Yaesu G-2000RC User manual

1
INSTRUCTION
MANUAL
G·2000RC
\Jï::) YAESU MUSEN CO., LTD.
\"I// C.P.O. BOX 1500
vV TOKYO, JAPAN

Y AESU G-2000RC
HEAVY - DUT Y ANTENNA ROTATOR & CONTROLLER
The Yaesu G -20 00R C is designed to support and rotate large-size ama-
teur and professional antenna arrays under remote control from the
stat ion op era ting p osition. The factory-lubricated rotator unit is housed
in wea t he rpro of melamine resin coated die-cast aluminum, to provide
maintenanc e-free operation under ail climatic conditions. A mast align-
ment gu age on the rotator housing simplifies accurate mechanical
alignment dur ing installation.
The cont roller unit is a handsomely-styled desktop unit which provides
360° indi ca tion of actual antenna bearing azimuth, in both compass
direction and degrees.
Please r ead this manual carefully before installing the G-2000RC.
- 1 -

Voltage requirement:
110-120 or 220-240 VAC
Power consumption:
100 VA
Motor voltage:
24 V, split phase
360° rotation time (approx.):
67 seconds @ 60 Hz
80 seconds @ 50 Hz
Rotation torque:
2,000 kg-cm (145 ft-lbs)
Stationary braking torque:
Brake ON: 10,000 kg-cm
(723 ft-lbs)
Brake OFF: 800 kg-cm
(58 ft-lbs)
Brake mechanism:
Solenoid-controlled wedge
with 90 stop positions
(every 4°)
Rotation range:
370°
Maximum dead vertical weight:
250 kg (550 lbs)
Maximum
(momentary vertical
weight:
800 kg ( l, 760 lbs)
Control cable requirements:
8-conductors -#18 AWG
or larger, #16 AWG or
larger if over 100 ft.
Maximum
cable resistance:
!-ohm for terminais 7 & 8,
2 ohms for
others.
Rotor size:
22.5 cm max. diameter.
52 cm high w/2 mast clamps,
24.5 cm high w/ l
mast clamp
Mast diameter:
49 -63mm (2 to 2-~ inches)
Controller size (WHO):
110 x 150 x 190
mm
Weight:
Rotator: 9 kg (20 lbs)
Controller: 2.5 kg (5.5 lbs)

UNPACKING & INSPECTION
When unpacking the rotator confirm the presence of the following items:
Rotator Unit
Controller Unit ,
Mast Clamp l*
Cable Plug l**
Hex Bolts -
M8 x 20
4
M8 x 30 4
M8 x 70 4
Split washer
12
fiat washer 8
M8 Nuts 4
Spare fuse
(l l7V:2A or
220V:IA)
If
any of these items are missing or appear to be damaged, save the
carton and packing material and notify the shipping company (or dealer,
if purchased directly at his shop).
Before
proceeding with installation, confirm that the AC voltage label
on the
rear of the Controller matches your local line voltage: either
"l l7V" for 110 to 120 VAC, or "220" for 220 to 240 V AC. If 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 voltage ranges).
*
**
if your installation requires two mast clamps you can purchase
the second clamp (Yaesu mode! GC-048) from your Yaesu dealer.
Note that cable is not included with the rotator, as the length
must be determined case-by-case. Contact your Yaesu dealer to
obtain the length of cable your installation requires.
- 3 -

1
CONTROL CABLE PREPARATION & CONNECTION
Before installing the antenna and rotator, make ail connections and
test rotator operation thoroughly on the ground.
Your control cable should have eight conductors which should be at
least # 18 gauge.
(1) Slide the socket cap and shell of the supplied cable plug
- over the rotator end of the cable, and far enough to allow
dressing the end of the cable.
(2) Using special care to avoid nicking the insulation of the
individual wires, strip back 15mm of the outer jacket of
the cable from the rotator end, and then strip 5mm of insu-
lation from each wire.
(3) Solder the wires to the plug terminais, noting the color of
the wire and number of each terminal for reference la ter.
Confirm that ail solder joints are good and clean, as this
part of the cable will be difficult to access after installation.
Don't slide the shell on yet.
(4) At the controller end of the cable, strip back 5cm of the outer
jacket, and then strip l5mm of insulation from each wire.
SOCKET CAi-'
so-
- 4

