Presentation

HF OPERATORS
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KenPro KR 5400
VHF Azimuth Rotor Repair
John White
VA7JW
22 May 2008
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KR 5400
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ƒ Ken Pro KR5400
ƒ “Standard Rotor” assembly
for Az El applications
ƒ Elevation rotor
ƒ Azimuth rotor
ƒ Controller
22 May 2008
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VHF – UHF Antennas
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ƒ Antenna Array
70cm yagi
2 M yagi
22 May 2008
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Rotor & Preamps
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EL Rotator
Mounted to AZ
AZ Rotator
Mounted to mast
2M & 70cm
Pre-Amps
Power Distribution
for Pre-Amps
22 May 2008
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Manual Instructions
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?
22 May 2008
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The Assembly
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Rotor Mounting
EL plate
Standard
In-Tower
mount
22 May 2008
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For AZ-EL
Invert AZ rotor
add
Elevation plate
per manual
NSARC HF Operators
¨
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Problems
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ƒ Worked perfectly on Install
ƒ After about 3 months, it did not work perfectly
ƒ Controller displayed incomplete and variable rate
of Azimuthal rotation
ƒ Directions displayed did not correlate at all with
actual direction
22 May 2008
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Trouble Shooting
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ƒ Antenna array rotated full 360 degrees
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ƒ Checked cables, connectors, surge protectors
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OK
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OK
 repaired one weather damaged connector though
ƒ Controller tracked simulated Az pot
OK
ƒ Az pot in rotor measured when rotated
OK
ƒ Where is the Problem ?
22 May 2008
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Call Ken Pro
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ƒ KenPro rotator line now owned by Yaesu
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 Yaesu G 5500 series rotor
ƒ Called Yaesu in California
 Vertex standard 714-827-7600 > Amateur Products
ƒ For the Az–El stack, was advised that,
 the bolts had to point down (what bolts?)
 that the terminal block had to be on the bottom (it is)
ƒ Then ….
22 May 2008
went on.
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Top of Az Rotor
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ƒ Note that the pipe clamp is removable
Top of Az
rotor housing
TOP
Top
Pipe Clamp
Removed
Nice clamp guides to position the clamp
22 May 2008
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Bottom of Az Rotor
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ƒ Presumed that the EL bracket goes on bottom of
AZ rotator since pipe clamp is normally on top.
ƒ No instructions to state otherwise
Bottom of Az
rotor housing
BOTTOM
EL bracket
No clamp guides to position the pipe clamp
22 May 2008
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As Mounted (incorrect)
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Bracket for
the EL rotor
Inverted Az Rotor
22 May 2008
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Correct Mounting
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Bracket for
the EL rotor
Inverted Az Rotor
22 May 2008
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What Difference
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ƒ You noticed?
ƒ The TOP of the AZ
rotor still faces UP
ƒ These Bolts face down
ƒ The Terminal board is
on the bottom
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Top
ƒ The Rotor housing MUST
remain “upright”
22 May 2008
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NSARC HF Operators
Bottom
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Why – because of the Gap
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ƒ Rotation has to take place between top & bottom
Weep Hole
The bottom side normally fixed in place
This being part of the top, rotates
There has to be a break between
the two housing to allow rotation.
The Gap
(very small & tight)
In this installation configuration, the gap is
now on top rather than sheltered
underneath as would be the situation for
the conventional in-tower position
22 May 2008
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Suspect
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ƒ The GAP will let water leak in
ƒ The water cannot drain out when Az housing is upside down
ƒ The Rotor is probably full of water
ƒ It had to come down
ƒ Right then (4 May 08)
22 May 2008
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Removal
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Look!
Its a bird,
It’s a plane,
its superham
Glen (VE7GPK)
Jim (VA7JGM)
Bas (VE7RIJ)
did all the hard work
22 May 2008
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Moment of Truth
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ƒ One drip (JW) holding another
Water pouring out
22 May 2008
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Open Up
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Can’t undo
the casing bolts
Use an impact
wrench to
loosen bolts
Removed pipe
clamp OK
22 May 2008
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Yuk!
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A new form
of lubricant
Full to the
brim with H20
22 May 2008
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Disassembled
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(on the bench)
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Nuts & Bolts
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Top housing
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Ring gear
Bottom
housing
Gear/Motor Mount Ass’y
Gear Mount Plate
22 May 2008
Gears
Motor
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Ball bearings
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Motor Mount Plate
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Bottom
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Terminal board
Az
Position
Pot
Motor
Gear / Motor Mount assembly - Bottom
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Motor Mount Plate
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Top
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Disk Brake
“Limit Switch”
Hinged Stop Arm
stops housing rotation
and stalls motor
Date Code 97-02
Gear / Motor Mount assembly - Top
22 May 2008
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Rework Process
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Soaked rotor ass’y in fresh water overnight
Disassembled and dried parts
Brushed & scrubbed off rust & corrosion
Cleaned W.W Pot with contact cleaners (many times)
Painted Gear Mount Plate (Tremclad primer & finish)
Soaked bearings & gear train in Oil
Re-greased housing ball races
Coated all other surfaces with AntiSeize (zinc loaded greasy stuff resists corrosion)
22 May 2008
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Re-Assembly
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Plate coated with thin
film of Anti-Seize
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Red is grease – not Rust
Painted
Some blemishes still evident
22 May 2008
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Cleaned up well
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Tested
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ƒ Connected Rotor to Controller
ƒ Test for 360 degree rotation
ƒ Test that meter tracks actual position
 set meter CAL on rear of controller
ƒ Set over rotation limits - rotation is “centered”
22 May 2008
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Yet to Do
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ƒ One pipe mast clamp is cracked
 opinion from welder, casting cannot be repaired
 unrelated failure
ƒ Part on back order.
ƒ Expect delivery mid June
ƒ Put up (hopefully) prior to Field Day
22 May 2008
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Thanks
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ƒ Thanks to all who helped out
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John
Jim
Bas
Glen
Janice
Bob
Bob
Rob’t
Barrie
AOV
JGM
RIJ
GPK
JMO
CYU
RPX
RPL
HBS
 Apologies if I missed anyone ..
22 May 2008
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