YAESU G-800DXA, G-1000DXA, G-2800DXA Antenna Rotator & Controller User Manual
This manual provides detailed information for the installation, operation, and maintenance of the Yaesu G-800DXA, G-1000DXA, and G-2800DXA antenna rotators and controllers.
Introduction
The Yaesu G-800DXA, G-1000DXA, and G-2800DXA are heavy-duty antenna rotators and controllers designed for rotating large tower-mounted amateur and professional antenna arrays remotely from the station operating position. These units feature a robust clamshell design with dual-stacked ball bearings for durability and water resistance. They utilize a variable-voltage DC motor for smooth operation and eliminate the need for large starting capacitors.
⚠️ IMPORTANT! Safety Precautions
The installation of a rotatable antenna on a tower system is a dangerous and potentially life-threatening task if due care is not taken.
- Never install a tower where it could fall across power distribution cables during a catastrophic failure (e.g., windstorm, earthquake).
- The control cable can carry lethal voltages during a lightning strike. Yaesu strongly recommends installing suitable lightning arrestors on all control and coaxial cables.
- During an electrical storm, unplug the control cable from the rotator controller, disconnect the AC cable from the wall outlet, and disconnect coaxial cables from antennas. Perform this only if lightning is not in the immediate area.
- If you have any doubts about your ability to install the rotator safely, enlist the services of a professional antenna installation company.
Key Features
- Robust clamshell design with dual-stacked ball bearings for load distribution and water resistance.
- Variable-voltage DC motor for smooth, reliable operation.
- Factory-lubricated rotator unit housed in melamine resin-coated die-cast aluminum for maintenance-free operation in all climates.
- Mast alignment gauge for accurate mechanical alignment.
- Handsome desktop controller with 360° radial indication of antenna bearing azimuth.
- Selectable rotating speeds (G-800DXA/G-1000DXA: 40-100 sec/360°; G-2800DXA: 50-120 sec/360°).
- Preset heading capability for automatic rotation to a desired direction.
- Special "auto slow start" and "auto slow stop" features on the G-2800DXA model to prevent antenna array and tower stress.
- Optional GS-232A Computer Control Unit for PC control via RS-232 serial interface.
Controller Front Panel
The controller front panel features the following controls:
- POWER Switch: Turns the controller on and off.
- LEFT/RIGHT Seesaw Switch: Rotates the antenna counter-clockwise (LEFT) or clockwise (RIGHT).
- PRESET Control and START Switch: Sets a desired antenna heading using the outer scale (180°-270°) or inner scale (0°-90° if North is set to 0°). Pressing START initiates automatic rotation to the preset heading. The LEFT/RIGHT switch can abort preset operation.
- SPEED Control: Adjusts the rotating speed between approximately 30 and 100 seconds per 360° revolution.
- OVERLAP Indicator: A red LED that illuminates when the antenna is rotated beyond approximately 180° from its original installation direction.
Controller Rear Panel
The controller rear panel provides connections and adjustment points:
- EXT CONTROL Connector: 6-pin mini-DIN for connection to the optional GS-232A Computer Control Unit.
- SELECT SWITCH: Set to "ADJ. MODE" for calibration, and "OPERATION MODE" for normal use.
- FULL SCALE ADJ Potentiometer: Calibrates the maximum rotation angle of the azimuth indicating needle.
- OVERLAP LED ADJ Potentiometer: Calibrates the OVERLAP Indicator.
- PRESET ADJ (A & B) Potentiometers: Calibrate the PRESET control angles. Pot. A for the 180° position, Pot. B for the 270° (450°) position.
- OUT VOL ADJ Potentiometer: Presets voltage range for the GS-232A Computer Control Unit calibration.
- Rotator Control Cable Jack: 6-pin jack for the cable from the rotator unit.
- FUSE Holder: Houses a 2-A fuse for 117V AC or a 1-A fuse for 220V AC.
- AC Cable: Connects to the AC mains supply.
Antenna Considerations
The type of antenna and installation method significantly impact performance and safety. Wind speed is a critical factor.
Pole-Mounted Antennas
For pole mounting, the product of [Antenna Wind Load Area (m²)] x [Height of Antenna Mast (m)] must be less than 0.45 for G-800DXA/G-1000DXA or 0.8 for G-2800DXA. A safety margin of at least 40% is recommended.
