INSTRUCTION MANUAL
Contents
1. 308 Industrial Park Road Starkville MS 39759 USA Ph 662 323 9538 FAX 662 323 6551 HAM IV Antenna Rotator HAM IV has 110 VAC Controller HAM IVX has 220 INSTRUCTION MANUAL GENERAL DESCRIPTION The HAM IV rotator consists of 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 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 Components amp Systems 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 shipping box are A Instruction Manual B Rotator Unit C Controller Unit D Mounting Hardware Pack E Connector Parts Pack Due to the wide variety of towers available each installation will have different requirements The gauge of the 8 wire cab2. 8 20 640076 Socket Cinch S 308 AB 1 21 5088400 Lever Switch for 3 S 4 amp 1 22 450403 Relief Strain Heyco 3772 220V version 2 23 506665 Screw 46 22 x 1 4 round head 2 24 560068 Washer Back up 220V Version na meae as riva 1 25 1073501 Transformer Power 220V version 1 26 1073301 Transformer Power 120V version 1 27 5020200 Transformer Meter 220V version 1 28 5017700 Transformer Meter 120V version 1 29 5151500 Capacitors Motor ron ro M ples eed oed EQ em que Per eer egi 1 30 5086100 Cord Line 3 wire 120V version a 1 31 450431 Relief Strain Heyco 1217 120V version 1 32 5079800 Cord Line 3 wire 220 VAC European Plug 1 33 5147702 MEDIE de kusqa UE ES 1 34 5175200 Switch OWO S D teet 1 35 723406 Potentiometer eae Bas 1 36 1056
3. BREAK RELEASE SWITCH CALIBRATION eocnEW CCW SWITCH Figure 10 Control Unit Front Panel amp EE FIGURE 11 PRINTED CIRCUIT BOARD ASSEMBLY ITEM 3 SEE DETAIL A Figure 11 Control Unit Top View 32 or 30 EUROPEAN PLUG SHOWN NOT SHOWN IN DETAIL A 11 and 36 2 20 13 and 37 DETAIL A BOTTOM VIEW Figure 12 Control Unit Back View 16 HAM IV Rotator Replacement Parts ITEM PART NO NO DESCRIPTION QTY 101 878712 Rotator complete with hardware 1 102 5030400 support Upper Mast bell casting S P doter 1 103 5136502 Brake Housing lower 1 104 5033501 Bearings Ball 49 per reta 98 105 5011300 Retainer Bearing one per race 2 112 5136101 G ar Steel DVE Xua uhuta saq oe eee est THREE 1 124 5137600 Moltor and PrIlOnh eS 1 125 5023100 P otentlOmeter RS She 1 126 5009900 MEI MI 1 140 179894 i n ep ebat at eit 1 141 510680 CLOW MO aeos Su u Ve oet 2 142 520057 Screw 46 32 x 3 8 Pan Head 2 143 5105700 Sorew 3512 24 x 3 4 ua N e ae 4 e 50115
4. Return the rotator to the full CW S position Mount the beam on the mast pointing South The coaxial cable should be looped in such a manner that it will not foul or tangle when the beam turns around in a circle to the full 360 counterclockwise position BEAM NOT TO EXCEED 7 5 SQUARE FEET 0 7 nf WIND SURFACE AREA LOAD 3 o A M E Q lt x 8 2 ae lt aid 1 5 5 IS N BEAM TO TOP OF ROTATOR gt NOTTOEXCEED2FEET 607 men e IV ROTATOR COAXIAL CABLE aT V WIRE CONTROL CABLE LOOP TO PERMIT FULL 52 360 ROTATION OF BEAM LNE i A PAH m cs SSS mn Figure 5 Rotator Mounted on Tower Top Plate RS gt gt gt 52 SN Ln NA TS lt i TY us NS BEAM TOP OF ROTATOR NOT TO EXCEED 2 FEET 607 BEAM NOT TO EXCEED 7 5 SQUARE FEET 0 7 m WIND SURFACE AREA LOAD COAXIAL CABLE TAM IV POTATOR LOOP TO PERMIT FULL 360 ROTATION OF BEAM LOWER MAST SUPPORT PN 61467 10 ONLY il WIRE CONTROL CABLE 1 t 1 qa APPROPRIATE GUY WIRES Wer 76 Z E Nc Figure 6 Pole Mounted Rotator OUTSIDE TOWER Referring to Figures 5 6 and 7 an outside tower or pole mount is made in the same manner except that the rotator is fastened by four 4 bolts only not six to the Lower Mast Support PN 51467 10 Since the eccentricity of the
5. If the 13 VDC is present check for 500 ohms across rotator leads No 3 and No 7 If 500 ohms is present from No 3 and No 7 see if the readings from No 3 to ground and No 7 to ground total 500 ohms NOTE intermittent condition in component in the rectifier or meter circuits within the control box as well as in the cable or potentiometer circuit in the rotator itself can cause meter fluctuation or error Possible cause of such trouble may be localized by placing a test DC meter across Terminals No 1 and No 3 or No 1 and No 7 comparing the action of the test meter with the panel meter NO ROTATION INDICATION OK Either the thermal cut out in the power transformer has opened or there is actually trouble in the motor circuit After allowing time for the thermal cut out to restore service proceed to Checking the Control Unit and Checking the Rotator from the Ground GROUND WIRES Ground on cable leads can burn out either the line fuse or the small fuse in the meter circuit If lead No 3 or lead No 7 is grounded it shorts out part of the potentiometer so that as rotation progresses to the other end the full DC voltage is applied across a decreasing portion until current becomes so high that the potentiometer burns out Note also that any grounds may put an overload on the power transformer which could cause the line fuse to blow or overload the rectifier circuit so that the 1 8 amp fuse blows HELPFUL S
