G-80(`sDx/ c- | ooosDx

INSTRUCTION
IYIANUAT
G-800s
/ G-rooos
c- | ooosDx
G-80('sDx/
YAESUMUSENCO., LTD.
c.P.o.Box r50()
YAESU
TOKYO, JAPAN
YAESU G-800S/SDX& G-1000S/SDX
HEAVY-DUTY ANTENNA ROTATOR & CONTROLLERS
G-8005 Controller
G-800SDX Controller
G-1000SController
G-l000SDXControiler
The Yaesu G-800S/SDX and C-1000S/SDX are designed !o support ánd rotate medium- to largesize amateur and professional antenna arrays under remote control from the statjon operating
position. The factory-Lubricated rotator unit is housed in weatherproof melamine resin coaled
die-cast aluminum, to provide maintenance-free operation under all climatic conditions. A
mast alignmenÈ gauge on the rocator housing simplifies accurate mechanical alignment during
installation.
The controller unit is a handsomely-styleddesktop unit which provides 360' indicarion of
actual antenna bearing azimuth, in both compass direction and degrees. The deluxe SDX versions include operator selectable rotating speeds from 43 to 93 seconds per rotation, Handsfree operation is provided by both S and SDX versions: rhe S version having locking direcrion
switches, and the SDX version having a preset feature rrhicb brings Èhe antenna around to
the preset heading au@matically after being set, and slows rotation speed as the antenna
approaches the desired heading to bring the antenna to a gentle stop. The operator may
select the stopper heading (rhe bearing through which the rotator cannot be lurned) most
convenient for his location and operation, állowing full rotálion th.ough north, south or
both, if desired. In any case, 90" overlapping rotation allows rotacion through the selected
stopper heading.
Plug connectors are provided on both the rotator and $e
and servicing is simple.
Pleasu read rhis manual carefully before installing the rotator.
controller, so cable connection
SPECIFICATIONS
Voltage requirement:
110-120 or 220-240 VAc
Rotation range:
450" +0/-5"
Power consumption:
I O OV A
Maximum vertical loa&
200 ks (440 lbs)
Motor voltags
S vers.: 20 VDC
SDX vers.: 12 to 22 VDC
Wind loading area:
Tower Mounted:less than 0.45 m2
Mast Mounted: less Èan 2.2 m2
450' rotation time:
S vers.: 55 sec.
SDX vers.: 93 ilo sec, to 43 115 sec.
ConEol cable;
s-conductors: #20 AWG or larger
Braking torque:
G-1000S/SDX:
6,000kg-cm (434 ft-lbs)
G-800S/SDX: 4,000 kg-cm (269 ft-lbs)
Rotation torque (all models):
600-1100kg-cÍn(43.4-79,5ft-lbs)
Mast diameter:
38 - 63mm(l-à Èo 2-, inches)
Weighc
G-1000S/SDXRotatori
G-800S/SDXRotator:
S Controllen
SDx ConÈroller:
3.5 kg (7.7 lbs)
3.4 kg (7.5 lbs)
3.2 kg (7.0 lbs)
3.6 kg (7.9 lbs)
Maximum continuousduty:
5 minuÈes
UNPACKING & INSPECTION
When unpacking lhe rolaror confirm the
If any of rheseitemsare missingor damÊged,
presence of fte following items:
save the packing marerial and norify the shipping company (or shop where your bought it).
Rotacor Unit
ConÈrollerUnit
Mast Clamp
Round Cable Plug
RecÈangularCable Plug
Hex Bolts -
I
I
I palr,
I ass'y
I ass'y
M 8 x 1 6
M8x25
M 8 x 7 0
Split washer
Flar washer
M8 Nuts
Spare Fuse
4
4
( l l 7 V : 2 4 ,2 2 0 V : l A )
*
t2
8
I
Note that control cable is not included, as
lhe length must be determined case-by-case.
Contact your Yaesu dealer to obtain the
Length of cable your installation requires.
Before proceeding with insrallarion, confirm
rhat the AC voltage label on the rear of the
Controller matches your Iocal line voltagei
either trllTvrf for ll0 to 120 VAC, ortt220í
for 220 to 240 VAC. lf the labelled voltage
range does not match, return the controller
to the dealer from whom you purchased it
(different power transformers are installed
for the different volrage ranges).
If you plan to install the rotator on tbe masq above or without a tower. contact your
Yaesu dealer |o purchase a second clamp (model GC-038 or GC-048).
