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Hy-Gain HDR-300A Instruction Manual
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Hy-Gain HDR-300A Instruction Manual

Hy-Gain HDR-300A Instruction Manual

Heavy duty rotator system
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HDR-300A
Heavy Duty Rotator System
Instruction Manual

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Summary of Contents for Hy-Gain HDR-300A

  • Page 1 HDR-300A Heavy Duty Rotator System Instruction Manual...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page CHAPTER 1 - INSTALLATION AND OPERATION ............1-1 Section I. Components of the HDR-300/A Rotator System ..........1-1 Gear Motor Assembly................…......l-1 Control Console..................…......1-1 Tower Compatibility ................…......1-2 Antenna Compatibility................…......1-2 Section II. Specifications ......................1-3 Section III. Pre-Installation Instructions................. l-4 Pre-Installation Check................…......1-4 Section IV Voltage Conversion....................
  • Page 3 Wiring for 230 VAC ..................... 1-11 HDR-300/A Rotator Mounting Hardware............1-13 Top View of HDR-300/A and Tower Mounting Plate for Hy-Gain Crank-Up Towers HG-54HD and HG-70HD........1-14 Typical Installation of Rotator Mounted Below Plate .......... 1-14 Gear Motor Assembly with Cover ................. 3-4 Output Gear and Shaft Assembly................

  • Page 4: Chapter 1 - Installation And Operation

    CHAPTER 1 INSTALLATION AND OPERATION Section I. Components of the HDR-300/A Rotator System General Description Gear Motor Assembly Azimuth indication is provided by a 3-turn, 1000 The HDR 300/A Rotator is a compact, high torque ohm wire wound potentiometer that is geared to antenna rotator that can be used for positioning the rotator output shaft.

  • Page 5: Tower Compatibility

    When the power switch is turned on, 5 VDC is Tower Compatibility supplied to the potentiometer in the rotator. As the The HDR-300/A is a large, heavy-duty antenna rotator is turned from 0° to 360°, output voltage rotator; therefore it is meant to be installed in from the potentiometer is varied from .833 to towers capable of withstanding near the maxi- 2.500 VDC.

  • Page 6: Section Ii. Specifications

    Section II. Specifications Control Cable Requirements: Recommended Minimum for Maximum Torque Length of Run 0-100 Feet: two #18 and six #22 AWG two #16 and six #18 AWG Bertek 6308-18 or Belden Belden 9405 8448 100-200 Feet: two #16 and six #18 Belden seven #14 Belden 8628 9405 200-300 Feet:...

  • Page 7: Section Iii. Pre-Installation Instructions

    Use the Effective Moment rating of the anten- Belden 9495 (3-#14 AWG) and Belden 8489 (4- nas to determine compatibility. #18 AWG) can be used in place of Belden 8628. Also, Belden 8620 (4-#16 AWG) and 3-#12 hook-up wire can be used in place of Belden 8629.

  • Page 8: Socket Contact Application

    Moisten the sheath with isopropyl al- STEP 2: Referring to Figure 1, Control Console cohol. Align the contact with the back Rear Panel, install a 2.5A fuse (1.5A of the cavity and insert it straight into for 230 VAC) and a 12A fuse in the the appropriate cavity until bottomed.
  • Page 9 STEP 7: Plug the 10 pin connector into the con- If North-centered, the display should read approx. trol console. Turn on the control con- 165 degrees. If not, adjust the ZERO pot for this sole power switch. The digital readout value.

  • Page 10: Control Cable Connector Attachments

    Figure 3 Control Cable Connector Attachments...

  • Page 11: Control Cable-Rotator Wiring Guide

    DETAIL A Actuator Shown in the "000" position. Figure 4 Control Cable-Rotator Wiring Guide...

  • Page 12: Section Iv Voltage Conversion

    Figure 5 Solenoid and Potentiometer Wiring Guide Section IV Voltage Conversion CAUTION: Refer to Figure 1 and install the fuse indicated for Dangerous and lethal voltage exist inside the voltage that will be used. this unit. Remove the power cord from the socket before servicing this unit.
  • Page 13 Figure 6 Wiring for 115 VAC...
  • Page 14 AA-0300-9-011 Figure 7 Wiring for 230 VAC...

