if you keep the parameters within 60 percent of the maximum specified ranges. Antenna K Coefficient = Antenna Rotation Radius (in m) X Total Antenna Weight Incl. Mast (in kg) Calculate the rotation radius and antenna weight based on the figures given by the antenna manufacturer. As the wind loading area is often not specified, we have listed the average values in the chart below: Wind Loading Areas for Common Antennas Band Elements Type Area (nr ) 7 2 2.2 7 1 Loaded 0.2 7 2 Loaded 0.6 7 3 Loaded 1.1 14 3 0-7 14 4 1.2 14 5 1,7 21 3 0.45 21 4 0.6 21 5 0.8 21 6 1.3 21 2 Swiss Quad 0.3 Band Elements Type Area (m- ) 28 3 0.3 28 4 0.42 28 5 0.6 28 2 Swiss Quad 0.3 7/14 3 trapped 0.5 7 / 14 4 trapped 0.8 14 / 21 3 trapped 0.4 14 / 21 4 trapped 0.5 21 /28 3 trapped 0.3 21 / 28 4 trapped 0.4 14/21/28 3 trapped 0.4 14/21/28 4 trapped 0.5 Band Elements Type Area (m2 ) 50 4 0.25 50 5 0.3 50 6 0.37 50 2 Swiss Quad 0.3 144 10 0.2 144 10 Stacked 0.44 144 10 x4 0.95 144 10 x2 x4 2.0 430 12 0.06 430 12 Stacked 0.12 430 12 x 4 0.3 430 12 x 2 x 4 0.6 PAGE4 Antenna Rotator Model G-450XL Use the following chart to calculate configurations for tower-mounted antennas: Antenna Type 50M 5 el 21 M 3 el Rotation Radius 2.5 m (98.4 inches) 4.2 m (165.4 inches) Weight 7 kg (15.4 Ibs) (mast: 2.5kg, or 5.5 Ibs)* 10 kg (22 Ibs) (mast: 2.5 kg, or 5.5 Ibs)* TOTAL Antenna K Coefficient 17.5 42 59.5 Wind Loading Area (in m2) 0.3 0.45 0.75 * Mast weight of 5kg ( I I Ibs) is divided equally between the two calculations. 6. Installing and Adjusting 1) Use 5-conductor (or 6-conductor) cable with a diameter of 0.5mm (#24 AWG). Only use as much cable as you need. NOTE: If the cable exceeds 40m (131ft) in length, increase the diameter to 0.75mm (#22 AWG). 2) Assemble the cable according to the following diagram: Tin the wire with solder. Controller Side Rotator Side Make sure to insert this first. Make sure to perform the following procedure with the POWER switch in the off position Do not use #1. 3) Connect the round plug to the rotator, and attach the other end to the Rotator Control Cable Jack on the controller, making sure to match the numbers on the pins (use only pins #2 to #6). 4) Check the power switch with the cable in this state. Insert the power plug in the wall socket, and turn the POWER switch on. The pilot lamp should light, and the direction indicator will rotate until it reaches the current direction of the rotator. 5) Press the LEFT switch on the controller to turn the rotator counterclock- wise. It will stop automatically. Confirm that the needle of the direction indicator rests exactly on the 0 (N) position. If there is needle error, loosen the screw in the center of the indicator and adjust the needle to 0. 6) Look at the rotator, choosing a point from which to mark its rotation. 