CONTROLLERADJUSTMENTS& SWITCHES
Bezel
Front
(l)
POWER switch
Press this switch to turn the Controller on
to rotate the antenna. Turn it off when the
rotator ls not ln use.
conFol), then press the {momentary) PRESET
switch to activate automatic rotation to the
desired heading. The LEFT/zuGHT switch
will abort preset operation.
12) LEFT/RIGHT Seesaw Switch
Press the LEFT side of this switch to rotate
tlte antenna counterclockwise. Press the RIGHT
side to rotate the antenna clockwise. ln S
versions only, pressing one side of tbe switch
once will start rotation, and pressing the
same side again will latch t}le rotator on
(so you can remove your finger). Pressing
the other side of the switch once will stop
aotation.
(41* SPEED Control
Set this control for che desired rotaring
speed between approximately 43 and 93 seconds
per 4500 revolution.
(3)*
PRESET Switch and Control
Set this control to the desired antenns heading
(according to the angular scale around this
+
{5) OVERLAP Indicator
This red LED giows when rhe anrenna is
rotated beyond about 360" (to 450') from
its original installation direction (0'). Check
this indicator before rotating the antenna
clockrrise, and turn the antenna counterclockwise to the desired position if the
indicator is on.
SDX versronsonly.
- 3 -
Rear
(l)*
RS-232C Cable Crornmet
lf the optional Digital Interface Unit is
installed, the RS-232C cable to the computer
exits through this grommet and passes through
the nylon cable clamp below it,
(2) FULL SCALE ADJ Porentiometer
This control calibrates the maximum rocation
angle of the azimuti indicating needle to
match the maximum angle of the rota!o..
{3)} PRESET ADJ A & B Potentiometers
These controls calibrate the angle of the
PRESET control on the front panel to march
the azimuth indicating needle. Po! A mus!
*
be adjusted only at the 4500 position, and
pot B only at lhe 0o position.
(4)*
OUT VOL ADJ Potentiometer
This control presets the voltage range at
pin 4 of the 8-pin External Control jack
inside, for calibrarion of the A-ro-D converter
on the {opiional) Dlgiral Interface Uni(.
{5) Rotator Control Cable Jack
The rotator cable connects to this 6-pin jack.
{6) FUSE Holder
A 2A fuse must be installed here for ÀC
mains voltages from 110 to 120V. A lA fuse
must be installed for 220 to 240V.
SDX versions only
4 -
CONTROL CABLE INSTALLATION
Belore installing !he antenna and rotator,
prepare the rocator control cable and test
rotator operarion thoroughly on rhe Sround
as described here. We recommend that after
this you also check the alignment of lhe
controller, as described in the following
(cenrer pin) is not used. Conf'rm all
solder joints are good and clean, as this
part of the cable will be hard to access
after installation. Don't slide the shell
( s ) Referring
to your notes of the wire color
ar each pin on the round (rotator) plu8,
connect the wires to the pjns of the
rectangular (controller) plug so thal lhe
wire from each pin on the rotator plug
connects ro rhe pin wjth the same number
2,
o n t h e c o n t r o l l e ri,e . , 1 t o 1 , 2 l o
erc. Pin 6 is not used. Don't slide the
shell on yeL.
Control Cable Preparation
Your control cabie should have five slranded
conductors of at least 0.smm (#22 Sauge) if
t h e c a b l e i s s h o r t e r t h a n 4 0 m ( 1 2 5 r ) ,o r
0.75mm (#18 gauge) if longer.
(l)
Disassemblethe Èwo supplied cable piugs:
slide the rubber boor off the round
plug, remove the selscrew in the shell
with a small screwdriver, and then un_
screw the shell from the plug. On the
rectangular plLr8, just remove the lwo
small screws in Lhe shell. Save $e setscrew from rhe round plug and the tlvo
small scrpws in a sale ploce urlrl :r-p
9, so you donrL loose them.
( 6 ) Temporarily connect the round plug to
ihe rotator, and the rectangular plug to
the jack on the controller. Make sure
thar the POwER switch is rr rh- off
{ourr po!r||on. anc tnen conrecl the
cord ro the AC power outlet,
\ 7 ) Turn on the POIVER switch. The piiot
lamps should light, and the direction
I n d r ^ o r o r m o v e t o l f e p o " r r r o no f t h e
rotator and stop.
\ 2 ) Slide the rubber boot and round shell
over lhe rotator end of the cable, iar
enough to aliow dressing lhe end of the
cable, Slide the rectangulár shell over
rhe olhêr (.ontÍoller) eno oÍ the cable.