6. 13 Inside View of HAM IV Rotator HOLES TO BE 17 64 CLEARANCE DRILL TOWER DRILLING TEMPLATE This information is believed correct but no warranty is given or implied and no liability is assumed by Hy Gain as to its accuracy or completeness Changes may be made from time to time so the user should verify all factors that may be critical This information is not to be construed as to authorizing or advising use of any patented invention LIMITED WARRANTY Hy Gain Warrants to the original owner of this product if manufactured by Hy Gain and purchased from an authorized dealer or directly from Hy Gain to be free from defects in material and workmanship for a period of 12 months for rotator products and 24 months for antenna products from date of purchase provided the following terms of this warranty are satisfied 1 The purchaser must retain the dated proof of purchase bill of sale canceled check credit card or money order receipt etc describing the product to establish the validity of the warranty claim and submit the original or machine reproduction of such proof of purchase to Hy Gain at the time of warranty service Hy Gain shall have the discretion to deny warranty without dated proof of purchase Any evidence of alteration erasure or forgery shall be cause to void any and all warranty terms immediately 2 Hy Gain agrees to repair or replace at Hy Gain s option without charge to the original owner any defective pro
7. advisable not to run it full speed into the end of rotation 3 Upon completion of turning always allow the rotator to coast down by keeping your finger on the Brake Release after you have released the rotation lever This procedure will allow the rotator to stop before you re engage the brake wedge Observing this sequence prevents the rotator from stopping suddenly thus preventing undue stress on the rotator beam and tower The motor has an internal brake which controls the coast down time and deceleration The internal motor brake is usually strong enough to prevent pinwheeling during operation even in high winds If the rotator is being operated in a very high wind observe the operation of the needle A little practice will acquaint the owner on how to operate the rotator smoothly GROUNDING The tower or other metal support device must be grounded to an earth ground at its location Use heavy copper cable looped so that if the tower comes down for any reason there will be adequate slack to prevent the ground wire from breaking Use one or more 8 foot copperjacketed steel stakes driven into the moist earth and fasten the wire securely at the stake and at the tower As mentioned in the Cautions portion the steel chassis of the control box should be either grounded to a metal cold water pipe in the house or back to the electric service entrance box where the power comes into the house This normally is accomplished with
8. and check out its operation prior to installation WIRING AND CHECK OUT A Decide the wire gauge size required and procure the number of feet of the proper cable see Table 1 Maximum Length 125 38 m 200 61 m 300 91 m Gauge for Terminals 1 amp 2 18 1 19 mm 16 1 42 mm 14 1 75 mm Table 1 8 PIN CONNECTOR SOCKET FOR ROTATOR END OF CONTROL CABLE 5 3 1 mame 2 SOLDER SIDE VIEW Gauge for Terminals 3 8 20 97 mm 18 1 19 mm 16 1 42 mm BLACK PIN1 WHITE PiN2 GREEN PIN3 BLUE PIN 4 ORANGE PIN 5 YELLOW BROWN PIN 7 RED PIN8 D With the rotator sitting in the upright position and connected to the control unit by the 8 wire cable plug the control unit power cord into a receptacle E Turn the power switch on The meter should be illuminated F Depress the Brake Release center lever then release it An audible click should be heard in the rotator This is the solenoid operating the brake wedge 8 PIN CONNECTOR PLUG FOR CONTROL CONSOLE END OF CONTROL CABLE BLACK PIM 1 WHITE GREEN PN BLUE 4 ORANGE PIN 5 YELLOW PIN 6 BROWN PIN 7 RED PIN 8 CONTROL CABLE BELDEN 8448 BELDEN 9405 IEWC 08612 Figure 2 Control Cable Connector Attachments NOTE The specifications call for heavier gauge wire in two locations Leads 1 and 2 must be heavier gauge and less total lead resistance B Assemble the rotor
