This week we received the rest of the parts from Allied Electronics that we needed to complete this project.
Ordering online is very easy & they ship really fast.
Most of the other parts are common items, If you need help with anything just send an email kc2pcr@gmail.com
PARTS LIST:
- Project box Link
- Molex - 6 position terminal strip Link
- Parallax IC BS-1 Project board Link
- Rear panel ac jack - salvaged part from computer psu
- 4 - 470uF capacitors -salvaged parts from computer psu
- 6vdc transformer- salvaged part from wall wart type psu
- 24 vac transformer - salvaged from original alliance rotor control
- 4 - dc controlled ac relays - Grayhill 70S2-04-B-06 DC 6A SOLID STATE RELAY
- 4 - Green 5v led indicators - Link
- 1 - Red 5v led indicator - Link
Above: Front panel marked & drilled with 1/4" holes for the led indicators.
Rear panel marked & drilled for the switch,terminal strip, ac jack & fuse holder.
The holes for the larger parts were drilled first and then hand filed to size. Panels are aluminum and very easy to shape up with simple hand tools.
Above: Gary n2nrj installing the terminal block on the rear panel, routing wires & soldering up the connections.
Above: With the parts laid out & spaced evenly, next we marked the empty case & drilled for each part to be bolted into place.
We located the BS-1 breadboard with it's db-9 programming port facing the rear panel to make it easy for any future programming updates to be made.
At first I used the transformer mount for a grounding junction block, this turned out to be a
major mistake as current ran into the ground system through the transformers after the unit was switched off!!
A result of the way I wired the switch.
I re-worked the design with the grounds wired directly to the ac jack & now switching the hot leads
to the transformers through the on/off switch & fuse holder.
This eliminated the problem with low voltage ac in the ground system when the unit is off.
Above: Gary n2nrj assembling the various parts & wiring permanently in the enclosure.
Above: The finished units with all of the components securely bolted into place. Ready for testing!
Above: Terminal strip for the rotor wire connections
5 wires are used to send the 24vac control current from the box up to the rotors, to control each of the rotors functions:
UP, DOWN, CW, CCW & COMMON GROUND
The rotators once mounted up on the mast, will share a common ground piggy backed from one rotor to the other.
There is a separate ground terminal for connection to the station ground system at the operating position.
Testing the finished controller
The completed assembly connected to 60 feet of 16awg 5 conductor cable with a 6 pole connector just below the rotors for easy disconnect in the event we need to remove and work on any part of this antenna system.
NEXT -Assembling the Cushcraft A627013S - link to page 3 below