Example: For a 14 MHz 3-element Yagi with a surface area of 0.7 m², a mast not longer than 0.3 m is suitable for G-800DXA/G-1000DXA (0.7 m² x 0.3 m = 0.21 m³), and a mast not longer than 0.6 m for G-2800DXA (0.7 m² x 0.6 m = 0.42 m³).
? Advice: It is recommended that antennas/masts do not exceed 60% of the maximum rating for a safety margin.
Diagram Description: A diagram shows a pole-mounted antenna with the rotator at the base. It indicates mast length limits: "Less than 0.3m (G-800DXA/-1000DXA)" and "Less than 0.6 m (G-2800DXA)". An optional mast clamp (GC-038 or GC-048) is also depicted.
Tower-Mounted Antennas
For tower mounting, the Wind Loading Area must be less than 2 m² (G-800DXA), 2.2 m² (G-1000DXA), or 3 m² (G-2800DXA). The "K" Factor ([Antenna Turning Radius (m)] x [Antenna + Mast Weight (kg)]) must not exceed 180 (G-800DXA), 230 (G-1000DXA), or 950 (G-2800DXA).
Example: A stacked antenna system (14/21/28 MHz 5-element Yagi, 18 MHz 3-element Yagi, 50 MHz 5-element Yagi) with a total K factor of 255 and a Wind Loading Area of 1.7 m² requires a G-2800DXA.
? Advice: It is recommended that antennas/masts do not exceed 60% of the maximum rating for a safety margin.
Diagram Description: A diagram illustrates a tower-mounted antenna system. It shows the rotator at the base of the tower, with the antenna mast extending upwards. An optional thrust bearing (GS-065) is shown mounted on top of the tower. The diagram also indicates the need for sufficient slack in coaxial cables.
Wind Loading Areas for Common Antennas (Typical)
| Band (MHz) | Elements | Area (m²) | Band (MHz) | Elements | Area (m²) | Band (MHz) | Elements | Area (m²) |
|---|---|---|---|---|---|---|---|---|
| 7 | 2-element | 2.2 | 28 | 3-element | 0.3 | 50 | 4-element | 0.25 |
| 7 | 1-element, w/loading coils | 0.2 | 28 | 4-element | 0.42 | 50 | 5-element | 0.3 |
| 7 | 2-element, w/loading coils | 0.6 | 28 | 5-element | 0.6 | 50 | 6-element | 0.37 |
| 7 | 3-element, w/loading coils | 1.1 | 28 | 2-element, Swiss Quad | 0.3 | 50 | 2-element, Swiss Quad | 0.3 |
| 14 | 3-element | 0.7 | 7/14 | 3-element, trapped | 0.5 | 144 | 10-element | 0.2 |
| 14 | 4-element | 1.2 | 7/14 | 4-element, trapped | 0.8 | 144 | 10-element, stacked | 0.44 |
| 14 | 5-element | 1.7 | 14/21 | 3-element, trapped | 0.4 | 144 | 10-element, x 4 | 0.95 |
| 21 | 3-element | 0.45 | 14/21 | 4-element, trapped | 0.5 | 144 | 10-element, x 4 x 2 | 2.0 |
| 21 | 4-element | 0.6 | 21/28 | 3-element, trapped | 0.3 | 430 | 12-element | 0.06 |
| 21 | 5-element | 0.8 | 21/28 | 4-element, trapped | 0.4 | 430 | 12-element, stacked | 0.12 |
| 21 | 6-element | 1.3 | 14/21/28 | 3-element, trapped | 0.4 | 430 | 12-element, x 4 | 0.3 |
| 21 | 2-element, Swiss Quad | 0.3 | 14/21/28 | 4-element, trapped | 0.5 | 430 | 12-element, x 4 x 2 | 0.6 |
Control Cable Preparation (G-800DXA/-1000DXA)
The user must supply and prepare the control cable for the G-800DXA and G-1000DXA models. The cable should have six stranded conductors of at least 0.5 mm (#20 AWG) diameter for lengths up to 40 m, or 0.75 mm (#18 AWG) or larger for longer cables.
- Disassemble the supplied round plug: slide off the rubber boot, remove the setscrew, and unscrew the shell.
- Slide the rubber boot and shell over the "rotator" end of the cable.
- Strip back the outer jacket and the insulation from each wire.
- Solder wires to the round plug pins, noting wire color and pin number. Pin 7 is not used.
- Crimp supplied pin contacts onto the wires on the opposite end of the cable.