9. cable as shown in Figure 1 CAUTION Shorts between terminals or grounded leads may damage the rotator C Temporarily attach the 4 1 4 20 x 1 1 4 screws Item 147 to the bottom of the rotor unit G Depress the Brake Release center lever hold it and simultaneously depress the CCW direction switch left The rotator should turn CCW looking from the top This is S E NW S Release the CCW direction switch the rotator will coast down and stop Now release the brake switch The rotator is now locked into position H Repeat the previous step for CW direction by depressing the brake switch first then the CW direction switch right CAUTION It is best to release the direction switch just prior to the end of rotation extreme CW or CCW position in order not to cause undue stress on the stop arm and or the gears ROTATOR UNIT CONNECTOR The Ham IV is now supplied with an 8 pin Cinch connector with lock This connector is not waterproof and requires a heatshrink boot to keep water out Slide the heatshrink supplied over both connectors after attachment and heat the rotor unit end of the shrink tube with a hot air gun or hair dryer The bottom should be left open to breathe Seal the top of the shrink tube with black electrical tape if necessary Make sure that this connector assembly is installed in a vertical position with proper strain relief MOUTING INSIDE TOWER The rotator is mounted i
10. the wire of the 3 prong plug which then depends on the wall outlet being ade quately grounded back to the service entrance as to the utility ground If there is any doubt have this checked bv a licensed electrician SOUTH CENTER METER SCALE CONVERSION The stock HAM IV Control Unit is shipped with the meter scale installed for North center operation ends of rotation are at the South position Some geographic locations and or popular working areas may favor having the meter South center ends of rotation are at the North position We have provided the HAM IV with an interchangeable meter scale We recommend the following 1 Disconnect the power 2 Remove the 8 wire control cable carefully labeling each wire with its corresponding terminal number This operation may be omitted if the control box can be worked on easily without removing the leads 3 Remove the top and bottom covers 4 Slip the lamp and holder off the lamp holder bracket Loosen the hex nut on the transformer that is holding the lamp holder bracket and swing the bracket clear of the wires leading to the printed circuit board 5 Carefully remove the hex nuts on the meter studs to free the printed circuit board Slip the P C Board off the studs and pull it down under the chassis CAUTION It is good practice to use a short test lead or jumper wire to short the meter studs when it is not in the circuit 6 Loosen the meter retaining clips and rem
11. 00 Plates M st Clamp etis 1 5038200 1 4 20 2 14 x3 2 8 3 5050200 Blatwasher 3416 eaten beo asia ois EE 4 T 110820035 Bolt 1 4 20 x 1 1 4 Hex HCAs 5 554099 pu 5 561177 Lockwasher Split 1 4 SS 9 170 5030400 Support Upper Maste odes a s iioi tu 1 171 450590 1 172 610215 8 2 0 ft 173 640091 Plug DOS Este e us 1 Parts Pack Connector 878713 essent nennen enne 1 174 640092 Socket 8 pim Cmeh quiae cui te ae 1 175 411830 taneb Shrink t b 2 nasa He uu sus 4 in 176 640077 Plus Pin Cinch RU shea DH EUN 1 Contained in Mounting Hardware Kit PN NOTE A complete parts listing is contained in the service manual PN 801935 6 CinchTM a Division of Labinal Component amp Systems 102 MOTOR 124 125 POTENTIOMETER ASSEMBLY SPUR GEAR ASSEMBLY 164 END OF ROTATION SWITCH ASSEMBLY 112 RING GEAR 104 105 en Am lai 1 ur dura S 136 159 4 140 141 Figure