(5) Twist the strands of each wire and form them into loops large
enough to encircle the terminal screws on the back of the
controller. Then lightly tin each loop with solder.
(6) Referring to your notes of the wire color at each terminal
on the rotator plug, connect the wires to the terminais on
the controller so that the wire from each terminal on the
rotator plug connects to the terminal with the same number
on the
controller, ie., 1 to 1, 2 to 2, etc.
CONTROLLER
(7) On the controller, make sure that the POWER switch is in
the OFF position, and that the BRAKE switch is in the
LOCK position. Then connect the line cord to the AC power
outlet.
(8) Turn on the POWER switch. The pilot lamps should light,
and the direction indicator move to the presetting position
(360°)
and stop.
(9) Set the BRAKE switch to RELEASE, and confirm that a
click is heard in the rotator.
(10) Press the LEFT switch, and confirm that the rotator and
direction indicator turn counterclockwise together. Release
the LEFT switch and confirm that the rotator slowly stops.
- 5 -

1
(11) Set the BRAKE s witch back to the LOCK position, and
listen again for the click.
(12) Repeat steps 9, 10 and 11, pressing the RIGHT switch instead
of the LEFT switch. The rotator and direction indicator
should turn clockwise.
(13) If operation does not occur _ as described above, check for a
wiring error in the cable connections. When everything checks
out in the above steps, slide the rotator plug shell up to
the plug, and screw it tightly into place.
Notes on Controller Operation:
The LEFT and RIGHT switches are disabled while the brake is locked.
While the brake is released stationary (braking) torque is approximately
800 kg/cm (694 lb/in).
If the antenna is rotated often while high wind or other twisting
forces stress the rotator, the power transformer in the Controller
may overheat (particularly in a hot environment). The warning indicator
beneath the BRAKE switch will then turn on, and the LEFT and RIGHT
switches will be disabled. After allowing time for the transformer to
cool, set the BRAKE switch to LOCK and press the RESET switch to
extinguish the warning lamp and re-enable the rotator.
If both LEFT and RIGHT switches are pressed at the same time, the
rotator turns clockwise.
- 6
-

PRE -INSTALLATION ALIGNMENT
Press the LEFT swltch and allow the rotator to turn fully counter-
clockwi se until it stops. The indicator should now point to 0° (North).
1f not, l oosen the screw in the center of the indi cator needle and
reset the needle.
NW
~
1
N
m NE
270 -W' -~- E-90
sw
s
1
180
SE
Press the RIGHT switch and allow the rotator to turn fully clockwise
until
it stops. The indicator should now point to 10° (East of North).
If not, adjust the calibration potentiometer on the rear pane l.
270-W
--- 370°
0
1 1
N
NW j_"' •-oo
sw
s
1
180
SE
- 7
REAR PANEL
~/
FULL SCALE
ADJUSTING--
POTENTIOMETER

The G-2000RC is designed to accommodate large antenna arrays. The
maximum safe load depends on the physical size of the antenna, method
and quality of mechanical installation, and maximum wind velocity at
the installation site.
The diagrams below show several recommended installations. Notice
that mounting the rotator inside of a tower provides the greatest
support capaci ty, and is _ preferable for larger antennas or in high-
wind areas. Use our GS-050 or GS-065 Tower Mount Bearing at the
top of the tower (and make sure that the Bearing is aligned precisely
I· with the center of the rotator, so the mast is exactly vertical).
If the rotator is mounted alone on the mast above the tower it should
be as close to the antenna as possible, to minimize the stress on the
rotator caused by wind pressure against the antenna. This bending
force on the rotator limits the supporting capacit y of this type of
installation to smaller antennas mounted close to the rotator. This
method is not recommended in high-wind areas.
Make certain that the antenna attaches to the mast at the center of
gravity of the antenna. That is, the antenna should be balanced, provid-
ing only downward force on the mast (when there is no wind). The
G-2000RC can support up to 250 kg (550 lbs).
Be sure to leave enough slack in the coaxial cable feedline around the
rotator so that it can rotate 370°.
- 8 -
Optional Lower
Mast Clamp

