HY GAIN AV 640 VERT ANT ASSEMBLY

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AV-640

8 Band Vertical Antenna

TRU

& ASSEMBLY

MANUAL

308 Industrial Park Road, Starkville, MS 39759

WARNING:

You can be killed if the antenna,

feedline, or the equipment used to

install the antenna accidentally

contacts utility lines. Never install

an antenna near utilit

lines.

Table of Contents

AV-640

Vertical Antenna

Instruction Manual

Table of Illustrations

Topic Page

Introduction 3

Theor

of Operation 3

AV-640 Specifications 4

Antenna Location 5

Antenna Mast 6

Antenna Groundin

Antenna Guying 6

Customer Supplied Components 6

Tools Required for Assembly 7

Safety Precautions 7

Verification of AV-640 Parts 8

Assembl

Procedure 11

Installation Procedure 16

Tuning Procedure 17

Maintenance 18

Technical Assistance 18

Warranty 30

Illustration Page

Chart A 19

Chart B 19

ure A20

ure B 21

Figure C 22

ure D 23

ure E 24

Figure F 25

ure G 26

ure H 27

Figure I 28

Figure J 29

WARNING: Improper installation and assembly can be hazardous!

Read these instructions thoroughly before attempting to install or

operate this product. High power transmitting devices produce voltages

that can cause severe burns or other injuries.

Introduction

Hy-Gain is proud to deliver the AV-640 Eight Band Vertical. Drawing on our

many years of Amateur Radio HF and VHF antenna design experience, we have

produced a well-engineered antenna capable of maximum efficiency, unmatched

performance, and superior construction.

Computer optimization of the AV-640 design yields the most efficient 3/8

wavelength electrical design with maximum gain and low angle of radiation for

long distance communication. No traps are used to achieve eight band

performance. The AV-640 is resonant on 6, 10, 12, 15 and 17 meters with

individual 3/8 wavelength radiators. The center radiator resonates on 20, 30 and

40 meters using parallel end loaded Teflon wire coils. Capacity hats on these

bands give wide 2:1 VSWR bandwidth and the antenna is kept to a height of 26

feet by the low inductance coils. There are no "tricks" or "mystery resonances"

used for impedance matching on any band.

No long-wire radials or counterpoise kits are necessary for operation of the AV-

640. The AV-640 is self contained for simple, convenient portable or fixed

operation.

Mechanical construction of the AV-640 is designed for extreme light weight and

high wind survival. Aircraft grade 6063-T832 aluminum and high strength

fiberglass are used for the entire radiator. The trap-free design presents a very

low wind surface area. Bulky tubing is not required to support unwieldy traps.

The broad 2:1 VSWR bandwidth on all bands lessens large frequency shifts

seen in other antennas when the antenna is wet or iced.

The AV-640 is covered by our Hy-Gain Warranty and supported by our customer

service team. We would like to thank you for purchasing this product from us and

ask that you let us know of any suggestion you may have. With proper assembly,

installation, and maintenance, your AV-640 will provide years of faithful service.

Theor

of O

eration

The AV-640 HF Multiband Vertical antenna consists of an end fed radiator that is

resonant in the 6, 10, 12, 15, 17, 20, 30 and 40 meter amateur frequency bands.

Resonances on each band are the result of impedance matching a 3/8

wavelength element with a broadband RF transformer. The characteristic

impedance at the base of the 3/8 wavelength radiator is in the order of a few

hundred ohms.

To match this impedance two tools are employed. First a counterpoise of 72"

spokes is mounted at the AV-640 base. The capacitance from this

round plane

helps lower the base impedance. Second, a 4:1 toroidal transformer (voltage

balun) steps the base impedance down to 50 ohms. This transformer uses (2)

ferrite cores for high power capability. Also, the windings are made of twisted

pair wire to improve coupling and reduce loss. A second high power

transformer is configured as a 1:1 current balun to help stop RF from traveling

back on the feedline shield. The radiator of the AV-640 is at DC ground

potential for static drain. This is accomplished by a radio frequency choke in

The center radiator of the AV-640 supports 1/4 wavelength stubs for 6 , 10, 12

and 17 meters. The stubs are placed approximately one tenth of a wavelength

(electrically 1/8 wavelength) above the AV-640 base. At the top of each stub the

impedance is very high at the frequency the stub is tuned. This high impedance

stops, (chokes) RF at this point creating a resonant 3/8 wavelength radiator.

There is minimal loss using this method as compared to standard trap circuits.