12. 1 Contact Pin 8 650180 Amp Receptacle shell 2 650181 Amp plug 1 650293 Contact Socket 8 Instruction Sheet 1 4 PLACES 8 WIRE 1 BOLTS 5 16 18 X 1 5 8 CONTROL NE AND 5 16 SPLIT LOCKWASHERS THAT CAME WITH THE ROTATOR Figure 7 Rotator Mounting with Lower Mast Support CinchTM a Division of Labinal Components amp Systems Inc AMP is a registered trademark of AMP Barrel AMP Inc 939 E Park Dr Harrisburg PA PRELIMINARY CHECK AND CALIBRATION IMPORTANT THERMAL PROTECTION If the rotator fails to turn after 4 or 5 minutes of continuous operation the thermal switch has come into play This protective device in the transformer automatically shuts off power if the rotator is used continuously for too long It will automatically reset after 10 minutes Turn the Control Unit Power ON with the upper right ON OFF switch The meter should be illuminated and the needle should be to the right 2 Depress the brake lever center and hold Depress the CCW lever left and operate the rotator to its full CCW position 3 With the rotator in its full CCW position if the meter is not at its full left position carefully adjust the zero CCW South position with the screw directly under the meter to exactly South 4 Meter Calibration Procedure Operate the rotator to its full clockwise position Adjust the calibration potentiometer until the meter indicates full scale to the right The meter is now calib
13. 300 Holder Fuse for F 2 120V version 1 37 710054 Holder Fuse for 2 220V version 1 38 5156100 Plate Fages ertet toe mee e Ete tee ass pasu 1 39 5089103 l akad asahan ha asas 1 40 506325 Bolt Hex Head 1 4 20 3 4 1 41 567110 Lockwasher 2 42 567120 PFlatwasher 4 oem 2 43 556960 Nut Hex 1 4 20 i oco aa te Sere etus ou ecm 1 44 550029 Nut Wang emet 1 45 710083 Holder ua aaa n L es Divus estere 1 46 567125 Lockwasher 10 Internal 4 Hy Gain reserves the right to change prices at its option Current prices may be obtained by calling writing the factory Wo di 3 i guit ESL KE 12 t tB n 4 E cy 11 3 l id 11 I t 1 l E I ii NOTE 9 WIRE 1 TERMINALS 1 amp 2 MUST BE CONNECTED USING THE TWO LARGER GAUGE WIRES OF CABLE THE WIRE CABLE SERIAS 1 2 X DENOTES WIREING CONNECTION TO THE P C BOARD 3 DENOTES MECHANICAL CONNECTION TO METER 2 FUSE 110V 1A Slo Blo 22V Figure 9 Wiring Schematic 33 35 CW SWITCH
14. Hz input Brake Positive electrically operated wedge 75 segments spaced 4 8 degrees apart Rotator Size 8 in 20 cm max diameter by 13 5 in 34 cm high Maximum Antenna Mast Size 2 1 16 O D 52 mm Mounting Hardware Stainless steel hardware and plated steel clamp plate Control Unit Size 8 5 in x 9 0 in x 43 in 21 6 cm x 22 8 cm x 11 0 cm Shipping Volume 2 280 cubic inches 37 350 ccms Shipping Weight 23 4 pounds 10 6 kb CAUTIONS Install properly and safely Towers often the highest metal parts tin the vicinity require caution during erection and placement Extreme care must be taken during erection so that metal towers and beams do not contact power lines even if the beams slip or rotate towers fall or fracture or metal wires blow in the wind etc Metal towers or other position mechanisms must be placed so that if they fracture or blow over in high winds they cannot contact power lines be a hazard to individuals or endanger property When no mounted within a tower with a thrust bearing as shown in Figures 5 and 6 the rotator must be DEBATED Metal towers must be grounded properly at the tower location before the tower is erected This is to minimize electrical hazard and the possibility of lightning damage DO NOT bury bare aluminum wires or stakes in the ground Use copper ground stakes The service entrance ground should be checked Th
15. PRESSURE I Unbalanced Weight Weight should be as closely balanced as possible Unbalanced weight creates a bending moment of force which is concentrated on the mast at the point where it is clamped to the rotator This moment tends to strain the mast at that point and also to bind the ball bearings by creating excessive downward pressure on one side and upward pressure on the other Such unbalance places additional stress on the motor gear train Unbalanced weight becomes critical as the distance from the antenna boom to the clamping point at the rotator is increased 2 Wind Pressure Wind pressure against the boom and elements produces a bending force on the mast which can cause the same stresses as unbalanced weight To strengthen the installation to withstand unbalanced weight and wind pressure the tip mast should be as short and as strong as possible In multiple arrays the antenna with the most wind area should be closest to the rotator 6 can also be used This installation is similar to Number 2 above and requires the optional Heavy Duty Lower Mast Support Kit and must be derated to 7 5 square feet In order to distribute the bending stress and prevent fracture of the mast the HAM IV rotator includes a specially designed steel clamping plate to clamp the mast to the rotator After procuring the type of tower or other positioning mechanism of the owner s choice the next step is to wire the rotator to the control box