( 8 ) P-pss the Lfl- | slde oí rhê .ee<a$ !w r.l-,
and confirm that the rotalor (when
vjewed from the top) and indicator needle
t u r n c o u nL e r c l o c k w i s e t o g e ! h e r . T h e n
p:ess rhe RICHT side of the seesaw
switch and confirm thal the roÈator and
indicator !urn clockwise, If rotation
does not occur as described, recheck
your cable connections.
( 3 ) Using special care !o avoid nicklng the
rnsularion of the indrvrdual wrrps, strip
back I5mm of lhe outer jacket of fte
. a b l e f r o m b o rh e r d s , a n d t h e n s t r i p
5mm of insulátion from each wire.
(e) If
( 4 ) Solder the wr-ês ro thp round pluS prns,
noting Lhe color of the wire and number
of each pin for reference later. Pin 6
- 5 -
rhe rotator and indicator work as
descflbed. repldce ll-e plug !hel1". "etscrew, two small screws and rLlbber boot
renoved in step l.
Controller Checkout & Alignment
These sreps are most easily carried out
after connecting the rotator cable, before
installing the rotator and antenna on the
mast or tower. They may be repeated after
installacionto confirm controller calibration.
The remaining steps on Èhis page are for
rhe SDX versions only.
( t ) Press $e LEFT side of the seesaw swilch*
unril the rorator rurns counterclockwlse
as far as it will go, and stops. The
indicaror needleshouldnow point pÍecisely
ro 0'. If it does not, or if you want to
change rhe starnng angle. see rRêposirioning rhe Direction Indjcatorr following
lhis procedure.
17) Ser lhe PRESET control to 0", and press
(6) Change the SPEED setting and confirm
rhar roiation speed changes accordingly.
rhe PRESET button (see rhe box below).
Rocacion should stop at 0o- Now turn
the PRESET conrrol sirghrly clockwise,
and note whelher the rotator moves. If
the rotator stopped befoÍe the indicator
reached 0', or if it did noÈ respond
when the PRESET conrrol was set slightty
clockwise, adjusÈ the PRESET ADJ B
(lower) potenuometerand repeat rhls step.
l 2 l Note the precise position of the rotator**
by referring to fte marks on the rorator
hou"inS lust above rhe cable sockeL.
Then press the RIGHT side of Èheseesaw
"wirch ro rurn the roraror turns cloclwlle
exacrly 360o (according to tbe marks on
the housing or acllral antennà posicion).
( 8 ) Set the PRESET control to 360o. Rotaron
should again srop ac 0". If not, adjust
the PRESET ADJ A (upper) pocentiomerer
and repeat this step.
{3) The rndrcarorre-o e "hould nnw po nr
to exactly the same position as in step
l, If noq adjusr Èe FULL SCALE ADJ
polentiomeler on the rear panel so that
ir does. The OVERLAP indicator should
come on at about 360'.
PRESET MODE OPERATION
(SDX versions only)
{ 4 J Press the RIGHT srvitch again to continue
clockwise rotation until the rotator
reaches iLs end-stop. The indicator should
now poinr ro about 90', and rhe OVERLAP
indicator should be on.
Pressing lhe PRESET button aclivates
the prese! mode: the rotator wiil turn
unril the indicator matches the PRESET
conrrol, and resettinS lhe conrrol will
s r a r r t h e a n r e n l at u r n i n ga g a i r a u t o m a r ically. Pressing the seesaw switch or
turning power off will cancel the
preser mode unril rhe PRESET bu*on
is pressedagain.
(s) T u Í n
the rotátor back and íorth to
each end-srop severaL times, confirming
lhac the indicator matches the roraror
rnalê
.r
lrfÊêrênr
\ê*inac
In SDX versions, set the SPEED conÈrol fully clockwise, and then hold Èe seesaw switch
during fotaLion. In S versions, press rhe seesaw svitch nomenlarily to srar! rotalion, ancl
press the other side of the switch to s!op.
If the rotator and anÈennaare already installed, nole lhe exact bear'ng of the antenna
boon instead of the marks on the rotator housing.
6 -
Repositioning the Direction Indicator
The azimurh indicaring needle may be repositioned, if desired, so thar the rorator stopping
poinc is south (or east or wesr) instead of
north (as shipped from Èhe factory). Of course
the rotator and antenna will have L(' oe
installed to maÈchlhe direcrion indicaror.
{l)
Turn on the controller and press Ée
seesaw switch to set rhe indicator needle
to 0o (stráight up). Then turn off rhe
POWER switch.