- Insert pins into the rectangular plug at the controller end, matching wire color/pin number to the rotator end.
- Temporarily connect the round plug to the rotator and the rectangular plug to the controller. Ensure the POWER switch is OFF.
- Plug in the controller's AC cable and turn the POWER switch ON. Pilot lamps should illuminate.
- Test rotation: Press LEFT switch, verify counter-clockwise rotation. Press RIGHT switch, verify clockwise rotation. If incorrect, check connections.
- If testing is successful, reassemble plug shells, setscrew, and rubber boot.
Diagram Description: Diagrams illustrate the assembly of a 6-pin plastic connector and a 7-pin metal connector. Another diagram shows the wiring for the control cable, indicating identical numbers to be connected between the rotator and controller ends.
Mounting the Rotator and Antenna
Indoor Performance Check and Alignment
Before final installation, perform these checks on the ground:
- Temporarily connect the control cable between the rotator and controller.
- Set the SELECT SWITCH on the rear panel to "ADJ. MODE".
- Ensure the POWER switch is OFF, then plug in the AC cable and turn ON. Verify pilot lights.
- Press LEFT switch and hold until the rotator stops at its counter-clockwise limit.
- Check if the controller's indicator needle points to 180° (South). If misaligned, remove and re-seat the bezel and needle.
- Align the rotator's calibration marks (on rotating bell and fixed base).
- Press RIGHT switch and hold until calibration marks realign. Verify the indicator needle has rotated 360° and points to 180°.
- If the needle is not at 180°, use a small screwdriver to adjust the FULL SCALE ADJ potentiometer on the rear panel.
- Press RIGHT switch again. Verify the OVERLAP LED illuminates as rotation passes 180°. Adjust OVERLAP LED ADJ potentiometer if needed.
- Verify rotation stops automatically at approximately 270° (West), indicating a 450° total rotation range.
- Test LEFT/RIGHT rotation several times. Set rotator to 270° (West).
- Set PRESET control to 180°, press START. Rotator should stop at 180°. Adjust PRESET ADJ A potentiometer if needed.
- Set PRESET control to 270°, press PRESET. Rotator should stop at 450° (270° West). Adjust PRESET ADJ B potentiometer if needed.
- Repeat steps 12-13 until reliable presetting is achieved.
- Set the SELECT SWITCH to "OPERATION MODE" and turn the POWER switch OFF.
Diagram Description: A diagram of the Controller Rear Panel is shown, highlighting adjustment potentiometers and switches.
Installing the Dial Heading Sheet
To set a desired compass direction (e.g., South) to the top of the dial:
- Turn on POWER, press seesaw switch to set needle to 180°, turn POWER OFF.
- Remove bezel and needle.
- Determine desired top direction and install the heading label sheet, aligning it with the azimuth scale.
- Replace needle and bezel.
PRESET Knob Calibration
This procedure is for aligning the PRESET knob if front panel adjustments are insufficient.
- Pull off the PRESET control knob.
- Set the potentiometer shaft to fully counter-clockwise, then turn 30° clockwise.
- Re-attach the knob, aligning its stopper with the counter-clockwise edge of the slot in the panel.
- Repeat steps 12-13 from the "Indoor Performance Check and Alignment" section.
- Set the SELECT SWITCH to "OPERATION MODE".
Installation of the G-800DXA/-1000DXA Rotator and Antenna on Tower
Important!! Before mounting the mast, drill a 9 mm hole through the mast bottom, centered 50 mm from the end, for the anti-twist support bolt.
- Drill the mast hole as described above.
- Attach the rotator to the tower's mounting plate using M8 x 16 bolts and spring washers.
- If using a thrust bearing (GS-065), mount it on the tower.
- Partly tighten the mast clamp to the rotator housing using M8 x 25 bolts.
- Insert the antenna mast through the bearing and into the rotator's mast clamps. Partly tighten the mast clamps using M8 x 70 bolts.
- ? Advice: Ensure bolts are inserted from the side with ridges to hold the bolt head.
- Pass the M8 x 95 screw through the mast clamps and mast, partly tightening the supplied square nut.
- Partly tighten thrust bearing mast bolts to center the mast. Then tighten them securely.
- Tighten all mast clamp nuts, except the one for the M8 x 95 bolt, until the spring washer is flat, then tighten an additional ½ to one turn. ❗ Caution: Do not over-tighten.