Also, VSWR bandwidth is not restricted by the °Q" of trap components. On 15

meters, the center radiator is terminated with a capacity hat to form a 3/8

wavelength radiator. No stub or coil is used on 15 meters. For 20, 30 and 40

meters, a coil and capacity hat are used on each band to create a 3/8

wavelength radiator. The coils are mounted at the top of the center radiator.

These three coils are connected in parallel. Parallel connection separates each

band to allow individual band tuning and has less loss than does series

connection. Also, the AV-640 coils have significantly less loss than a standard

trap because the AV-640 capacity hats exhibit greater capacitance than a

typical trap, therefore, less inductance is required.

AV-640 S

ecifications

VSWR at Resonance: Less than 1.5:1 at antenna typical

Gain: 3 dBi nominal

Hei

ht: 25 ft 10 in

Wei

ht: 22 lbs

Horizontal Radiation Angle: 360 degrees

Vertical Radiation Angle: 16 degrees at 1/4 wavelength high

Wind Surface Area: 2.5 s

Wind Survival: 80 mph

Antenna Location

The best performance for receiving and transmitting will be obtained by mounting the

antenna in a clear location above or away from buildings, buildings, towers, feedlines,

utility wires, and other antennas. While your own ingenuity and particular circumstances

will determine the final mounting method, remember, any object within 75 Set torn the

base of the antenna can influence the performance of the AV-640.

Band (m) 2:1 VSWR

(KHz) CW

(Watts Out) POWER SSB

(PEP Watts) RTTY

(Watts Out)

40 150 1500 1500 500

30 175 1500 1500 500

20 500 1500 1500 500

17 500 1500 1500 500

15 500 1500 1500 500

12 500 1500 1500 500

10 1500 1500 1500 500

6 1500 300 300 100

WARNING: Always mount this antenna so that it is out of the reach

of adults as well as children and pets. The counterpoise rods can

cause injury and or severe RF burns.

• NEVER mount this antenna in a location that will permit

unsuspecting people to come in contact with any part of the

antenna.

• NEVER mount this antenna where a mechanical failure might

allow the antenna, antenna support or feedline to contact power

lines or other utility wires.

• ALWAYS ground the feedline at the point where it enters a

building to a good earth ground for lightning protection.

• ALWAYS follow the guidelines for antenna installations as

recommended by the US Consumer Product Safety Commission.

Antenna Mast

The recommended support mast for the AV-640 is steel water pipe between the sizes of 1-

1/4" OD to 2 1/2" OD and with a length that will place the antenna base at a safe height.

Do not use thin walled conduit, aluminum tubing, or "TV" mast. The AV-640 is designed

to operate at a height of 8 or more feet for proper performance. Placement on the side of a

house or garage at eaves level is acceptable as long as the counterpoise whips will not be in

contact any snow on the roof Placement above metal roofs is acceptable if the antenna

base is at least 5 feet or more above the metal surface.

Antenna Groundin

Although the AV-640 is designed to operate efficiently without the requirement of an earth

ground, SAFETY GROUNDING must still be provided to protect equipment, property

and persons from the hazards of lightning strikes and other weather related electrical

discharges. In addition the coaxial cable feeding the antenna should have the shield

grounded to eliminate the risk of any indoor equipment failure from allowing hazardous

voltages from appearing indoors and creating a shock hazard. The support mast should be

grounded with a large diameter ground wire.

The AV-640 is DC grounded for static discharge. This is accomplished with a choke coil

in the Matching Unit. This coil could fail under high voltage spikes from a near or direct

lightning strike.

Additional protection can be accomplished by grounding the shield of the coax where it

enters the building to a good earth ground or directly burying the cable in the earth for

several feet before it enters the building. The coaxial cable should be totally disconnected

from the station during threatening weather conditions for maximum lightning

protection.

Antenna Gu

For normal operation up to 80 mph winds, the AV-640 will not require guying. For

extreme locations such as tall building rooftops, a safety guy is recommended. Use

Dacron® rope to guy the center radiator. Attach ropes 14 feet above the antenna base.

Use care not to disturb the radiator stubs.

Customer Su

lied Com

onents

• Quality low-loss 50 ohm coax cable with PL-259 connectors

• VSWR Analyzer (MFJ-259B or equiv.) or HF transceiver with VSWR meter

• Mounting mast with required hardware to provide sturdy support

Tools Required For Assembly

• 1/4" Standard Blade Screwdriver • 7/16" Nut Driver

• #1 Phillips Screwdriver • 7/16" Open End Wrench

#2 Phillips Screwdriver • 10 nun Open End Wrench

3/8" Open End Wrench • Tape Measure 20'

3/8" Nut Driver • Safety Glasses

5/16" Nut Driver • Pliers

5/16" Open End Wrench

Safety Precautions

WARNING: You can be killed if the antennas, feedline, or the

equipment used to install the antenna accidentally contacts any utility

lines. Never install an antenna near power lines!