16. UGGESTIONS Be sure to check your rotator cable for shorting open circuits incorrect wiring intermittent con nections shorted terminals rodent damage and mast support or thrust bearing binding CHECKING THE CONTROL UNIT 1 Voltages with Unit Plugged In To check the control unit plug the line cord into AC power With no connections to the terminals turn the ON OFF switch to the ON position the meter light will illuminate The meter needle will remain on the left hand S Terminals 1 and 2 should show 30 volts AC approximately when the Terminals 1 and 5 should show 30 volts AC with brake release lever depressed and CW lever depressed Terminals 1 and 6 should show 30 volts AC with brake release lever depressed and CW lever depressed Terminals 3 and 7 should show approximately 13 VDC 12 2 Resistances with Unit Not Plugged In Disconnect the AC power source and discon nect the 8 wire control cable Be sure to tag each wire with the corresponding terminal number The control box can be checked without removing the cover by using a volt ohmmeter to check values across terminals Resistance across Terminals 1 and 2 should read 4 ohms Read same value across Terminals 1 through 5 with clockwise switch lever right hand de pressed and across Terminals 1 through 6 with counterclockwise switch lever left hand depressed Resistance across input line cord with ON OFF switch in the ON position and the brak
17. duct under warranty provided the product is returned postage prepaid to Hy Gain with a personal check cashiers check or money order for 8 00 covering postage and handling 3 Under no circumstances is Hy Gain liable for consequential damages to person or property by the use of any Hy Gain products 4 Out of warranty Service Hy Gain will repair any out of warranty product provided the unit is shipped prepaid repaired units will be shipped COD to the owner Repair charges will be added to the COD fee unless other arrangements are made 5 This warranty is given in lieu of any other warranty expressed or implied 6 Hy Gain reserves the right to make changes or improvements in design or manufacture without incurring any obligation to install such changes upon any of the products previously manufactured 7 All Hy Gain products to be serviced in warranty or out of warranty should be addressed to hy gain 308 Industrial Park Road Mississippi 39759 USA and must be accompanied by a letter describing the problem in detail along with a copy of your dated proof of purchase 8 This warranty gives you specific rights and you may also have other rights which vary from state to state
18. e household convenience outlet should be the 3 prong type grounded back to the service entrance e Control Box is not weatherproof and must be located in the house ham shack or other protected location Read this manual completely before proceeding The HAM IV rotator has been carefully designed and manufactured to give many years of trouble free service when carefully and professionally installed It consists of the strongest and best commercially available components TYPES OF INSTALLATION There are three general types of installations see Figures 4 5 and 6 The recommended Installation is an Inside Tower Mount with a thrust bushing or bearing to provide support and resist high wind loads When the rotator is properly mounted this way it can be rotated to turn an antenna or beam of 15 square feet wind surface area The wind loading during storms the rotational inertia of the beam and unbalanced weight are more important than the dead weight of the beam It is important to minimize the height of the beam above the rotator to minimize the overturning force induced in a high wind see Unbalanced Weight and Wind Pressure 2 An outside Tower Mount see Figure 5 is optional The rotator is not well protected but the installation is simpler With an Outside Tower Mount the rotator must be derated to 7 5 square feet 3 A telescoping or other type mast see Figure UNBALANCED WEIGHT AND WIND