- Connect the rotator control cable's round plug to the rotator base and secure the connector ring. Slide the rubber boot over the connector and secure its back end to the cable with electrical tape for weatherproofing. Secure the cable to the tower.
- Have a ground crew member set the controller to 180° (South). Watch the M8 x 95 bolt to ensure it does not bind. If binding occurs, adjust the thrust bearing and/or mast clamps. Once free of binding, tighten the square nut securely.
- Provide sufficient slack in the coaxial cable for the antenna's full 450° rotation range. Secure the coax to the tower.
- After installation, test the system by operating the rotator through its full range.
Diagram Description: Several diagrams illustrate the installation process for the G-800DXA/-1000DXA, including drilling the mast, attaching the rotator, mounting the mast clamp, and connecting cables. Figure 7 shows a pole-mounted setup with mast length considerations, and Figure 8 shows the need for slack in coaxial cables.
Installation of the G-2800DXA Rotator and Antenna on Tower
Important!! Before mounting the mast, drill a 9 mm hole through the mast bottom, centered 82 mm from the end, for the anti-twist support bolt.
- Drill the mast hole as described above.
- Attach the rotator to the tower's mounting plate using M8 x 18 bolts and spring washers.
- If using a thrust bearing (GS-065), mount it on the tower.
- Partly tighten the mast clamp to the rotator housing using M8 x 30 bolts.
- Insert the antenna mast through the bearing and into the rotator's mast clamps. Partly tighten the mast clamps using M8 x 70 bolts.
- ? Advice: Ensure bolts are inserted from the side with ridges to hold the bolt head.
- Pass the M8 x 95 screw through the mast clamps and mast, partly tightening the supplied nut.
- Partly tighten thrust bearing mast bolts to center the mast. Then tighten them securely.
- Tighten all mast clamp nuts, except the one for the M8 x 95 bolt, until the spring washer is flat, then tighten an additional ½ to one turn. ❗ Caution: Do not over-tighten.
- Connect the rotator control cable's round plug to the rotator base and secure the connector ring. Slide the rubber boot over the connector and secure its back end to the cable with electrical tape for weatherproofing. Secure the cable to the tower.
- Have a ground crew member set the controller to 180° (South). Watch the M8 x 95 bolt to ensure it does not bind. If binding occurs, adjust the thrust bearing and/or mast clamps. Once free of binding, tighten the nut securely.
- Provide sufficient slack in the coaxial cable for the antenna's full 450° rotation range. Secure the coax to the tower.
- After installation, test the system by operating the rotator through its full range.
Diagram Description: Several diagrams illustrate the installation process for the G-2800DXA, including drilling the mast, attaching the rotator, mounting the mast clamp, and connecting cables. Figure 15 shows a pole-mounted setup with mast length considerations, and Figure 16 shows the need for slack in coaxial cables.
Installation Note: If using a roof tower with a long mast, a "Guy Bearing" (like GS-050 or GS-065) is recommended. Ensure alignment of the guy bearing and rotator.
Specifications
| MODEL | G-800DXA | G-1000DXA | G-2800DXA |
|---|---|---|---|
| Power Supply Voltage | 117/220 VAC, 50/60 Hz | 117/220 VAC, 50/60 Hz | 117/220 VAC, 50/60 Hz |
| Power Supply Current Consumption | 1 A (117 VAC) 0.5 A (220 VAC) | 1 A (117 VAC) 0.5 A (220 VAC) | 1.5 A (117 VAC) 0.7 A (220 VAC) |
| Rotor Voltage | 11 - 24 VDC | 11 - 24 VDC | 11 - 24 VDC |