• Be careful while climbing and carrying the antenna. It is heavy

enough to cause you to lose your balance if it is handled too casually

or if any part of the antenna snags on a gutter, ladder, tree, or other

item.

• Mount the antenna high enough and in the clear so that it is out of

reach by any person or pet. Do not allow trees or other structures

near the radiator portion of the antenna. The counterpoise whips can

cause serious eye injury.

• Ensure that the mast is sturdy enough to support the weight of this

antenna including the windload of the antenna.

Verification of Parts

Refer to the Box Contents and Parts Bags listings below to identify all parts. Also refer to

Page 10 for drawings of the various brackets used in the AV-640. If any part is missing

or damaged, turn to the Technical Assistance portion of this manual. There is extra

hardware supplied with the antenna. All hardware is Stainless Steel.

Box Contents

Part Number Part Description ED Number Quantity Received

17-AV640-4 Instruction Manual Bag IM 1

17-AV640-1 Parts Bag #1 PB1 1

17-AV640-2 Parts Bag #2 PB2 1

17-AV640-3 Parts Bag #3 PB3 1

80-AV620-1 AV640 Matching Unit MU 1

810-0620-1 Base Insulator 1 1/4" x 12" IN 1

11-0640-1 AV-640 Coil Assembly L1 1

20-AV640-1 Base Tube 1 1/2" x 12" BA 1

20-AV640-2 Radiator Section 1 1/2" x 72" BB 1

20-AV640-3 Radiator Section 13/8" x 75" BC 1

20-AV640-4 Radiator Section 1 1/4" x 75" BD I

810-0640-9 Radiator Section 5/8" x 36" BE 1

17-AV640-9 Small Tube Bundle ST 1

17-AV640-10 Spoke Bundle BS 1

738-0620 Antenna Mounting Plate AM 1

Small Tube Bundle

Part Number Part Description ID Number Quantity Received

810-0620-21 Stub Section 1/4" x 36" CG 1

810-0620-14 Stub Section 1/4" x 48" CF 1

810-0620-15 Stub Section 1/4" x 72" CE 3

810-0640-16 Stub Section 3/16" x 19" CA 1

810-0640-17 Stub Section 3/16" x 32" CD 1

810-0640-18 Stub Section 3/16" x 34" CC 1

810-0640-19 Stub Section 3/16" x 57" CH 1

758-2764 72" Stainless Steel Whip CW 7

oke Bundle

810-0640-24 1/8" 6" Aluminum Rod SP1 2

810-0640-25 1/8" 12" Aluminum Rod SP2 4

810-0640-26 1/8" 24" Aluminum Rod SP3 4

810-0640-27 1/8" 36" Aluminum Rod SP4 4

810-0640-28 1/8" 40" Aluminum Rod Spares 2

Parts Ba

Contents

Instruction Manual Ba

Part Number Part Description ID Number Quantity Received

925-AV640 AV-640 Instruction Manual MN . 1

925-0006 H -Gain Warrant Card WC 1

784-1780 Warning Label WL 7

Parts Bag #1

Part Number Part Description ID Number Quanti Received

656-03755 6-32 x 3/8" Screw SS S1 48

656-05005 6-32 x 1/2" Screw SS S2 4

656-12505 6-32 x 1 1/4" Screw SS S4 10

656-1500S 6-32 x 1 1/2" Screw SS S3 6

656-1750S 6-32 x 13/4" Screw SS S5 2

705-0632S-K 6-32 Nut Keps s SS N1 71

660-0375S 10-32 x 3/8" Screw SS S6 8

711-1037S #10 Lock Washer SS W1 4

705-10325 10-32 Nut SS N2 8

705-1032SNL 10-32 Nut Nylon Insert SS N3 8

662-20005 1/4-20 x 2" Bolt SS S8 4

662-25005 1/4-20 x 2 1/2" Bolt SS S9 4

705-2520SNL 1/4-20 Nut Nylon Insert SS N5 8

745-31005 1" Hose Clam SS HC2 1

745-31505 1 1/2" Hose Clam SS HC1 3

810-0620-16 Stub Slice 3/16" x 1 1/2" SS 3

745-3108 Counterpoise Ring SS RI 2

765-1009 Plastic Ca 1/4" C1 3

765-1062 Plastic Ca 5/8" C2 1

Parts Bag #2

Part Number Part Description H) Number Quantity Received

735-1610 Radiator Clam Bracket RB 16

758-9195 Mast Saddle MS 2

808-1786-6 Mast Plate MP 2

Parts Bag #3

Part Number Part Description ID Number Quantity Received

