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 •Controller Rear Panel

190 ADJ Rotator Control Jack Cover
Potentiometer Cable Jack

POWER
Switch ,
OVERLAP
e.eee.
Indicator
LED

•^1 I ^\d Screw for LEFT Switcn R|GHT Switch

Direction Indicator Power Cable Cable Clamp

Needle

•Rotator Unit •Rotator Unit Attachment Measurements

(f, 8 Washer
<j68 Spring Washer
M8 Nut

Clamps

Rotator Unit

2. Supplied Items (make sure everything has been included)

Rotator M8 Spring Washers 8

Controller M8 Hex Nuts 4
U-Bolts 6-Pin Metal Connector 1
Clamps Waterproof Cap 1
M8X 16 Hex Bolts Instruction Manual 1
M8 Flat Washers Warranty Card 1

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 Antenna Rotator Model G-450XL

3. G-450XL Specifications
Rotation Torque 650Kgf-cm (47.0 ft-lbs) at 60Hz
{550Kgf-cm (39.8 ft-lbs) at 5QHz>
Braking Torque 3000Kgf-cm (217 ft-lbs)
Max. Vertical Load 110kg or less (normal) (242 Ibs)
300kg (momentarily) (660 Ibs)
Mast Outside Diameter 048-050
Rotation Range 450°
360° Rotation Time 51 sec at 60Hz (63 sec at 50Hz)
Braking Type Drum Brake
Antenna K Coefficient (See page 4) 100
Wind Loading Area Unsupported Mast: 0.5m2 (used with 0.5m mast)
Tower Supported Mast: 1m2
Max. Continuous Duty 5 minutes
Station/Antenna Cable 0.5mm (#24 AWG) 5-conductor cable
(0.75mm (#22 AWG) when cable is 40m (131 ft) or longer)
Rotator Dimensions 0169x266
Rotator Weight approx. 3.2kg (7.04 Ibs.)
Voltage Requirement 110-120 or 220-240 VAC
Motor Voltage 24VAC
Optional Parts
• 6-Conductor Cable • GC-038 Lower Mast Clamp
• GS-050 Universal Thrust Bearing

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.

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Antenna Rotator Model G-450XL

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 Height

(Example: An antenna with a wind loading area

of 0.4m 2 and a mounted height of 0.6m is
i
acceptable, as the product of the two is 0.24.)
An antenna with a wind loading area of 0.4m 2
can be used if the indicated height is less than
60cm (23.6 inches).
IMPOTANT: Keep the weight of the mounted
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 7 7 7 7 14 14 14 21 21 21 21 21

Elements 2 1 2 3 3 4 5 3 4 5 6 2

Type Loaded Loaded Loaded Swiss Quad

Area (nr ) 2.2 0.2 0.6 1.1 0-7 1.2 1,7 0.45 0.6 0.8 1.3 0.3

Band 28 28 28 28 7/14 7 / 14 14 / 21 14 / 21 21 / 2 8 21 / 28 14/21/28 14/21/28

Elements 3 4 5 2 3 4 3 4 3 4 3 4

Type Swiss Quad trapped trapped trapped trapped trapped trapped trapped trapped

Area (m- ) 0.3 0.42 0.6 0.3 0.5 0.8 0.4 0.5 0.3 0.4 0.4 0.5

Band 50 50 50 50 144 144 144 144 430 430 430 430

Elements 4 5 6 2 10 10 10 10 12 12 12 12

Type Swiss Quad Stacked x4 x2 x4 Stacked x 4 x 2x 4

Area (m2 ) 0.25 0.3 0.37 0.3 0.2 0.44 0.95 2.0 0.06 0.12 0.3 0.6

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 Antenna Rotator Model G-450XL

Use the following chart to calculate configurations for tower-mounted antennas:

Antenna Type Rotation Radius Weight Antenna K Wind Loading
Coefficient Area (in m 2 )
50M 5 el 2.5 m 7 kg (15.4 Ibs) 17.5 0.3
(98.4 inches) (mast: 2.5kg,
or 5.5 Ibs)*
21 M 3 el 4.2 m 10 kg (22 Ibs) 42 0.45
(165.4 inches) (mast: 2.5 kg,
or 5.5 Ibs)*
TOTAL 59.5 0.75
* Mast w e i g h t of 5kg ( I I Ibs) is d i v i d e d e q u a l l y between the two c a l c u l a t i o n s .

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.

Rotator
Controller Side
Side
Make sure to insert this first. Do not use #1.

• Make sure to perform the following procedure with the POWER switch in the off position

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 ( V R 1 ) on the printed circuit board inthe controller).

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Antenna Rotator Model G-450XL

8) 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).
9) 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 c o m p l e t i n g the previous i n s p e c t i o n ,
move the rotator back to the i n i t i a l f u l l y
counterclockwise point and turn off the power.
2) Attach the rotator to the center of the roof
Leave some
tower attachment plate. slack in the 1m or less
3) Attach a bearing to the top of the roof tower. cable.
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 Adjust these
the antenna so that it can rotate more than so that they 1m or more
are parallel.
360° and still not be too tight. Rotator
6) After the above procedure is finished, check
the movement of the rotator. Especially make
Spring
sure that no part is receiving excessive stress, II Washer
and that the antenna direction matches that M8X16 Hex Bolt
of the indicator.