(2) Crasp rhe edge of the bezel,rurn it 10"
councerclockwise, and pull it off,
(3) Gripping the needle, move ir to rhe
desired heading (we suggestonly mulcipies
of 90" - that is N, E, S or W, since
the orange and blue markers on rhe
bezel can only be instatted in rhese
directions).
{4) Replace lhe bezel so rhat $e orange
marker ends up aligned wirh the needl4.
NOTE: When installing th€ antenna afrer
resetting the needle direction, make sure Èo
atm lhe antenna in same direction as Èhe
ne\À,needle setaing.
The compass heading labels can also be
repositioned on rhe dtrecLlon .ndtcètor .ace,
for situaiions where it may be more convenlent
PiteDtiobête.
Sbaft
to have the upmost indicator position be
oth€r than north.
(1) Perform sreps I and 2 of rhe procedure
ar the left,
(2) Note the position of the needle, rhen
Srasp it at iÈs center, and pull it straighr
off.
( 3 ) Push the E and W (or N and S) sloes
of the compassheading label sheeclowards
the center, and remove the sheet.
( 4 ) Determine which compass direcrion you
desire to be upmosq and reinstall rhe
compass heading label sheer.
R e p l a c e t h e n e e d l e a n d b e z e i i n the
as Èhey were before.
PRESET Knob Alignment (SDX vers. only)
If it is not possibleto calibrare rhe pRESET
knob using the A and B potenÈiomererson
the rear panel, pull off the PRESET control
knob, turn the shafr fully counterclockwise,
and rernstall rhe knob wl(h lrs poinrer a(
0' on the PRESET scale. The knob sropper
should be aligned with the countercrocKwtse
edge of the sloÈ in rhe panel behjnd the
ROTATOR
INSTALLATION
Thê G-800S/SDX rora|or unit is designed Èo
accommodate
medium-sizeantennaarrays, while
the G-1000S/SDX rotaror uniL is designed ro
accommodate large ancenna arrays. The maximum safe load depends on rhe wind surface
area, srze and weight of the anÈenna(s),
meÈhodand qualiÈy of mechanical instailarion,
ánd maximum wind velocity at rhe installacion
site. If your anÈennaspecilications do nol
include vr'ind surface area, reíer to Èhe Chart
on mls page.
The diagrams beiow show several recommenoeo
installations.Notjce that moun!ing the rotacor
insjde of a tower provides lhe greatest supporc
capaciry (anlenna wind surface area up !o
2m' for rhe C-800S/SDX, or 2.2m2 for rhe
C-1000S/SDX), and is preferable for targer
antennas or in high-wind areas. Use our
Cs-050 or C(,-065 Tower Mounr Bêanng ar
lhe lop of rhe lower (and make sure rha!
the bea.ing is aligned precisely wirh the
center of the rotator, so the mast is exactly
verticall.
o f i n s t a l l a t i o n t o a n r e n n a sw i t h n o r m o r e
than 0.45lLm square meters of wind surface
area, where Lm js Èhe length of mast (in
metersl beÈween Èhe antenna and rotaLor.
In addition ro antenna wind loading and
regardless of the rype of installation, rhe
overall size and weight of the antenna should
be considered. As a general rule, for Èhe
G-800S/SDX, the product of rhe rotating
radius and weight of the antenna should
not exceed 180 kg-m (1299 fr-lbs), and for
the G-r000s/sDx, 230 kg-m (2020 ft_lbs).
Where mulÍple antennas are to be installed
on the same mas! make sure to add the
wind loading for each antenna, and the
products of weight and radius for eacn wnen
calculating che above loading factors.
Make certain that the antenna attáches to
the mast ar the center of gravily of rhe
a n t e n n a . T h a t i s , l h e a n È e n n as h o u l d b e
balanccC, providing only downward force on
lhe mast (when lhere is no wind). These
rotacors can support up lo 250 kg (550 lbs),
If the rotator is mounred on the mast àbove
the tower iÈ should be as close to the ancenna
as possible, to minimize !he stress on the
rotator caused by wind pressure against the
antenna. This bending force on rhe roracor
1imi6 the supportingcapacity of lhis rvnp
Be sure to leave enough slack in the coaxiàl
cable feedline around the rotaÈor so that it
can rotate 450o.
ÁNTENNA WIND SURFACE AREA CHART
Mast Bracket
a -
Freq. EleArea
Freq. Ete
(MH, me.ts nf
(ltlH, mêits
7
2
2.2
l4/2r
3T.
7
|
o.2
11/21
4T.