758-9200 2 1/2" U-Bolt Assembly SS UB 2

735-1618 Single Stub Base Bracket SB1 2

735-1611 Dual Stub Base Bracket SB2 1

737-8100 Single Stub Insulator P3 5

738-2600 90 Degree Stub Insulator P1 2

738-2602 180 Degree Stub Insulator P2 2

11-AV620-1 Jumper Wire J1 1

90 Degree Stub Insulator

P/N 738-2600 Qty (2)

Plastic

ID# P1

180 Degree Stub Insulator Single Stub Insulator Dual Stub Base Bracket

P/N 738-2602 Qty (2) P/N 737-8100 Qty (5) P/N 735-1611 Qty (1)

Plastic Plastic Aluminum

ID# P2 ID# P3 ID# SB2

Single Stub Base Bracket Radiator Clamp Bracket

P/N 735-1618 Qty (2) P/N 735-1610 Qty (16)

Aluminum Aluminum

ID# SB1 ID# RB

TASK I

Center Radiator Assembl

( ) Refer to Figure A to assemble the Center Radiator. Attach BA tubing section to either

end of the Base Insulator (IN) with (2) 1/4-20 x 2" bolts (S8) and (2) 1/4-20 nylock nuts

(

)

. Do not ti

hten the nuts at this time.

( ) Find the (2) counterpoise rings (RI). Press the flat sides of the rings together and slide

them onto the Base Insulator

(

)

. Leave rin

s loose at this time.

( ) Attach the drilled end of tubing section BB to the Base Insulator (IN) with (2) 1/4-20

x 2" bolts

(

)

and

(

)

1/4-20 n

lock nuts

(

)

. Do not ti

hten the nuts at this time.

( ) Place (1) hose clamp (HC 1) over the slotted end of tubing section BB. Slide unslotted

end of BC tubing section 6 inches (15 cm) into BB. Tighten hose clamp. NOTE: For

protection against oxidation, a conductive paste such as NoAlox® may be used between

telescoping pieces of aluminum tubing only. Do not apply the paste to insulators or coax

connections.

( ) Place (1) hose clamp (HC 1) over the slotted end of tubing section BC. Slide unslotted

end of BD tubin

section 6 inches

(

15 cm

)

into BC. Ti

hten hose clam

( ) Place (1) hose clamp (HC 1) over the slotted end of tubing section BD. Insert AV-640

Coil Assembly (LI) 4 inches (10 cm) into tubing section BD. Tighten hose clamp.

( ) Place (1) hose clamp (HC2) over the slotted end of coil assembly AV-640L1. Slide an

end of tubing section BE into top of L1 coil assembly. Set length to desired L40 value

from Chart A

)

(

)

Place 5/8"

lastic ca

(

)

on end of tubin

section BE

TASK II

Stub Base Bracket Assembly

( ) Refer to Figure B for Stub Base Bracket Assembly. Study Figures B and C to learn

how the stub base brackets are attached for each band. Note how the brackets are offset

90 de

rees from each other for

er antenna assembl

( ) Find the aluminum Stub Brackets (SB 1 & SB2). Attach a Radiator Bracket (RB) to

each Stub Bracket with (2) 6-32 x 3/8" screws (S I) and (2) 6-32 Keps nuts (N1) as shown

in Figure B.

( ) Find a Single Stub insulator (P3). Attach it to a Radiator Bracket (RB) with (2) 6-32 x

3/8" screws (S I) and (2) 6-32 Keps nuts (NI).

( ) Mount each Stub Base Bracket to the AV-640 Radiator using a Radiator Bracket

(RB), (2) 6-32 x 1 1/2" screws (S3), and (2) 6-32 Keps nuts (N1). Place the Single Stub

insulator opposite the Single Stub Base Bracket shown in Figure C.

( ) NOTE the degrees offset for each bracket and the distance from the base insulator

(IN) in Figure C. Position the Stub Brackets ABOVE the Radiator Brackets.

TASK III

Stub Insulator Assembly

( ) Place the AV-640 Radiator on a flat surface such as a driveway or garage floor. This

will aid in mounting the Stub Insulators by keeping them aligned with each other.

