HY GAIN HDR 300AX ROTATOR

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HDR-300A

Heavy Duty Rotator System

Instruction Manual

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.............................................................................................. l-9

Section V Calibration and Installation Procedures..............................................................1-12

Calibration........................................................................................…................................1-12

Installation........................................................................................…................................1-12

Section VI. Operations and Maintenance.............................................................................1-15

Operations .......................................................................................….................................1-15

Use the Digital Readout System......................................................…................................1-16

Maintenance .....................................................................................…................................1-16

CHAPTER 2 - TROUBLESHOOTING AND SERVICE INFORMATION.......................... 2-1

Section 1. Troubleshooting .................................................................................................... 2-1

Section II. Voltage and Resistance Measurements..................................................................2-5

Voltage and Resistance Charts............................................................................................2-5

Section III. How to Get Factory Service................................................................................ 2-6

Service Information ........................................................................................................... 2-6

CHAPTER 3 - HDR-300/A PARTS LIST AND SCHEMATICS.......................................... 3-1

LIST OF ILLUSTRATIONS

ure Pa

1 Control Console Rear Panel ...................................................................................1-4

2 Socket Contact Application ....................................................................................1-5

3 Control Cable Connector Attachments...................................................................1-7

4 Control Cable - Rotator Wirin

Guide................................................................... l-8

Detail A-Actuator Shown in the "000" Position ................................................1-8

5 Solenoid and Potentiometer Wiring Guide.............................................................1-9

6 Wiring for 115 VAC .............................................................................................1-10

7 Wiring for 230 VAC ............................................................................................. 1-11

8 HDR-300/A Rotator Mounting Hardware............................................................1-13

9 Top View of HDR-300/A and Tower Mounting Plate fo

Hy-Gain Crank-Up Towers HG-54HD and HG-70HD.................................... 1-14

10 T

ical Installation of Rotator Mounted Below Plate .......................................... 1-14

11 Gear Motor Assembly with Cover ......................................................................... 3-4

12 Output Gear and Shaft Assembly........................................................................... 3-4

13 Gear Motor Assembly - Side View ........................................................................ 3-5

14 Gear Motor Assembly - Top View ......................................................................... 3-5

15 Gear Motor Schematic............................................................................................3-6

16 Steel and Fiber Gears.............................................................................................. 3-6

17 Exterior View - Control Console............................................................................ 3-7

18 Interior View of Control Console........................................................................... 3-7

19 Schematic Main P.C. Board .................................................................................... 3-8

20 Main P .C. Board...................................................................................................... 3-8

21 Components and Wiring of Main PC. Board ........................................................ 3-9

22 Schematic of Display PC. Board ......................................................................... 3-10

23 Display P.C. Board ................................................................................................ 3-10

24 Components of Display PC. Board - PN 871166-1 ........................................... 3-11

25 Rear Mounted Components - Front Panel of Control Console ........................... 3-11

PLEASE RECORD THE FOLLOWING INFORMATION FOR YOUR RECORDS:

Date of Purchase:_______________________________________________

Purchased From:________________________________________________

Price Paid:____________________________________________________

Serial Number (on Gear Motor):___________________________________

CHAPTER 1

INSTALLATION AND OPERATION

Section I. Com

onents of the HDR-300/A Rotator S

stem

General Description

Gear Motor Assembl

The HDR 300/A Rotator is a compact, high torque

antenna rotator that can be used for positioning

large antenna systems. The gear train is

constructed of heavy steel-spur gears for maximum

strength and reliability. To provide for quiet,

vibration free operation, a fiber drive gear from the

motor is used. An aluminum housing reduces

weight and helps prevent corrosion. The gears are

lubricated with a low temperature grease that is

stable from -60°F to 280°F The HDR-300/A also

features a new 17-4 PH stainless steel heattreated

output shaft for increased corrosion resistance and

increased wear resistance.

Azimuth indication is provided by a 3-turn, 1000

ohm wire wound potentiometer that is geared to

the rotator output shaft. An analog output is ob-

tained by a varying DC voltage as the rotator is

turned. Because a 3-turn potentiometer is used,

the amount of over-travel can be as great as 180°

without damage to the potentiometer. However,

the over-travel is limited to approximately 20° by

the limit switches. This gives a maximum travel

of 400°. Ferrite beads have been added to the

wires on the potentiometer to reduce susceptabil-

ity to high-power RF

General Descri

tion

The gear train is driven by a 1/10 HP permanent

magnet split capacitor motor. The motor is sup-

plied with 24 VAC, 50/60 Hz, single phase power

through one of two limit switches. Gear motor

stall torque at 70°F typically exceeds 5000

inch/pounds. Full load torque exceeds 2300

inch/pounds. The motor contains a thermal over-

load circuit breaker which will not allow the mo-

tor to operate if it is too hot. The breaker will

automatically reset after the motor cools down.

This usually takes 5 to 15 minutes depending

upon ambient temperature. The gear motor will

operate reliably from -30°F to +120°F

The HDR-300/A Rotator has a low voltage sole-

noid brake/clutch assembly. This assembly is in-

stalled on the motor shaft and prevents gear

damage by slipping when the braking torque or

brake-holding torque exceeds 7500 inch/pounds.