19. e lever depressed should read 3 8 ohms CHECKING THE ROTATOR FROM THE GROUND You may possibly avoid bringing the rotator down by making electrical checks from the control box position This is done by disconnecting the eight wire control cable from the control unit From the schematic diagram it is apparent that the resistance of the lead wires will be added to the resistance of the motor windings and potentiometer strip in making the resistance checks as shown in Table 2 Read Between To Check Resistance Terminals Brake 75 ohms leads 1 2 Solenoid 1 2 Motor Winding 2 5 ohms leads 1 8 1 2 Motor Winding 2 5 ohms leads 1 4 1 2 Motor Switch 2 5 ohms leads 1 6 1 2 Motor Switch 2 5 ohms leads 1 5 Entire Motor 5 ohms leads 8 4 Right Limit Switch 0 ohms leads 8 5 Left Limit Switch 0 ohms leads 4 6 Entire Pot 500 ohms 3 7 Pot Arm to End 0 to 500 ohms 3 1 Pot Arm to End 0 to 500 ohms 7 1 Table 2 ADDITIONAL CHECKLIST 7 sure cable is of proper size for length Check continuity of control wires for loose used Refer to Table 1 connections caused by wind 8 Substitute a 3 foot piece of new rotator cable 2 Tape down control cable securely all the way to bench test unit Proper operation will to rotator indicate a defective rotator cable on the mast or tower or a cable not large enough to 3 Check motor winding through control cable create proper turning torque as outlined in Table 2 9 Low
20. le 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 Specifications Input Voltage 120 VAC 50 60 Hz Optional 220 VAC 50 60 Hz Motor 24 VAC 2 25 Amp capacitor start capacitor run Brake Solenoid 24 VAC 5 0 Amps Power Transformer 120 VAC 26 V AC 10 duty thermal switch protected Optional 220 VAC 26 V AC 10 duty thermal switch protected Meter Transformer 120 VAC 23 VAC continuous duty Optional 220 VAC 23 VAC continuous duty Meter DC voltmeter 1000 ohms volts 1 MA full scale Meter Scale Direct Reading North centered 5 degree increments Optional Direct Reading South centered 5 degree increments Maximum Antenna Size A Tower Mounted as per Figure 3 15 sq ft 1 4 sq m of wind surface area B Outside Tower or mast Mounted as per Fig 5 or 6 7 5 sq ft 0 7 sq m of wind surface area Maximum Effective Moment EM 2 800 ft Ib 387 Kg M Operational Temperature Range 30 deg F to 210 deg F 34 deg to 99 deg C Maximum Interconnect Cable Resistance A Terminals 1 and 2 8 ohm B Terminals 3 4 5 6 7 and 8 2 0 ohms Rotation Time 45 60 seconds with 60
21. line voltage and cold weather will slow rotation Using an extra long or small wire extension cord can lower line voltage 4 Check cable between leads Static lightning charges or direct hits will cause carbon arcs in control cable at numerous spots along the cable that cannot be seen This resistive path will break down with voltage applied to rotator Replace cable 5 Check both control and rotator connectors for shorts 6 Rotation in one direction usually indicates a loose or broken cable wire bad relay and bad sensing transistors in some units PARTS LIST HAM IVControl Unit Replacement ITEM PART NO NO DESCRIPTION QTY 1 5156502 Control Unit 220V AC complete 1 2 5156500 Control Unit 120V AC complete 1 3 5139000 Printed Circuit Board 1 11 1034403 Puse Amp F 2 LIOV VersI n EBEN noes 1 12 5089501 Meter Os S a iu eii eo RD 1 13 710053 Fuse 1 Amp Slo Blo F 2 220V version 1 14 5138600 Switch Snap S 3 5 4 1 15 5141100 COVer ta a aqu dre ee b cie die 1 16 5141200 COVER L ra e e X 4 17 5152700 Pads SERI Ga a aaa a ea akapa 9 18 520057 Screw 46 32 x 3 8 Pan Head
22. lt in the mast clamp is tight LACK OF POWER If the antenna rotation is slow or sluggish or hard to start check for proper voltages If the voltages are correct the 130 156 mfd motor start capacitor could be at fault It is recommended that a new capacitor be tried before any other action is taken If the electrical circuit is okay then check for mechanical binding Pay particular attention to bearings and alignment of the shaft on an inside tower mount On any inside tower installation care must be exercised to get the top mast shimmed to the exact rotational center of the rotator upper mast support If temperatures are at 30 F 34 C or lower operation will be slow or sluggish This is normal If the capacitor is good the temperature is well above 30 F and there 15 no mechanical binding above the rotor the rotor may not be receiving the proper voltage levels to achieve maximum torque Check the cable resistances and wire sizes For cable runs over 300 move the motor capacitor to the tower IMPROPER METER INDICATION The brake and motor operate independently of the indicating system If the pilot light burns at proper brilliancy the instrument transformer is okay and the output is not shorted Check the 1 8 amp meter circuit fuse with the ohmmeter Check for about 13 VDC across Terminals No 3 and No 7 with the switch operated If the proper voltage is not obtained check the individual components in the meter circuit