( ) Refer to Figure D for Stub Insulator Assembly. There are three types of stub

insulators: Single, 90 Degree and 180 Degree. The 180 Degree insulators are used with a

Single Stub insulator to make a Three Stub insulator. The locations of the Single

insulators are labeled «A", 90 Degree insulators are labeled "B" and the Three Stub

insulators are labeled "C".

( ) Attach 90 Degree Stub Insulators (P1) to a Radiator Bracket (RB) using (2) 6-32 x

3/8" screws (S1) and (2) 6-32 Keps nuts (N1) as shown in Figure D.

( ) Attach Single Stub Insulators (P3) to a Radiator Bracket (RB) using (2) 6-32 x 3/8"

screws (S l) and (2) 6-32 Keps nuts (NI).

( ) For Three Stub Insulators, attach a Single Stub and a 180 Degree Stub Insulator (P3

& P2) to a Radiator Bracket (RB) using (2) 6-32 x 1/2" screws (S2) and (2) 6-32 Keps

nuts (N1).

( ) Mount the Stub Insulators on the AV-640 Radiator using a Radiator Bracket (RB), (2)

6-32 x 1 1/4" (S4) screws, and (2) 6-32 Keps nuts (N1). USE the dimensions in Figure E

to space and rotate the insulators into their proper locations. Position the Stub Insulators

ABOVE the Radiator Brackets.

TASK IV

Stub Assembl

(

)

Refer to Fi

ure F for the stub assembl

rocedure.

( ) TEN METER STUB: Notice on the 3/16" x 32" rod CD the ends are tapped at

different lengths. Thread an end of tubing section CE onto the I" tapped length end of

rod CD. Thread it on at least 3/4" (2 cm) and carefully tighten with pliers until it is

tight against rod CD. Do not compress the tubing where it is threaded onto the rod.

NOTE: A small amount of WD-40® or NoAlox® can be used on these threaded

connections to ease assembly. Do not use oil. WD-40 will evaporate over time and

NoAlox is a conductive paste.

NOTE: THIS CONNECTION WILL NOT LOOSEN OVER TIME AS THERE IS NO

TORQUE ON THE CONNECTION WHEN THE STUB ASSEMBLY IS MOUNTED

ON THE ANTENNA.

( ) TWELVE METER STUB: Notice on the 3/16" x 34" rod (CC), the ends are tapped at

different lengths. Thread an end of tubing section (CF) onto the 1" tapped length end of

rod (CC). Thread it on at least 3/4" (2 cm) and carefully tighten with pliers until it is tight

against rod CC. Do not compress the tubing where it is threaded onto the rod.

( ) Thread a stub splice (SS) into the end of tubing section CF at least 3/4" (2 cm) until it

is ti

ht inside the tube.

( ) Thread an end of tubing section (CG) onto the stub splice (SS) until it reaches tubing

section CF. Carefully tighten tubing section (CG) against CF with pliers. Do not

compress the tubing where it is threaded onto the stub splice.

( ) SEVENTEEN METER STUB: Notice on the 3/16" x 19" rod (CA), the ends are

tapped at different lengths. Thread an end of tubing section CE onto the 1" tapped length

end of rod (CA). Thread it on at least 3/4" (2 cm) and carefully tighten with pliers until it

is tight against rod CA. Do not compress the tubing where it is threaded onto the rod.

( ) Thread a stub splice (SS) into the end of tubing section CE at least 3/4" (2 cm) until it

is ti

ht inside the tube.

( ) Thread an end of another tubing section (CE) onto the stub splice (SS) until it reaches

tubing section CE. Carefully tighten tubing section CE against the previous tubing

section CE with pliers. Do not compress the tubing where it is threaded onto the stub

( ) SIX METER STUB: Installation of the six meter stub is optional. If six meter

operation is not desired do not attach the stub to the radiator. Leaving the stub off will not

effect operation of the other bands. The stub is a 3/16" x 57" rod (CH). It is a single

section stub and does not require assembly.

TASK V

Stub Mounting

( ) Refer to Figure G to install the stub assemblies on the AV-640 Radiator. The bottom

of each stub assembly can be slid into the corresponding top stub insulator and fed

through consecutive insulators until it reaches the corresponding stub bracket.

6 Meter Stub

( ) If operation on 6 meters is desired, find the six meter stub (CH). Slide the threaded

end of the stub through the top of the stub insulator as shown in Figure G. Continue

through the second insulator until the stub meets the Stub Base Bracket.

