In brief, I tilted over the mast, took off the Yaesu G-450 which I had been using, installed a new G-1000 model, screwed everything back together, raised the mast and after calibration and installing a new USB controller, everything worked.
OR you can read the long winded version (or just look at the pictures) next:---
Here at GM4FVM we have two masts and thus two rotators. On the main mast is (was) a Yaesu G-450 rotator.
At present on that mast are three antennas. First is the two band (two feed) DUAL four element on 50MHz and five element on 70MHz. Above that comes an 18 element I0JXX yagi for 432MHz and above that is an eight element I0JXX for 144MHz. Since I recently moved the 70cm antenna to a position between the other two antennas I have become a bit concerned that this may have added too much load for the G-450, especially in this windy area.
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| The G-450 looking tired |
Another concern I had was that the G-450 actually comes from an unknown background. I bought it in a silent key sale along with various other things (like the IC-7100 which I still use daily). I had no plan to use it, thinking it might give up parts. However, when my own G-450 failed I just put up this one and gave it no more thought. I do not know how old it is, or what work it has been doing before I got it.
And finally, I wanted to get more accuracy when it comes to directing the antennas. The G-450 has been operated using a Hy-gain YRC-3 controller. This gives me antenna control from the computer screen, and allows automatic moon tracking and so forth. The Hy-gain controller is fine for use on the lower bands, but it was not really accurate enough for the narrow beam width of the 70cm antenna. It would do for terrestrial work, but for moon bounce it cannot reach the accuracy I need (or what I think I need).
I have had computer control for a long time, originally using a controller kit from EA4TX and a Yaesu G-600 rotator. That arrangement went back about 20 years and the G-450s and the Hy-gain controller arrived about ten years ago. In fact the G-450 had been a step backwards in specification compared to the old G-600 and recently I began to worry if the G-450 was no longer up to the job of turning more, larger, antennas I now have.
So I began to think of a new stronger rotator. In the end I decided on the Yaesu G-1000. Compared to the G-450 this offered 33% more braking torque, up to nearly 100% more turning torque (depending on rotation speed) and 100% more weight capacity. The K factor, the overall measure of load performance, is 130% greater and the wind loading is 120% greater than the G-450. Overall this looked like a sensible step up to take.
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| The G-450 alongside the G-1000 |
The G-1000 has a DC motor while my older G-450 uses an AC motor. Hy-gain YRC-3 is switchable between AC and DC so it would drive the G-1000, but I wanted to step up to more accurate positioning while retaining computer control. The G-1000 controller has a six pin DIN socket on the back which allows the use of a Yaesu outboard box to connect to a computer via a USB socket.
The snag with the Yaesu USB box is that it costs £400+. After looking at a couple of alternatives I chose an ERC-Duo USB box which is often available in the UK for about £120. As it was out of stock when I needed one I ordered one from Wimo in Germany. The ERC box would allow me to interface between the G-1000 controller and PST-Rotator running on my computer and allow me full control and tracking.
When a suitably still day arrived to change over the rotators I hatched a plan to replace them without taking the antennas off their supporting pole. This would be tricky, given the weight involved but I hoped to support the pole from underneath. This would take the pressure off the rotator when the mast was tilted over, and allow me to change over. In the event it worked well. It would have worked even better if I had managed to get every aspect of the plan correct.
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| Mast tilted with pole supported and G-450 uncoupled from the pole |
Once I had got everything in the right place I could uncouple the G-450 and remove it. Then by undoing the bolts on the upper bearing I could move the pole up the rotator cage and leave enough room to get the G-1000 into the space.
Along with the rotator in the SK sale came a spare Yaesu rotator cable. This had been cut and mended in three places but has proved to be of much use down the years. I used it to test and calibrate the G-1000 in the shack before the day when the change over was to be done. Whilst the calibration might be slightly different with my normal cable it would be close enough. In fact it proved to be within about two degrees. What went wrong here was that I set the rotator to 110 degrees when I always set my antennas to 100 degrees. Good plan which worked in almost all ways save one silly mistake.
I was able to slot the new rotator into the gap and lower the pole into the top bracket. Then there was the tricky job of tightening the bolts on the rotator which Yaesu insist has to be done in strict order in quarter turns at a time. This is good advice as I have snapped alloy fitting before with these rotators. Do not over-tighten!
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| G-1000 installed |
That done I could lower the pole with the rotator (and antennas!) attached, do up the bolts on the base and start re-aligning the bearing at the top of the rotator cage. I was aware that this bearing had become slightly out of kilter over the years and so it needed to be done anyway.
With all that complete there were still a few jobs to do. Yaesu recommend testing and I did this first using the Hi-gain controller and the spare cable. I took this out to the mast and did various tests ensuring the everything was rotating freely. This was done with the mast still tilted but with the support removed, which meant that the antennas could rotate through 360 degrees.
Next task was to do some final tests from the shack using the G-1000 controller. These proved that only minor calibration corrections were needed, but everything was 8 degrees off target. That was because I had set it up in advance at 110 degrees. My rule of thumb is that antenna booms parallel to the ground equals 100 degrees. Doh! But it would have been 2 degrees off on the other side anyway so that was not so much of a problem.
This time I did a careful job, checking the "parallel to the ground" theory with a spirit level. I set each antenna carefully and then raised the mast vertically. Outside job done.
Careful twiddling got the G-1000 controller spot on. The G-1000 controller is much more accurate in its alignment than the G-450 was as it allows five different settings to be juggled. Once this was working OK, it was time to align the ERC-Duo USB box.
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| ERC-Duo box with 50 pence piece for scale |
In contrast with the big heavy Yaesu controller, the ERC-Duo box is tiny and draws its current from the USB cable. This is basically another controller which gives its instructions to the Yaesu controller. Thus it needs to be calibrated separately. It comes with a link to download and install a "Service tool" and a "Rotator Control" piece of software. I used the service tool to do the alignment and save the data onto the computer. I will not be using the rotator control as the ERC-Duo can take instructions from PST-Rotator.
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| Final result. |
All done now. I managed quite easily to get the Yaesu controller and the ERC-Duo to agree on the bearings and for that to line up with my key points viewed from outside. That needed an eight degree correction, easily done by moving the Yaesu pointer and setting an eight degree offset on PST-Rotator.
I find it more accurate to use this "parallel to the ground = 100 degrees" alignment than trying to find North - eccentric I know, but practical. Obviously this angle will be unique to every tilting mast, but once you have worked it out it will stay true. On my other mast it is 98 degrees so the original and extension walls of our house are not exactly parallel ....
The only slight issue just now is that when I transmit on 2m the pointer on PSTRotator moves about four degrees clockwise. Just the pointer, the antennas and the pointer on the G-1000 controller do not move. This is RF is getting into the ERC-Duo leads somewhere, and I am busy trying to solve that minor problem.
The new rotator moves quietly and quite quickly - the rotation speed is variable. It certainly behaves much better than the G-450 ever did. I am happier that this can take the strain of those three antennas, even though I am already wondering if the 432MHz beam would not be better on the other mast !!!!
But why, oh why, do Yaesu keep selling rotators with huge expensive mechanical pointers when a simple digital display would do just as well? And why do they charge £400+ for a USB box when all rotator controllers should have USB connections as standard. SPID rotators have their failings, but at least they have no moving parts to break down and they connect easily to a computer.
73 Jim
GM4FVM