7) Next, press the RIGHT switch on the controller to turn the rotator 360 in a clockwise direction, watching the point on the rotator that you chose in step #6. Make sure that the rotator returns to the correct position. Also watch the needle on the direction indicator, checking that it returns exactly to the 0 (N) position. If it does not align correctly, adjust the ADJ potentiometer on the rear panel of the controller. Furthermore, ensure the OVERLAP indicator LED lights up when the rotator near the end of its 360 rotation (If it does not light up, adjust the potentiometer (VR1) on the printed circuit board inthe controller). PAGES Antenna Rotator Model G-450XL 8) 9) Press the RIGHT switch again, moving the rotator and the direction indicator 90 clockwise. The OVERLAP indicator LED will light up, informing of the 90 rotation overlap (use this warning for safe operation). Test the clockwise and counterclockwise rotational movements a few more times. If you turn on the controller with the cable unattached, the direction indicator will rotate about 300 from the 0(N) position before stopping. If you want to change the original position of the direction indicator (e.g. clockwise stop at south), adjust the screw in the center of the indicator to the desired position. If both (LEFT/RIGHT) switch are pressed simultaneously, RIGHT (clockwise) movement takes precedence. 7. Installing Rotator Unit IMPORTANT: The method of installation depends on the type of tower being used. The following example describes the procedure for installing on a roof tower. 1) After completing the previous inspection, move the rotator back to the initial fully counterclockwise point and turn off the power. 2) Attach the rotator to the center of the roof tower attachment plate. 3) Attach a bearing to the top of the roof tower. 4) Take the mast and pass it through the top side of the bearing, then set it in the mast clamp on the rotator and tighten the bolts. 5) Leave enough slack in the coaxial cable from the antenna so that it can rotate more than 360 and still not be too tight. 6) After the above procedure is finished, check the movement of the rotator. Especially make sure that no part is receiving excessive stress, and that the antenna direction matches that of the indicator. Leave some slack in the cable. 1m or less Adjust these so that they are parallel. 1m or more Rotator Spring II Washer M8X16 Hex Bolt 8. Maintenance and Inspection If you experience trouble during rotator operation, refer to the following charts for troubleshooting. Voltage between Controller Jacks Resistance between Rotator Jacks D C) $) d about 30V (AC) bout 3.5V (DC) about 30V (A POWER switch ON about 3.5V LEFT switch ON - about 30V RIGHT switch ON about 30V ) 3 (DC) (AC) (AC) 1 2 3 4 5 6 1 2 ci- sco n 3 soon o soon 4 CO CO CO 5 CO CO CO 80 6 CO CO CO 4n 40 PAGE6 Antenna Rotator Model G-450XL Controller No. 1 2 3 4 5 6 7 8 g 10 11 12 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 DESCRIPTION FRONT PANEL POWER SWITCH Not Used M3x6 SCREW FOR POWER SWITCH L/ROTATE SWITCH (2P) Not Used R/ROTATE SWITCH (3P) Not Used 3x8 SCREW OVERLAP LED LED P.C.B. NAME PLATE GEAR BASE VR CONTROL MOTOR PULLEY M2.6x5 SCREW FOR MOTOR LARGE PULLEY RUBBER BELT GEAR *t=1 GEAR *t=1 E RING GEAR #2 VR GEAR M3x3 VR GEAR SETSCREW 3x5.5 SPACER COLLAR INDICATOR PLATE 3x6 SCREW DIAL SCALE EYELET LAMP Not Used SPACER M3x10 SCREW INDICATING NEEDLE