( ) Mount the stub in the Stub Base Bracket hole using (2) 10-32 standard nuts (N2) and

a #10 Lockwasher (W l) as shown in Figure G.

( ) Set Length L6 according to the desired operating frequencies in Chart A (Page 19).

10 and 12 Meter Stubs

( ) Select the 10 meter stub assembly and slide the threaded end through top of the proper

stub insulator. Continue feeding the stub through the next three insulators.

( ) Attach the stub in the 10 meter Stub Base Bracket hole using (2) 10-32 standard nuts

(N2) and a #10 Lockwasher (Wl) as shown in Figure G.

( ) Set 10 meter stub length L10 according to the desired operating frequency in Chart A

(

e 19

)

( ) Select the 12 meter stub assembly and slide the threaded end through top of the proper

90 degree stub insulator. Continue feeding the stub through the next three insulators.

( ) Attach the stub in the 12 meter Stub Base Bracket hole using (2) 10-32 standard nuts

(N2) and a #10 Lockwasher (W l) as shown in Figure G.

( ) Set 12 meter stub length L12 according to the desired operating frequency in Chart A.

17 Meter Stub

( ) Select the 17 meter stub assembly and slide the threaded end throughtop of the proper

90 degree stub insulator. Continue feeding the stub through the next five insulators.

( ) Attach the stub in the 17 meter Stub Base Bracket hole using (2) 10-32 standard nuts

(N2) and a #10 Lock-washer (W l) as shown in Figure G.

( ) Set 17 meter stub length L17 according to the desired operating frequency in Chart A.

( ) Place a 1/4" plastic cap (C1) on the open end of tubing sections for each stub assembly

(

ure G

)

TASK VI

Matching Unit Mounting

( ) Refer to Figure G for the mounting location of the Matching Unit (MU). Use the

lower pair of bolts through the Base Insulator (IN) to mount the MU as shown in Figure

G. Remove the (2) 1/4-20 nuts (N5) from the (2) 1/4-20 x 2" bolts (S8) previously

installed.

( ) Place the Matching Unit on the bolts and secure in place with the (2) nuts. Be sure the

coax connector end of the Matching Unit faces the base (bottom) of the antenna.

( ) Using a 6-32 Keps nut (N1), connect one end of the jumper wire (JI) to the

counterpoise terminal of the Matching Unit. Do not over-tighten this nut. The other end of

the jumper wire is attached later.

TASK VII

Counterpoise Assembly

( ) Refer to Figure H to assemble the counterpoise.

( ) Loosely attach the counterpoise rings (RI) to the base insulator (IN) with (2) 6-32 x 1

3/4" screws (S5) and (2) 6-32 Keps nuts (NI).

( ) Loosely attach the counterpoise rings (RI) together with (8) 10-32 x 3/8" screws (S6)

and 10-32 nylock nuts (N3).

( ) Place the (7) 72 inch (183 cm) counterpoise whips (CW) into the slots provided in the

sides of the rings. The slot facing the Matching Unit (MU) does not receive a whip.

( ) Tighten the 10-32 nuts (N3) around the rings to secure the whips.

( ) Place the loose end of jumper wire (Jl) under the closest 6-32 screw (S5) that holds a

ring to the base insulator as shown in Figure H. Tighten the (2) 6-32 nuts (N l) that secure

the rings to the base insulator.

( ) Attach a warning label to the end of each whip as shown in Figure H.

TASK VIII

Antenna Mounting Plate Assembly

( ) Refer to Figure I for assembly of the Antenna Mounting Plate (AM).

( ) Place (4) 1/4-20 x 2 1/2" bolts (S9) through the Mast Plate (MP), Mast Saddle (MS),

and antenna mounting plate (AM) and secure with 1/4-20 nylock nuts (N5). Do not

tighten the nuts.

( ) Place the antenna base under the Mast Saddles and align the end of the base with the

edge of the mounting plate as shown in Figure I.

( ) Tighten the (4) bolts to hold the antenna base in place. Do not over-tighten the nuts.

( ) Place the (2) U-bolt assemblies (UB) into the holes in the antenna mounting plate as

shown in Figure I. Leave nuts loose until installation of the antenna.

TASK IX

Capacity Hat Assembly

( ) Refer to Figure J for assembly of the four Capacity Hats.

( ) Rotate the AV640 Coil Assembly (Ll) so the top end of the 17 meter stub is away

from the AV640 Coil Strap as shown in Figure J. To rotate the coil assembly, loosen

the lower coil hose clamp (HC 1). Tighten hose clamp when finished.

