2025 Rotator Project: Difference between revisions
Began documenting like it's my job or soemthing |
Elaborated on rotator replacement procedure. |
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== Background == | == Background == | ||
[[File:2025RotatorGearAnnotated.png|left|thumb|335x335px|OR2800, with the believed point of failure called out in red.]] | |||
Over the course of the last decade, progressively increasing play in the beam's directional holding ability has been observed by club members. Up to spring 2025, the beam could freely rotate as much as +/- 90 degrees of whatever setting was specified on the M2 Systems RC2800-A rotator controller (intended functionality is that the beam is statically held at whatever setting an operator specifies without any excess rotation at all). Additionally, operators noted a reduced range of rotation, with the beam generally slowing down - before stopping - at any settings above 250 degrees or below 50 degrees of rotation. | Over the course of the last decade, progressively increasing play in the beam's directional holding ability has been observed by club members. Up to spring 2025, the beam could freely rotate as much as +/- 90 degrees of whatever setting was specified on the M2 Systems RC2800-A rotator controller (intended functionality is that the beam is statically held at whatever setting an operator specifies without any excess rotation at all). Additionally, operators noted a reduced range of rotation, with the beam generally slowing down - before stopping - at any settings above 250 degrees or below 50 degrees of rotation. | ||
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== Project Documentation == | == Project Documentation == | ||
The legacy OR2800 rotator was opened and assessed. It was determined that the thrust bearing sealing the main box assembly from the upper mast unit had corroded and failed, leading to water intrusion. The thrust bearings were removed (INA Ball Thrustbearing: D9, 1” bore dia) and internal gearing wirebrushed and cleaned. The unit will be repacked with grease and assembled when new parts and materials arrived. Functionality was confirmed on the bench through rotating with a legacy RC2800 rotor. | |||
The beam assembly mates to the rotator via a jaw clamp device. Two jaws sit atop the rotator (depicted in yellow above) inbetween which a vertical mast with the beams mounted sits. To retain this mast on rotation, the jaws are torqued until tight. Consequently, the procedure for removing the rotator is to rather simply lift the beam/mast assembly that sits in the jaws up 3-4 inches to clear said jaws, at which point the rotator can be slid out from under the masts and replaced. This procedure is accomplished using a winch and gin pole - located in the corner of the shack - which can be attached to the main tower and serves as a pulley for mast lifting and hoisting operations. | |||
Revision as of 17:29, 9 August 2025
Overview
The W9YT club station primarily operators a 20m/15m/10m beam, in addition to a 6m beam, all positioned by an M2 antenna systems OR2800 Orion motor, controlled via a RC2800-A box. Over time, the functionality of this system has decreased to a critical level, threatening the structural integrity of the beam, feedlines, and tower, necessitating repairs. The club has a reserve, older model 2800 and 2800 controller that it intends to restore and place into operations so that the newer model currently in use can be removed and repaired.
Background
Over the course of the last decade, progressively increasing play in the beam's directional holding ability has been observed by club members. Up to spring 2025, the beam could freely rotate as much as +/- 90 degrees of whatever setting was specified on the M2 Systems RC2800-A rotator controller (intended functionality is that the beam is statically held at whatever setting an operator specifies without any excess rotation at all). Additionally, operators noted a reduced range of rotation, with the beam generally slowing down - before stopping - at any settings above 250 degrees or below 50 degrees of rotation.
As of the time of writing (August 2025), damage sustained by antenna feedlines and other associated equipment suggests the beam may be able to fully rotate 360 degrees freely. The initial assessment of station engineers was that the internal gearing mechanisms (outlined in red) of the OR2800 Orion antenna rotator/positioned had sheared.
The initial antenna play and decreased lack of direction authority indicated that some of the gear teeth had rusted and subsequently mechanically failed, resulting in a gap in gear teething inside of the rotator.
Project Documentation
The legacy OR2800 rotator was opened and assessed. It was determined that the thrust bearing sealing the main box assembly from the upper mast unit had corroded and failed, leading to water intrusion. The thrust bearings were removed (INA Ball Thrustbearing: D9, 1” bore dia) and internal gearing wirebrushed and cleaned. The unit will be repacked with grease and assembled when new parts and materials arrived. Functionality was confirmed on the bench through rotating with a legacy RC2800 rotor.
The beam assembly mates to the rotator via a jaw clamp device. Two jaws sit atop the rotator (depicted in yellow above) inbetween which a vertical mast with the beams mounted sits. To retain this mast on rotation, the jaws are torqued until tight. Consequently, the procedure for removing the rotator is to rather simply lift the beam/mast assembly that sits in the jaws up 3-4 inches to clear said jaws, at which point the rotator can be slid out from under the masts and replaced. This procedure is accomplished using a winch and gin pole - located in the corner of the shack - which can be attached to the main tower and serves as a pulley for mast lifting and hoisting operations.