Mast Bracket Assembly & Antenna Positioning
(
1) Loosely fasten the mast bracket halves ( 1) to the rotator housing
using four
short bolts, split washers and fiat washers (2).
(2) Insert the mast into the bracket, and finger-tighten the four longer
bolts
(3) with split washers, fiat washers and nuts (4).
(3) Set the controller so that it indicates precisely 0° (North). Then,
using an
accurate map and known landmarks, position the antenna
(without using the controller) so that it points to true North.
Alternatively, consult a Geodetic Survey map for your area to
determine the Magnetic Deviation at your location, and then use
a compass to position the
antenna so that it points to true North
(Magnetic North + Magnetic Deviation). Be careful not to disturb
the antenna direction when tightening the mast bracket in the
next step.
(4) Referring to the mast .gauge markings on the rotator housing, tap
the mast bracket halves to center the mast white alternately
tightening the short bolts (2) and nuts (4) on the long bolts
alternately.
(5) Confirm the calibration of the controller indicator by rotating the
antenna precisely 360° so that the antenna itself is pointing in
the same direction as before. If the indicator does not show
exactly 0° again, adjust the FULL SCALE potentiometer on the
rear of the controller slightly, and repeat this step.
- 9 ~

markings
Use M8- l6 screws when
mounting inside
Tower
CAUTION: The G-2000RC is designed for vertical mounting only. One
half of the housing is marked "UP". Water and contaminants will damage
the motor unit if it is mounted horizontally or upside-down.
The rotator motor is rated for five-minutes intermittent duty. However,
it
can safel y run continuously for as long as ten minutes providing
that it be brought to rest for at least ten minutes afterwards.
- 10 -

- 11 -

PARTS LIST
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20) .
(21)
(22)
(23)
(24)
(25)
(26)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(40)
Gear Mounting Plate # 1
Motor
Brake Wedge
Switch Arm
Solenoid
Retracting Spring
Solenoid Pin
Brake Wedge Cover
Brake Wedge Support Pin
Spring
4mm dia. 'E'-Ring
3mm dia. 'E'-Ring
Wedge Holder Plate
Insulation Sheet
Potentiometer
Pot Di vider Gear # 1
Pot Gear Shaft
Pot Divider Gear #2
Pot Pinion
Revolution Stopper
Stopper Pin
M3 x 5 Stopper Screw
Limit Switch
Gear Shaft # 1
Gear Shaft #2
-(30) Rotation Gear Ass'y
Stud Support Sleeve
Gear Mount Plate #2
Rotation Switch
Lower Housing
Ball Bearings
'O'-Ring
& (39) Upper Housing
Internai Gear
Rubber Sea!: Socket
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(61)
(62)
(63)
(64)
(65)
- 12 -
Socket
Plug
Mast Clamp
3mm
dia. Spring
M3 x 6 Screw
M3 x 15 Screw
M3 x 25 Screw
2mm dia. x 12 Tapping Screw
M4 x 8 Screw
Split Washer
M4 x 8 Screw
Star Washer
5mm
dia. Split Washer
M5 x 16 Screw
5mm dia. Split Washer
M6 x 20 Hex Screw
8mm dia Split Washer
M8 x 12 Hex Boit
-(60) 8mm dia. fiat Washer
8mm dia. Split Washer
M8 x 30 Hex Screw
M8 x 70 Hex Screw
M8 Hex Nit
Socket Cap

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G-2000RC SCHEMA TIC DIAGRAM
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SW4a RI GHT 1 '(j
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Mluo 1
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LIMI T SWITCH
SW6
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6 o-----o:--eo---
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: SWB ~
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7 ()
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8

1
OPTIONAL PARTS
GS-050 50mm
THRUST BEARING
GC-048
MAST CLAMP
- 14 -
GS-065 65mm
THRUST BEARING

~
YAESU
V