( ) Place (8) 6-32 x 3/8" screws (S1) and (8) 6-32 Keps nuts (Ni) in each Counterpoise

Ring assembly on the AV-640 Coil Assembly (LI). Leave the nuts loose so that the

spokes can be slid between the rings.

( ) There are spokes of lengths 6", 12", 24",36" and 48". Place the spokes in the ring

assemblies as shown in Figure J. The shorter spokes will be on the bottom end of the

coil and the longer spokes will be on the upper end of the coil. The 40" spokes are

spares. Tighten all hardware on the ring assemblies. The formed ends of the spokes can

be positioned in any direction.

( ) NOTE: For tuning 15, 20 & 30 meters, the lengths of a spoke is adjusted as shown in

Figure J, (1,15, L20 & L30). Since the AV640 has a broad low VSWR, it is suggested the

AV640 spokes be installed at their initial lengths of 6", 12", 24" & 36". If any of the bands

(15, 20 & 30 meters) are resonant too low in frequency, one of the corresponding spokes

can be pruned. Only one spoke will require pruning. Please refer to the Tuning section on

Page 17 and Figure J for more information.

Installation

The AV-640 antenna should be mounted at least 8 feet above ground. The main reason for

this minimum height is safety. The AV-640 will work well at a minimum height of five

feet but precautions from dangerous voltages must be taken.

Always have help for the installation process. Do not attempt to install the antenna

alone. Review the requirements for Antenna Location and safety precautions regarding

Power Lines earlier in this manual.

The easiest method of installing the AV-640 is to first mount the Antenna Mounting

Plate (AM) on the support mast. Tighten the mounting plate U-Bolts. Have the Mast

Saddles and Mast Plates (MS & MP) loosely mounted on the mounting plate. Raise the

antenna and slide the antenna base under the Mast Saddles (MS) until the antenna base is

flush with the lower edge of the mast plate (Figure I). Tighten the antenna base in place.

The AV-640 may be roof mounted on a tripod or similar support. Keep the AV-640 base

a minimum of 5 feet above the roof surface. This minimum dimension is the same for

any roof material type. Attach a suitable ground wire to the support mast as mentioned

in the Grounding section of this manual.

Tunin

The AV-640 should be checked with an VSWR meter before permanent installation to

verify proper assembly and Matching Unit performance. Place the AV-640 at least 8 feet

above ground and in as clear an area as possible. Connect the coax to the antenna base and

test the VSWR using either an MFJ-259B VSWR Analyzer or equivalent or a transceiver

and VSWR meter.

The 2:1 VSWR Bandwidth should be referenced to determine performance. VSWR

measurements made at the antenna base are the most accurate and may show a

slightly narrower VSWR bandwidth than the specifications chart lists. Be sure to use

very low power (less than 5 watts) when measuring VSWR at the antenna base.

The AV-640 has few variables in its design. Therefore, VSWR should be very close

to specifications. Each band can be adjusted individually. Refer to Chart A (Page 19)

for antenna dimensions and use Chart B (Page 19) to calculate the amount of

adjustment needed to place the AV-640 on frequency.

To adjust the 40 meter band, refer to Figure A and vary the length of L40. To raise the

resonant frequency, shorten the length of L40. Use Chart B (Page 19) to, calculate the

amount of adjustment needed to place the AV-640 on frequency.

Individual adjustment of 15, 20 & 30 meters is accomplished by pruning one spoke in the

corresponding capacity hat. Only one spoke is adjusted and it does not matter which

spoke is selected. Refer to Chart B to calculate the amount of spoke to prune and Figure J

for spoke location. (It is unlikely 15 meters will require adjustment). Also, it is strongly

suggested the AV640 be assembled and tested with the spokes at the initial lengths of 6",

12", 24" & 36" to determine if any pruning is actually required. If the resonant frequency

is too high, make a longer spoke from one of the 40" spare spokes.

Stub lengths can be adjusted for tuning the 6, 10, 12 & 17 meter bands. Chart A has the

length dimensions, Chart B shows the amount of length to change, and Figure G displays

the stub tuning locations.