7
2r,c'0.6
21/2A 3Tr
7
3tr
l.t
2t/2a
T
14
3
0.1
14/21/23 3'rt
t4
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1.2
t4/2V2A 4Tr
t4
5
1.7
50
4
2t
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0,45
50
5
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4
0.6
s0
6
2t
5
0,8
50
2SQ
2t
6
1.3
t44
t0
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r41
t0r2
28
3
0.3
t44
IOr4
28
0,42
144 10x2x4
!
28
5
0.6
430
12
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2SQ 0,3
430
r2x2
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3'lr
O.5
43O
t2x4
7/r4
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4Tr 0,8
* t = vith loading coits
SQ = swrss Quad confiCu.aiion
Tr - Trapped nultibander
No narking - iÍll-size monobandêr
Area
m:
0.4
0.5
0.3
o.4
0.4
0.4
0.25
0.3
0.3?
0.3
0.2
0.44
0.95
2.O
0.06
0.12
0,3
0.6
Mast Bracket Assembly & Antenna Positioning
11) Loosely fasten the mast bracket hàlves
( I ) to the rotaaor housing using four
shorÈbolts, spliÈ washersand flar washers
12).
t2) Insert the mast into the bracket, and
Referring to Èhe mast gauge markings
on lhe rotalor housing, tap lhe mast
bracker halves to center the mast while
alternarely tightening the short bolts
(2) and nuts (4) o. Èhe long bolts alternately.
finger-tighlen lhe four longer bolts (3)
with splii washers, flat washers and
nuts (4).
( 3 ) Se! the controllêr so thac ir indicares
precisely 0o (Norch). Then, using an
accurate map and known landrnarksj
position the antenna (without using che
controller) so that it points to true
North, AlÈernatively, consulr a Geodetic
Survey rnsp for your area to dêiermlne
the Vlagneric Dêvjation ar your locdLlon,
ànd then use a compass to posilion the
antenna so thaÈ it points to lrue North
(Magnelic North + Magnetic Deviation).
Be careíuL nol to disturb the anrerrra
direcrion when Íghtening the mast bracket
ln the next step.
Mast Gauge
markings
CAUTION: The G-800 and c-1000 roracors
are designed for verttcal mounring only.
One haif of the housing is mark€d trTOP
SIDE'. Warer and conraminantswill damage
the motor unit if it is mounred horizontally
The rotator moror is raÈd for five-minules
i n t e r m i t t e n t d u c y . H o w e v e r , i t can safely
run conlinuously for as long as
PÍoviding that it be broughÈ to
least len minutes afterwaÍds.
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9l
áw
38
G-800S/SDX only
32
29
4)
11
I
16
Í4
I
7
.6
PARTS LIST
Rotator Unit
(l)
12)
(3)
(4)
(5)
{6)
Lower Housing
Upper Housing
M6 Split washer (x4)
M6x20 Screw {x4)
Ball Bearing
Socket Gasket
(8)
(9)
(10)
(11)
(12)
( 13)
(14)
(15)
(16)
{l?)
3x10 Tapping Screw (x3)
Inner HousingSeal Plate
BindingScrew (x2)
Inner Housing
M3x8 screw
DC Motor
Motor Mount Plate
M3x6 Scre{ (x3)
Lo!íer Gearbox Plate
M3x8 Screw (x4)
(18) Coil Spring
(19) SpringWinder
(20) M3xg Setscrew
(21) Motor Pinion Gear
(22) 2.5mmE Ring
(23) Gearshaft(x3)
(24),(27)
Gear Assry n
(25) Gear Ass y C
(26),(28)
sandwichGear #l
(29) Divider Gear #l
(30),(31)
Divider Gear #2
(32) Spacer Bushing
(33) Upper Gearbox Plate
(34) MOx6Bolt (x4)
(35) Rotation Limiter
(36) Retainer Ring
(37) Limit Switch
(38) M3xl6 Screw
(39) Pot. Mounting Plare
(40) Binding Screw
(41) Potentiometer
{42} Pot. FIat Washer
(43) Pot. Lock Washer
(44) Pot. Nut
(45) Pot. Gear #l
(46) Pot. Cear Setscrew
I47l Por. Gear #2
{4E) Mast Clamp (GC-03E)
(49) M8x70 Bolt
(50),(53)8Ím split washer
(51) M8 Nut
(52) ErnmWasher
(54) MEx25Bolt
OPTIONAL PARTS
GS-050 50mm
THRUST BEARING
THRUST BEARING
cc-038
GC-048
MAST CLAMP
MAST CLAMP
't4 -