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) 1 2 3 4 5 6
\
about 30V (AC) ci-
1
\ sco n soon CO CO CO

2 o~ CO CO CO
\ soon
bout 3.5V (DC) about 30V (A 3
3 •\ CO CO CO

POWER switch ON @<->@ about 3.5V (DC)

LEFT switch ON ©«->@ about 30V (AC) 4 \ 80 4n
RIGHT switch ON ©«© about 30V (AC) 5 \ 40
6 \
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 Antenna Rotator Model G-450XL

Controller
No. DESCRIPTION Yaesu P/N QTY
1 FRONT PANEL S8000164 1
2 POWER SWITCH N 7090051 1
3 Not Used — —
4 M3x6 SCREW FOR POWER SWITCH S8000784 2
5 L/ROTATE SWITCH (2P) N7090O52 1
6 Not Used — —
7 R/ROTATE SWITCH (3P) N7090053 1
8 Not Used — —
g 3x8 SCREW S8000785 15
10 OVERLAP LED S810O437 1
11 LED P.C.B. S810O438 1
12 NAME PLATE S8001252 1

15 GEAR BASE S80O081 1 1

16 VR CONTROL Q900O405 1
17 MOTOR M21 90008 1
18 PULLEY S8000787 1
19 M2.6x5 SCREW FOR MOTOR S8000788 2
20 LARGE PULLEY S8000789 1
21 RUBBER BELT S8000738 1
22 GEAR *t=1 S8000790 1
23 GEAR *t=1 S8000790 1
24 "E" RING S80O0791 1
25 GEAR #2 S80O0792 1
26 VR GEAR S800O1 59 1
27 M3x3 VR GEAR SETSCREW S8000793 1
28 3x5.5 SPACER S8000794 1
29 COLLAR S8000795 1
30 INDICATOR PLATE S8000155 1
31 3x6 SCREW S8000796 11
32 DIAL SCALE S8000161 1
33 EYELET S8000797 2
34 LAMP Q 1000068 1
35 Not Used — —
36 SPACER S800O1 60 3
37 M3x10 SCREW S8000798 3
38 INDICATING NEEDLE S8000162 1
39 INDICATOR NEEDLE SETSCREW S8000799 1
40 CHASSIS S8000166 1
41 POWER TRANSFORMER L3 190004 1
42 Not Used — —
43 M4x10 SCREW S800080O 4
44 M4 NUT S8000801 4
45 TERMINAL BOARD S800O1 69 1
46 M3 SPRING WASHER S80O1254 1

49 LOCK WASHER S800O8O2 1

50 M3x15 SCREW S80008O3 1
51 M3 NUT S8000804 2
52 VR MOUNTING BRACKET S8000163 1
53 VR 10kQ (NV17CA-10S) Q9000404 1
54 P.C.B. ASSY S81 00439 1
55 RUBBER GROMMET S80008O5 1
POWER CORD (117V3W) S81 00271
56 1
POWER CORD (220V3W) S81 00270
57 FRONT PANEL SUPPORTING PLATE S80001 72 2
58 3x6 SCREW S800O8O6 2
59 CABLE CLAMP S8000171 1
60 4x8 SCREW S8000807 1
61 COVER S8000167 1
62 RUBBER FOOT S8000173 4
63 3x8 SCREW S80008O8 2
64 TERMINAL COVER S80OO17O 1

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Antenna Rotator Model G-450XL

Controller Unit Exploded View

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 Antenna Rotator Model G-450XL

Rotater
No. DESCRIPTION Yaesu P/N QTY
1 LOWER PLATE S80O1255 1
2 BRAKE DRUM S80O1 1 74 1
3 BINDING SCREW S8000369 2
4 Not Used — —
5 MOTOR (U-129) S810O440 1
6 BRAKE SPRING WINDER S8000952 1
7 M3x3 SET SCREW S8000953 1
8 M3x8 SCREW S8001256 4
g COIL SPRING S8001257 1
10 "O" RING 4x6 S8001258 1
11 MOTOR PINION GEAR S8000947 1
12 "E" RING RETAINER S8000946 1

15 GEAR BASE S8001259 1

16 VR (AZIMUTH) ROTATOR S810O317 1
17 BEARING S800126O 2
18 GEAR ASSY S80O1261 1
19 GEAR S8001262 3
20 Not Used — —
21 UPPER PLATE S80O1264 1
22 4x8 SCREW S8OO1265 3

25 STOPPER S8OO1266 1
26 VR GEAR S8O01267 1
27 M4x8 SCREW S8001268 1
28 VR GEAR S8001269 1
29 4x1O SCREW S8OO1270 4
30 CONTROL GEAR *t=1 S800O457 1
31 RETAINER RING S8000393 1
32 GEAR SHAFT #3B S8OO1271 1
33 GEAR SHAFT ±t=3A S8OO1 272 1
34 GEAR ASSY S8O01273 1
35 GEAR ASSY S8001213 2
36 GEAR S8001274 1
37 COLLAR L=10 S80O1275 1
38 COLLAR L = 4 S8001276 1

43 CAPACITOR 60V AC/ 100 A/ F Q9000477 1

44 3x6 SCREW S8000369 2

50 LOWER HOUSING S8000360 1

54 M6x16 BOLT S8001277 3

55 SOCKET GASKET S8000943 1
56 6-PIN SOCKET S8100313 1
57 3x10 SCREW S8001228 3
58 BALL BEARING S80OO364 98
59 RING HOUSING S8001 1 73 1
60 COVER S8001278 1
61 M6x20 BOLT S80O1279 4
62 NAME PLATE S80O128O 1
63 PIPE CLAMP S8OOO224 2
64 M8 U-BOLT S8O01282 2
65 M8 WASHER S8001283 4
66 M8 SPRING WASHER S8001284 8
67 M8 NUT S8O01285 4
68 6-PIN PLUG S81 00321 1
69 CONNECTOR BOOT S8OO1014 1
70 Not Used — —

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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