  • Page 15: Section V Calibration And Installation Procedures

    Assemble the rotator to the rotator It these items are replaced or become un- mounting plate. (For Hy-Gain towers see Figures calibrated, refer to Chapter 2, Section III for 7 and 8.) The rotator requires four (4) mounting calibration procedures.

  • Page 16: Hdr-300/A Rotator Mounting Hardware

    Item Item Description Description Platform Plate Nut, hex, 5/16", stainless steel Platform Flatwasher, 5/16", stainless steel Mast Clamp Lockwasher, split, 3/8", stainless steel Key, 1/4 sq. x 15/8", plated Lockwasher, split, 5/16", stainless steel Bolt, hex head, 3/8"-16 x 3 1/2", stainless steel Flatwasher, 3/8", stainless steel Bolt, hex head, 5/16"-18 x 1", stainless steel Screw, pan head, #10-24 x 6"...

  • Page 17: Top View Of Hdr-300/A And Tower Mounting Plate For Hy-Gain Crank-Up Towers Hg-54Hd And Hg-70Hd

    Figure 9 Top View of HDR-300/A and Tower Mounting Plate for Hy-Gain Crank-Up Towers HG-54HD and HG-70HD Figure 10 Typical Installation of Rotator Mounted Below Plate...

  • Page 18: Section Vi. Operations And Maintenance

    Tighten the setscrew into the platform. Lower For towers that must be climbed for installation, the mast into the mast clamp. Tighten the four follow these instructions: (4) 3/8 inch bolts so that the mast is held securely. Center the mast above the output shaft and tighten the four (4) 5/16 inch bolts on the Make sure that the rotator will match the holes platform.

  • Page 19: Use The Digital Readout System

    Use the Digital Readout System The HDR-300/A incorporates a very accurate The HDR-300/A has numerous features to digital display of azimuth bearing information. prevent water entry. The output shaft uses a spe- This display will always indicate the exact direc- cial V -shaped )-ring to prevent water entry at tion of the antenna once calibrated.

  • Page 20: Section 1. Troubleshooting

    CHAPTER 2 TROUBLESHOOTING AND SERVICE Section L Troubleshooting Troubleshooting Symptom Possible Causes Power Switch has no effect Fuse not installed. Fuse Blown. Power Switch lights but LED's do not 14 wire jumper cable disconnected. light. Digital readout not zeroed. Digital display still reads "-85" and "-99" or Control cable not plugged in.
  • Page 21 Troubleshooting Continued Symptom Possible Causes Digital display reacis greater than "10" (Step Pontentiometer not installed correctly. 7, Chapter 1, Section III). Digital readout not zeroed. Potentiometer wired incorrectly. 10 pin connector wired incorrectly. 8 pin connector wired incorrectly Brake switch has no effect when switched to Solenoid wired incorrectly.
  • Page 22 Troubleshooting Continued Symptom Possible Causes Rotate Switch has no effect. (cont.) Limit switch wired incorrectly. Not pushing hard enough on rotate switch. 12 Amp fuse not installed or blown out Motor is too hot - wait 10 minutes. Motor hums when rotate switch is pressed Motor output shaft is binding within the motor.
  • Page 23 Troubleshooting Continued Symptom Possible Causes Digital readout is changing more than t 1 High winds causing antenna to rock. degree with brake switch locked. High RF field near control cable. Brake system failed. 250 gF capacitor not working. Digital readout is changing more than t5 Extremely high winds causing antenna to rock.