23. nside a tower see Figure 4 to the flat tower plate by means of four 4 bolts furnished in the hardware kit Use the following procedure 1 Locate the rotator in the tower directly under the bushing Note that the tower plate must be cut out to allow the connecting 8 wire cable to pass through the plate Use the template in the back of the manual Too small of a hole will not allow the connector to pass through 2 Plug the connectors together and secure the cable to the tower in such a manner that the cable will not be strained HIGH RATIO HEAT SHRINK TUBING UNIT TO CONTROL UNIT Figure 3 Locking Tvpe Cinch Connectors 3 rotator is attached to the tower plate by means of four 4 bolts and lockwashers see Figure 4 The flat tower plate must be drilled in four 4 places using the template provided with this manual unless the tower plate is already properly drilled 4 Tighten the four 4 bolts but not to final tightness Observe how the rotator turns It must rotate in such a manner as to turn the mast concentrically in the thrust bearing 148 4 PLACES li 149 4 PLACES a TOWER LEG PLATE b _ 7149 4 PLACES 4 77 4 PLACES Figure 4 Rotator Mounting in a Tower 5 Trial assemble the mast to the top of the rotator using the U bolts nuts and lockwashers through the rotator and clamp plate as shown in Figure 4 The maximum mast diameter that may be
24. ntered scale TROUBLESHOOTING CAUTION This unit has been thoroughly tested and cycled before shipment Follow the connector wiring carefully between Rotator and Control Box Incorrect wiring will burn out the rotator potentiometer and void the warranty Be sure Rotator and Control Units are compatible Do not intermix models with different operating voltages This results in sluggish or non operating performance burned out motors overheated transformers and burned out rotator potentiometer etc GENERAL DESCRIPTION Most operational difficulties with rotators are traceable to broken shorted or grounded wires usually at the rotor connections Time spent in cutting the leads to exact lengths soldering and clamping to prevent strain on the control cable will pay dividends MECHANICAL PLAY Frequently the slight motion of the antenna array in gusts of wind is due more to the natural flexing of the elements and mast than it is due to actual play in the rotator mechanism A slight amount of play is built into the rotator to avoid binding due to environmental changes ANTENNA ROTATES IN HEAVY WIND This is usually a matter of the mast slipping in the support If slipping or turning is suspected return the rotator to the end of rotation and visually check to be sure that the antenna 1s in the original stop location as installed Check the nuts on the U bolts to insure that they are tight Also check that the center bo
25. ove the meter from the chassis 7 Insert a small knife blade between the clear meter cover and black housing at either corner of the top edge and gently pry the cover loose from that corner Repeat for the other corner The meter cover should pop 8 Carefully slip a knife blade under each corner of the lower edge of the white meter scale and twist slightly until the scale clears the two small indexing pins Remove the scale turn it over and reinstall it Make sure the scale fits over the indexing pins and that it is flush and tight against the black housing This will assure free movement of the indicator needle 9 Reinstall the meter remove the temporary jumper the P C Board and lamp hardware Check for pinched shorted end overstressed wires 10 Reinstall the top and bottom 11 Reconnect the 8 wire control cable in the exact sequence as they were removed If your beam was installed originally using the HAM IV with a North center scale the antenna mast must be loosened and repositioned In order for the meter to indicate properly the front of your beam must point North when the rotator is at the ends of rotation Recalibrate the meter NOTE In the past the South Centered meter scale was on the reverse side of the factory installed North Centered scale The unit is now provided with a separate South Centered scale This will help to avoid damage to the face of the meter scale during removal of the North Ce