INDICATOR NEEDLE SETSCREW CHASSIS POWER TRANSFORMER Not Used M4x10 SCREW M4 NUT TERMINAL BOARD M3 SPRING WASHER LOCK WASHER M3x15 SCREW M3 NUT VR MOUNTING BRACKET VR 10kQ (NV17CA-10S) P.C.B. ASSY RUBBER GROMMET POWER CORD (117V3W) POWER CORD (220V3W) FRONT PANEL SUPPORTING PLATE 3x6 SCREW CABLE CLAMP 4x8 SCREW COVER RUBBER FOOT 3x8 SCREW TERMINAL COVER Yaesu P/N S8000164 N 7090051 S8000784 N7090O52 N7090053 S8000785 S810O437 S810O438 S8001252 S80O081 1 Q900O405 M21 90008 S8000787 S8000788 S8000789 S8000738 S8000790 S8000790 S80O0791 S80O0792 S800O1 59 S8000793 S8000794 S8000795 S8000155 S8000796 S8000161 S8000797 Q 1000068 S800O1 60 S8000798 S8000162 S8000799 S8000166 L3 190004 S800080O S8000801 S800O1 69 S80O1254 S800O8O2 S80008O3 S8000804 S8000163 Q9000404 S81 00439 S80008O5 S81 00271 S81 00270 S80001 72 S800O8O6 S8000171 S8000807 S8000167 S8000173 S80008O8 S80OO17O QTY 1 1 2 1 1 15 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 11 1 2 1 3 3 1 1 1 1 4 4 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 4 2 1 PAGE7 Antenna Rotator Model G-450XL Controller Unit Exploded View PAGES Antenna Rotator Model G-450XL Rotater No. 1 2 3 4 5 6 7 8 g 10 11 12 15 16 17 18 19 20 21 22 25 26 27 28 29 30 31 32 33 34 35 36 37 38 43 44 50 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 DESCRIPTION LOWER PLATE BRAKE DRUM BINDING SCREW Not Used MOTOR (U-129) BRAKE SPRING WINDER M3x3 SET SCREW M3x8 SCREW COIL SPRING O RING 4x6 MOTOR PINION GEAR E RING RETAINER GEAR BASE VR (AZIMUTH) ROTATOR BEARING GEAR ASSY GEAR Not Used UPPER PLATE 4x8 SCREW STOPPER VR GEAR M4x8 SCREW VR GEAR 4x1O SCREW CONTROL GEAR *t=1 RETAINER RING GEAR SHAFT #3B GEAR SHAFT t=3A GEAR ASSY GEAR ASSY GEAR COLLAR L=10 COLLAR L = 4 CAPACITOR 60V AC/ 100 A/ F 3x6 SCREW LOWER HOUSING M6x16 BOLT SOCKET GASKET 6-PIN SOCKET 3x10 SCREW BALL BEARING RING HOUSING COVER M6x20 BOLT NAME PLATE PIPE CLAMP M8 U-BOLT M8 WASHER M8 SPRING WASHER M8 NUT 6-PIN PLUG CONNECTOR BOOT Not Used Yaesu P/N S80O1255 S80O1 1 74 S8000369 S810O440 S8000952 S8000953 S8001256 S8001257 S8001258 S8000947 S8000946 S8001259 S810O317 S800126O S80O1261 S8001262 S80O1264 S8OO1265 S8OO1266 S8O01267 S8001268 S8001269 S8OO1270 S800O457 S8000393 S8OO1271 S8OO1 272 S8O01273 S8001213 S8001274 S80O1275 S8001276 Q9000477 S8000369 S8000360 S8001277 S8000943 S8100313 S8001228 S80OO364 S8001 1 73 S8001278 S80O1279 S80O128O S8OOO224 S8O01282 S8001283 S8001284 S8O01285 S81 00321 S8OO1014 QTY 1 1 2 1 1 1 4 1 1 1 1 1 1 2 1 3 1 3 1 1 1 1 4 1 1 1 1 1 2 1 1 1 1 2 1 3 1 1 3 98 1 1 4 1 2 2 4 8 4 1 1 PAGE9 Antenna Rotator Model G-450XL Rotater Unit Exploded View 24 23 57 PAGE 10 Antenna Rotator Model G-450XL Controller Unit Circuit Diagram X o PAGE 11 YAESTJ Performance without compromise. YAESU MUSEN CO., LTD. C.P.O. Box 1500, Tokyo, Japan YAESU EUROPE B.V. Snipweg 3, 1118DN Schiphol, The Netherlands YAESU GERMANY GmbH Am Kronberger Hang 2, D-65824 Schwalbach, Germany YAESU UK LTD. Unit 2, Maple Grove Business Centre Lawrence Rd., Hounslow, Middlesex, TW4 6DR, U.K. YAESU U.S.A. 17210 Edwards Rd., Cerritos, CA 90703, U.S.A. Printed in Japan E07431000