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Hy-Gain HAM IV User Manual

Hy-Gain HAM IV
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308 Industrial Park Roa
d
S
tar
k
v
ill
e,
MS
39759
USA
Ph: (662) 323-9538 FAX: (662) 323-6551
HAM IV / HAM IVX
Antenna Rotator
HAM IV has 110 VAC
Co
ntr
o
ll
e
r HAM I
V
X ha
s
22
0
INSTRUCTION MANUAL
GENERAL DESCRIPTION
The HAM IV rotator consists of a bell type
rotator, a metered control unit and the necessary
mounting hardware. The stock HAM IV is
intended for in-tower mounting on the base plate
which is part of the tower. However, in some
instances, mast mounting is desired. The Lower
Mast Support Kit, PN 51467 10, contains a lower
mast support and the necessary hardware to
facilitate mounting the HAM IV Rotator on top
of a mast.
The rotator unit must be wired to the control unit
with an 8-wire cable. The control unit must be
placed inside the house or other protected
location. Included in the shi
pp
in
g
box are:
A. Instruction Manual
B. Rotator Unit
C. Controller Unit
New features in the HAM IV include an 8 pin
Cinch connector on the rear panel of the control,
a chassis ground connection on the 110 VAC
model, and a locking CinchTM connector at the
rotor unit.
CAUTION
When using the lower mast support, antenna
size is restricted to 7.5 square feet of wind
surface area
Cinch'm a Division of Labinal Com
p
onents & S
y
stems
,
D. Mountin
g
Hardware Pac
k
E. Connector Parts Pack
Due to the wide variety of towers available, each
installation will have different requirements. The
gauge of the 8-wire cable to connect the control
unit to the rotator depends upon the distance
between the rotator and control. The longer the
distance, the larger the diameter of the wire
required. Various antennas or beams require
different installation methods.
Figure 1
Control Unit - Front Panel
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Hy-Gain HAM IV Specifications

General IconGeneral
BrandHy-Gain
ModelHAM IV
CategoryStyling Iron
LanguageEnglish

Summary

General Description

General Safety Precautions

Caution regarding antenna size restrictions for mast mounting.

Specifications

Cautions

Installation Safety Guidelines

Safety advice for tower erection, placement, and power line proximity.

Mounting Configuration Warning

Warning about rotator mounting without a thrust bearing.

Types of Installation

Inside Tower Mount Installation

Details on mounting the rotator inside a tower with thrust bushing/bearing.

Outside Tower Mount Installation

Description of optional outside tower mounting, with derated capacity.

Mast Mounted Installation

Instructions for mounting on a mast using a lower mast support kit.

Unbalanced Weight and Wind Pressure

Understanding Unbalanced Weight

Explanation of how unbalanced weight affects mast and rotator stress.

Managing Wind Pressure Effects

How wind pressure impacts the mast and installation strength.

Wiring and Check-Out

Selecting Control Cable Gauge

Guidance on choosing the correct wire gauge based on cable length.

Rotor Cable Assembly

Instructions for assembling the rotor cable.

Initial Rotor Unit Attachment

Temporary attachment of screws to the bottom of the rotor unit.

Connecting and Powering Control Unit

Procedure for connecting and powering the control unit.

Power Switch and Meter Illumination Check

Verifying meter illumination after turning on the power switch.

Brake Release Mechanism Test

Testing the brake release lever for an audible click.

Counter-Clockwise (CCW) Operation Test

Testing the rotator's CCW movement and stopping.

Clockwise (CW) Operation Test

Testing the rotator's CW movement and stopping.

Operation Safety Cautions

Caution on releasing direction switch to avoid stress on rotator/gears.

Rotator Unit Connector

Mounting Inside Tower

Rotator Placement in Tower

Locating the rotator under the bushing and cutting the tower plate for the cable.

Securing Control Cable

Plugging connectors and securing the cable to prevent strain.

Mast Trial Assembly and Diameter Check

Trial assembly of the mast and checking maximum diameter requirements.

Initial Bolt Tightening and Rotation Check

Tightening bolts initially and checking for concentric mast rotation.

Mast Alignment and Shimming

Ensuring proper mast alignment and shimming for concentric rotation.

360° Rotation Alignment Check

Checking for unrestricted 360° rotation after alignment.

Final Bolt Tightening

Final tightening of the rotator mounting bolts to specified torque.

Securing Mast in Upper Support

Tightening the bolt to prevent mast rotation in the upper support.

Outside Tower and Pole Mounting

Mast Support Kit Mounting Caution

Caution about antenna size restriction when using the lower mast support kit.