26. rated Do not adjust the calibration potentiometer when the rotator is in any position other than full clockwise When the control unit is turned OFF the meter needle will fall to the left S position and return to indicate the rotator position as soon as the control unit is turned ON again It will not damage the unit to leave it turned ON for extended periods NORMAL OPERATION To operate the rotator it is necessary to understand the HAM IV Brake Release Lever and its function The brake lever middle lever on the Control Unit operates a brake wedge mechanism in the rotator which locks the rotator into position mechanically The rotator cannot turn unless the wedge is retracted by depressing the middle lever The normal operation is as follows 1 Retract the brake wedge by holding down the Brake Release middle lever 2 Turn the rotator to the compass location by pushing down and releasing either the left hand or the right hand lever Allow a few seconds for the rotator to coast down Then re engage the brake wedge by releasing the Brake Release middle lever OPERATING PRACTICE The rotator has several mechanisms to protect it from misuse but the following precautions are advisable 1 If you have a very large beam the rotator can be nudged to exactly the desired position by alternately working the left and right control allowing it to coast down before the brake wedge is allowed to engage 2 Itis
27. rotator turning in reference to the tower is no longer important the shimming procedure is not necessary The four 4 bolts must be torqued to the same specification and the 8 wire cable securely fastened The lower mast should be pinned with the 5 16 18 x 4 bolt as shown in Figure 7 CAUTION The rotator is designed for vertical operation with the bell shaped housing in the up position Water and other contamination will get into the motor unit if it s mounted horizontally upside down 5 6 5 6 5 PLACES 5 4 5 PLACES M 2 4 OPTIONAL KITS HEAVY DUTY LOWER MAST SUPPORT KIT 51467 10 Optional The stock HAM W is intended to mount on the base plate inside of the tower However in some instances outside tower or mast mounting is desired as per Figures 5 and 6 This kit P N 5146710 contains a heavy duty lower mast support and the necessary hardware to facilitate mounting the HAM IV on top of a tower stub or mast CAUTION When the rotator is installed using the lower mast support kit the antenna size must be restricted to 7 5 square feet of wind surface area WEATHER PROOF CONNECTOR KIT Optional The Cinch Connectors on the Rotor Unit may be replaced by AMPO CPC weatherproof connectors The connectors when properly installed will enhance the reliability of your HAM IV This kit contains the following PN Description Qt 650179 Amp Receptacle 9 pin 1 65029
28. used is 21 16 O D We recommend 1 1 2 nominal steel pipe with 1 9 O D in standard wall thickness of 145 For stacked arrays or very large beams we recommend extra heavy duty wall thickness of 200 Both steel pipes can be purchased to specification ASTM120 TOWER MOUNTING NOTE Apply a coating of heavy duty motor oil or grease to the threads of the stainless steel bolts and U bolts to prevent seizing On any inside tower installation care must be exercised to get the antenna mast shimmed to the exact rotational center of the rotator The geometry is such that a mast of 2 062 21 16 52 mm O D pipe will be exactly centered If the O D of your mast is less than this you should shim out to these dimensions 6 If the rotator top bushing and mast are aligned there should be unrestricted rotation through 360 If not the rotator may have to be moved slightly on the flat plate If a high quality bearing is used in the top of the tower recommended the shimming procedure must be done more carefully as closer tolerances are required It is important that the rotator does not try to turn the mast eccentrically with the top bushing or bearing 7 Tighten the four 4 bolts carefully to approximately 100 inch pounds of torque 8 Insert the 1 4 20 x 1 1 4 bolt with a locking nut into the center tapped hole in the clamp plate Tighten down to assure that the antenna mast does not turn in the upper mast support
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