| 360° Rotation Time (Non Loaded) | 100±10 sec to 40±5 sec (Variable) | 100±10 sec to 40±5 sec (Variable) | 120±10 sec to 50±5 sec (Variable) |
| Rotation Range | 450° ±3° | 450° ±3° | 450° ±3° |
| Rotation Torque | 600 to 1,100 kgf-cm (43 to 80 ft-lbs) | 600 to 1,100 kgf-cm (43 to 80 ft-lbs) | 800 to 2,500 kgf-cm (57 to 180 ft-lbs) |
| Braking Torque | 4,000 kgf-cm (289 ft-lbs) | 6,000 kgf-cm (434 ft-lbs) | 25,000 kgf-cm (1800 ft-lbs) |
| Maximum Vertical Load | 200 kg (441 lbs) or less (continuous) 800 kg (1764 lbs) (momentary) | 200 kg (441 lbs) or less (continuous) 800 kg (1764 lbs) (momentary) | 300 kg (661 lbs) or less (continuous) 1,200 kg (2646 lbs) (momentary) |
| Mast Outside Diameter | $38 to φ63 | $38 to φ63 | $48 to φ63 |
| Braking Type | Mechanical and Electrical stoppers | Mechanical and Electrical stoppers | Mechanical and Electrical stoppers |
| Antenna K Coefficient | 180 or less | 230 or less | 950 or less |
| Wind Loading Area | 0.75 m² x 0.6 m or less (Pole Type) 2 m² or less (Tower Type) | 0.75 m² x 0.6 m or less (Pole Type) 2.2 m² or less (Tower Type) | 1 m² x 0.8 m or less (Pole Type) 3 m² or less (Tower Type) |
| Maximum Continuous Duty | 3 minutes | 3 minutes | 3 minutes |
| Operating Temperature Range | 0 °C to +40 °C (Controller) -20 °C to +40 °C (Rotator) | 0 °C to +40 °C (Controller) -20 °C to +40 °C (Rotator) | 0 °C to +40 °C (Controller) -20 °C to +40 °C (Rotator) |
| Rotator Dimensions | $186 x 300 mm ($7.3 x 11.8 inch) | $186 x 300 mm ($7.3 x 11.8 inch) | $200 x 345 mm ($7.8 x 13.6 inch) |
| Rotator Weight | Approx. 3.6 kg (7.9 lbs) | Approx. 3.6 kg (7.9 lbs) | Approx. 6.5 kg (14.3 lbs) |
| Controller Dimensions (W) x (H) x (D) | 200 x 130 x 193 mm (7.8 x 5.1 x 7.6 inch) | 200 x 130 x 193 mm (7.8 x 5.1 x 7.6 inch) | 200 x 130 x 193 mm (7.8 x 5.1 x 7.6 inch) |
| Controller Weight | Approx. 2.8 kg (6.2 lbs) | Approx. 2.8 kg (6.2 lbs) | Approx. 3.8 kg (8.4 lbs) |
Diagram Description: A diagram shows the attachment dimensions for the rotator, indicating bolt hole patterns and diameter measurements.
Accessories & Options
Unpacking & Inspection
When unpacking, verify the following items are present:
For G-800DXA/-1000DXA:
- Controller Unit: 1
- Rotor Unit: 1
- Mast Clamp: 1 pair
- 7-pin Round Plug (with Rubber Boot): 1 set
- 6-pin Rectangular Plug: 1 set
- M8 x 95 mm Socket Head Cap Screw: 1
- M8 x 16 mm Hex Bolts: 4
- M8 x 25 mm Hex Bolts: 4
- M8 x 70 mm Hex Bolts: 4
- Split Washers: 14
- Flat Washers: 10
- M8 Nuts: 4
- Square Nut: 1
- Plastic Dial Heading Sheet: 1
For G-2800DXA:
- Controller Unit: 1
- Rotor Unit: 1
- Mast Clamp: 1 pair
- Control Cable (40 m, 6 core cable): 1
- M8 x 95 mm Socket Head Cap Screw: 1
- M8 x 30 mm Hex Bolts: 4
- M8 x 70 mm Hex Bolts: 6
- Split Washers: 14
- Flat Washers: 4
- M8 Nuts: 7
- Plastic Dial Heading Sheet: 1
If any items are missing or damaged, save packing material and notify the shipping company or seller.
Optional Accessories
- GC-038: Mast Clamp (for G-800DXA and G-1000DXA)
- GC-048: Mast Clamp (for G-2800DXA)
- GS-050: Universal Thrust Bearing (for 50 mm mast)
- GS-065: Universal Thrust Bearing (for 65 mm mast)
- GS-232A: Computer Control Unit (RS-232C Serial)
- C-25MWP: Control Cable (25 m)
- C-40MWP: Control Cable (40 m)
- GA-2500: Absorber Joint (for G-800DXA and G-1000DXA)
- GA-3000: Absorber Joint (for G-2800DXA)
Diagrams
The document includes connection diagrams for the G-800DXA/-1000DXA and G-2800DXA, illustrating the internal wiring and external connections of the rotator and controller units. Circuit diagrams are also provided for detailed electronic schematics of the controller and rotator units.