Heavy-Duty Lower Mast Support Kit

Details on the optional kit for mast mounting the rotator.

Weather-Proof Connector Kit

Information on an optional kit to replace Cinch connectors with weatherproof ones.

Preliminary Check and Calibration

Thermal Protection Feature

Explanation of the thermal switch that automatically shuts off power during continuous use.

Initial Control Unit Power-On

Turning on the control unit and checking meter illumination.

CCW Calibration Procedure

Operating the rotator to full CCW position for calibration.

Zero (CCW South) Meter Adjustment

Adjusting the meter to indicate South at the full CCW position.

Full Scale (CW North) Meter Calibration

Calibrating the meter by adjusting the potentiometer at full CW position.

Meter Behavior When Off

Description of meter needle behavior when the control unit is turned off.

Normal Operation

Engaging Brake Release for Operation

Retracting the brake wedge to allow rotator movement.

Rotating to Compass Location

Turning the rotator using the direction levers.

Operating Practice

Nudging for Precise Positioning

Technique for precise positioning using nudging with large beams.

Avoiding Full Speed at Rotation Ends

Advice against running the rotator at full speed into the limits.

Controlled Coasting for Stopping

Allowing the rotator to coast down before engaging the brake.

Grounding

Tower Grounding Procedure

Instructions for grounding the tower or metal support device to earth ground.

Control Box Grounding

Grounding the steel chassis of the control box to a metal cold water pipe or service entrance.

South-Center Meter Scale Conversion

Disconnecting Power for Conversion

First step in meter scale conversion: disconnecting the power supply.

Disconnecting Control Cable

Removing and labeling the 8-wire control cable for conversion.

Removing Control Unit Covers

Instructions for removing the top and bottom covers of the control unit.

Accessing Lamp Holder Bracket

Removing the lamp and holder to access the transformer and bracket.

Removing Meter Stud Nuts

Removing hex nuts from meter studs to free the printed circuit board.

Meter Stud Shorting Caution

Caution about using a test lead to short meter studs when not in circuit.

Removing the Meter

Loosening retaining clips and removing the meter from the chassis.

Removing Meter Cover

Gently prying off the clear meter cover to access the scale.

Replacing Meter Scale

Removing and reinstalling the meter scale correctly over indexing pins.

Reassembling Control Unit Components

Reinstalling meter, P.C. Board, and lamp hardware, checking for issues.

Reinstalling Control Unit Covers

Reinstalling the top and bottom covers of the control unit.

Repositioning Beam After Scale Change

Repositioning the antenna mast if the scale was changed to South center.

Recalibrating Meter After Conversion

Recalibrating the meter after completing the scale conversion.

Note on Meter Scale Design

Information about the separate South Centered scale provided.

Troubleshooting

General Troubleshooting Cautions

Cautions regarding unit testing, wiring compatibility, and voltage.

Common Operational Difficulties

Identifying common issues like broken/shorted wires and their impact.

Understanding Mechanical Play

Explanation of natural play in the rotator mechanism and its cause.

Antenna Rotation in Heavy Wind

Addressing issues like mast slipping or turning during high winds.

Lack of Power or Sluggish Operation

Diagnosing causes for slow or hard starting, including capacitor and voltage issues.

Improper Meter Indication

Troubleshooting meter readings, pilot light, transformer, and fuse issues.

No Rotation - Indication OK

Ground Wires

Helpful Suggestions

Checking the Control Unit

Voltage Checks with Unit Plugged In

Performing voltage tests on control unit terminals with AC power connected.

Resistance Checks with Unit Unplugged

Performing resistance tests on control unit terminals after disconnecting power.

Checking the Rotator from the Ground

Additional Checklist

Control Wire Continuity Check

Checking continuity of control wires for loose connections caused by wind.

Securing Control Cable

Taping down the control cable securely all the way to the rotator.

Motor Winding Check

Checking motor winding through the control cable as outlined in Table 2.

Cable Between Leads Check

Checking cable for static lightning charges or direct hits causing carbon arcs.

Connector Short Check

Checking both control and rotator connectors for shorts.

Direction Rotation Issues

Identifying causes for rotation in only one direction.

Proper Cable Size Verification

Ensuring the control cable is of proper size for the length used.

Bench Testing Rotator Cable

Substituting a short cable piece for bench testing to identify defective cables.

Impact of Voltage and Weather

Understanding how low line voltage and cold weather affect rotation speed.

Parts List

Wiring Schematic

Control Unit - Top View

Control Unit - Back View

HAM IV Rotator Replacement Parts

Inside View of HAM IV Rotator

Tower Drilling Template

Limited Warranty