  • Page 24: Section Ii. Voltage And Resistance Measurements

    Section II. Voltage and Resistance Measurements Voltage and Resistance Charts Control Unit, 10 pin socket: Between Pin Numbers Voltage or 1hlerance Resistance f 10% 1-3 (with rotate switch to the right) 24 VAC 2-3 (with rotate switch to the left) 24 VAC t 10% 4-3 (with brake "Free")

  • Page 25: Section Iii. How To Get Factory Service

    Section III. How to Get Factory Service/Calibration Service Information NOTE: we will not ship by means of a carrier that Do not ship equipment to the manufacturer with- will not fully insure the shipment. Some carriers out prior authorization. We prefer to send special have a $200.00 limit.
  • Page 26 Voltage at full CW 3.89 3.89 Service Information If you are encounter technical problems and need assistance, you should contact Hy-Gain Customer Service Department. All requests, inquires, warranty claims, or for ordering replacement parts, contact: -Gain 308 Industrial Park Road Starkville,...
  • Page 27 CHAPTER 3 HDR-300/A PARTS LIST AND SCHEMATICS PARTS NOTE: Item numbers may not necessarily be in numerical order. Item Part No. Description Qty 870511 Gear Motor Assembly................1 250117 Gear, 1T2-32038..................1 470643 Cover, black plastic................1 (Not Used) 722958 Potentiometer, 3-turn (1 K ohm) ............1 *740200-2 Gear Motor, VW47................1 500350...
  • Page 28 HDR-300/A PARTS LIST (cont.) Item Part No. Description Qty 564792 Lockwasher, split, 5/16", stainless steel ..........8 567180 Flatwasher, 3/8", stainless steel............4 640024 Plug, 10 pin..................1 (Not Used) 871869 Control Console Assembly ..............1 51845039 Screw, Philips, #4-40 x 3/8".............. 2 250105 Spacer, hex head, #8-32 x 3/8"............4 179808...
  • Page 29 GEAR MOTOR PARTS Item Part No. Description Qty 740200-2 Gear Motor, VW47..................1 740200-A Gear Housing, aluminum casting (upper) ...........1 Gear Housing aluminum casting (lower) ..........1 Solid Output- Gear Shaft Output Assembly (358810)......1 Machined Steel Gear #2 ..............1 Machined Steel Gear #3 ..............1 Steel and Fiber Combo Gear #4............1 Motor Assembly, 24 VAC, including end plate and mounting hardware ................1...
  • Page 30 COMPLETE ASSEMBLY Figure 11 Gear Motor Assembly with Cover Figure 12 Output Gear and Shaft Assembly Item Item Description Description Cover, black plastic Solid Output Gear and Shaft Assembly #1 Potentiometer, 3-turn Motor Assembly, 24 VAC, including end plate Gear Motor mounting hardware Gear housing, aluminum casting (upper) Motor Capacitor...
  • Page 31 Figure 13 Gear Motor Assembly-Side Figure 14 Gear Motor Assembly-Top View Item Item Description Description Potentiometer, 3-turn (1K ohm) Motor Capacitor Gear Motor Limit Switch and Insulator and Hardware Motor Assembly, 24 VAC, including end plate and Jumper Wire mounting hardware Jumper W iere Solenoid, 24 VAC, and mounting bracket and screws Plastic Paddle Arm and Push-Out...
  • Page 32 Figure 15 Gear Motor Schematic Figure 16 Steel and Fiber Gears...
  • Page 33 Figure 18 Interior View of Control Console...
  • Page 34 Figure 19 Schematic Main P .C. Board Figure 20 Main PC. Board...
  • Page 35 Main P .C. Board - PN 871165-2 Parts List for Main P.C. Board (871165-2) Part Designator Part Number Description C101 and C102 52158025 Capacitor, dis c, ceramic, .1 pF, 25V Cl and C2 722463 Capacitor, electrolytic, l000pF, 16VDC C3 and C4 52158025 Capacitor, disc, ceramic, .1pF, 25V 51821016...
  • Page 36 Figure 22 Schematic of Display P .C. Board Figure 23 Display PC. Board...
  • Page 37 Figure 24 No. Description Screw, Type A, pan head, #6 x 5/16" 50 Power Switch Brake Switch Rotate switch Display PC. Board Assembly Figure 25 Rear Mounted Components-Front Panel of Control Console...