If the VSWR is less than 1.5:1 at the frequencies you operate, do not spend extra time

trying to improve the VSWR. Any improvements beyond 1.5:1 yield minimal gains in

antenna performance and cause excess wear on the antenna, roof or mast. Please note the

length of coax will vary the VSWR on certain bands. Lengths less than 50 feet have

stronger harmonic resonances than longer lengths. If a particular band will not properly

resonate, try adding 3-5 feet or more of coax. Record the resonant frequencies with and

without the added coax. There will be a change in resonant frequencies on one or more

bands. RF loss at HF is not a major problem with RG8X or larger coax. There will be a

minimal performance difference between a 50 ft. length and a 75 ft. length of coax.

To lessen the possibility of RFI/TVI, roll up 6-8 turns of coax 8" inches diameter

approximately one quarter wave (or multiple) from the base of the antenna. Use the

quarter wave length of the frequency that causes the greatest amount of

Maintenance

The AV-640 should be inspected mechanically at least once a year. Normal wear and tear

varies si

nificantl

with climate.

Anti-Oxidation paste such as NoAIOX® or others can be applied to the radiator tubing

sections. Use small amounts. Do not place the paste on the coax connector or inside of the

Matching Unit.

Inspect the inside of the Matching Unit on a regular basis. Remove dirt, bugs, or

questionable material. Look for any degradation of parts. High voltage static

discharges (lightning) may cause a failure to the small coil in the Matching Unit. This

coil is a protection device. Make sure it is in good shape.

Do not screw and unscrew the nylon insert nuts several times. If portable operation

is desired, use stainless steel hardware without the nylon locking feature.

The AV-640 may be painted. Clean all aluminum surfaces well to improve paint

adherence. Paint the antenna after it is assembled and tuned. DO NOT PAINT

PLASTIC PARTS.

Technical Assistance

Technical assistance is available during normal business hours on weekdays. Hy-Gain

is located in the Central Time Zone. Our hours are 7:00 AM till 4:00 PM CST Monday

through Friday.

Hy-Gain can be reached by telephone, FAX, email and regular mail at the

following addresses:

Hy-Gain Telephone (662) 323-9538

308 Industrial Park Road FAX (662) 323-5803

Starkville, MS 39759 email "hy-gain@hy-gain. com"

Telephone (800) 973-6572 Web Page "http://www.hygain.com

Service history has shown that most problems are operating or installation errors, rather than

equipment failures. Most problems can be resolved over the telephone. Please contact our

staff before shipping parts or equipment to us.

The packing material used to ship this antenna is designed to prevent shipping damage.

Please reuse the original shipping carton if possible. Hy-Gain will not be responsible for

shipping damage on returned items with improper packing.

Band Portion L40 L30 L20 L17 L15 L12 L10

See Fi

ure AJ JGJGG

CW 28” 23 ½” 11 ½” 161” 5 ½” 116” 102 ½”

CENTER 21” 23 ½” 10” 161” 5” 116” 101”

SSB 18” N/A 9” 160 ¾” 4” 116” 99 ½”

Band Portion L6

See Figure G

50-52 MHz 55 ½”

52-54 MHz 54 ¼”

Band Length Adjustment

40 Meters 17 KHz

er inch

30 Meters 50 KHz

er inch

20 Meters

100 KHz per inch

17 Meters 60 KHz

er ½ inch

15 Meters 100 KHz

er inch

12 Meters 150 KHz

er ½ inch

10 Meters 100 KHz

er ½ inch

6 Meters 300 KHz per ½ inch

FIGURE A

AV-640 Center Radiator Assembly

FIGURE C

Installation of AV-640 Stub Base Brackets

FIGURE D

Installation of Stub Insulator

FIGURE E

Installation of Stub Insulators

FIGURE F

Stub Assembly

Figure G

Stub Installation

FIGURE I

AV-640 Antenna Mounting Plate Assembly

ain® 24-MONTH LIMITED

hy-gain Warrants to the original owner of this product, if manufactured by hy-gain and purchased from

an authorized dealer or directly from by-gain to be free from defects in material and workmanship for a

period of 24 months from date of purchase provided the following terms of this warranty are satisfied.

l. 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 by-gain at

the time of

warranty service. by-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 product 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 by-gain liable for consequential damages to person or property by the

use of an

ain

roducts.

4. Out-of-warranty Service: by-gain will repair any out-of-warranty product provided the unit is

shipped prepaid. All 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

7. All by-gain products to be serviced in-warranty or out-of-warranty should be addressed

ain, 308 Industrial Park Road, Starkville, Mississi

39759, USA and must be accompanied by a letter describing the problem in detail along

with a co

our dated

roof-of-

urchase.

8. This warranty gives you specific rights, and you may also have other rights which vary from state

to state

HY GAIN AV 640 VERT ANT ASSEMBLY

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