This value may drop if the clutch is allowed to

slip several times. The braking torque and brake-

holding torque will always be greater than 5000

inch/pounds unless the rotator system is subjected

to misuse, neglect or incorrect wiring.

Control Console

The Control Console actually consists of two

separate systems. The first system supplies 24

VAC to the motor. The second system supplies 5

VDC to the azimuth potentiometer and receives

the analog signal from the potentiometer which is

converted into seven segment LED's digital form

and displayed on the front panel.

The 24 VAC transformer comes wired for 115

VAC, although it can be easily rewired for 230

VAC operation. Power is supplied to the rotation

control switch through the brake control switch.

Before the antenna can be turned the brake must

be in the "FREE" position. This also permits the

operator to allow the antenna to coast to a stop

before locking the brake. This will prevent the

brake/clutch assembly from slipping under high

torque conditions. The brake switch has a re-

minder light to tell you that the antenna is free to

rotate.

When the power switch is turned on, 5 VDC is

supplied to the potentiometer in the rotator. As the

rotator is turned from 0° to 360°, output voltage

from the potentiometer is varied from .833 to

2.500 VDC. This analog voltage is compared to a

reference voltage and finally converted into a

digital format for display purposes. The display

system is capable of displaying -99° to +999°,

although the limit switches on the rotator limit the

rotation from -20° to +380°. Potentiometers are

available through the back plate for zero and gain

calibration.

A new main PC Board, P/N 871165-2, and a

small adjustment to the position of the 3-turn po-

tentiometer allows the HDR-300/A to operate as a

North-centered or South-centered antenna rotator.

Tower Com

atibilit

The HDR-300/A is a large, heavy-duty antenna

rotator; therefore it is meant to be installed in

towers capable of withstanding near the maxi-

mum wind loading capacity of this rotator, which

is 25 square feet (2.3 sq. meters). The HDR300/A

may be installed in smaller and mediumduty

tower structures, but the installation will be more

difficult and in some cases will degrade the

operation of some features of the tower.

We recommend that you install this rotator in a

tower that is rated for at least 15 square feet of

wind area. For towers with wind loading capaci-

ties of less than 15 square feet, either the T2X

"Tailtwister" or Ham IV may be installed easily

and operated safely.

This new main PC Board has (4) four trim pots

and one 2 position slide switch. The two new trim

pots affect how the rotator switches from 359

degrees to 000 degrees while in the Northcentered

mode of operation. The slide switch selects either

North-center or the original South-center

operation. Choose whether you wish to use the

rotator in North or South-centered operation. If

you want South-centered operation, place the

switch in the right (open) position. If you want

North-centered operation, place the switch in the

left (closed) position.

Antenna Com

atibilit

As stated earlier, the HDR-300/A is a large,

heavy-duty antenna rotator, and as such, should

be used primarily in systems that require this ca-

pacity. For antenna systems that exhibit less than

15 square feet of wind area, the HDR-300/A is

NOT required. The Ham IV may be used to turn

wind areas up to 15 square feet and the T2X

"Tailtwister" may be used to turn wind areas up to

20 s

uare feet.

Alternatively, do not exceed the maximum wind

area capacity of this rotator (25 square feet).

Also, the wind area ratings of antennas with

boom lengths longer than 30 feet are not valid to

use when selecting a rotator. Long-boom yagi or

logperiodic antennas require more braking and

turning torque than shorter antennas with the

same wind area.

NOTE: The maximum antenna area of 25 square

feet is only valid if no antenna boom is more than

30 feet long and all elements are less than 50 feet

lon

Section II. Specifications

Control Cable Requirements:

Recommended

Length of Run Minimum for Maximum Torque

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: seven #14 Belden 8628 Itwelve #14 Belden 8629

CAUTION:

Before purchase of the control cable is made, consideration

should be taken to the wire size and O.D. of the cable in

comparison to the connectors being used.

Belden 9495 (3-#14 AWG) and Belden 8489 (4-

#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.

Use the Effective Moment rating of the anten-

nas to determine com

atibilit

The three large wires are used on pins 1, 2, and

3. The four smaller wires are used on pins 4, 8,

9, and 10. The maximum resistance in the three

large wires should not exceed 0.5 ohms each.

Section III. Pre-Installation Instructions

Pre-Installation Check

It is required that a preliminary operational check

be made on the rotator system prior to actual in-

stallation. First, check each item against the Parts

List. If any of these items are missing or

damaged, follow the instructions on our warranty

label.

Next, set up the control unit and the rotator as-

sembly for an operational check using the

following procedure:

STEP l: Determine if you wish to operate this

unit on 115 VAC or 230 VAC. The

HDR-300/A comes prewired for 115

VAC, but can be easily modified for

230 VAC operation. If 230 VAC

operation is desired, go to Section IV

before returning to Step 2.

Figure 1

Control Console Rear Panel

STEP 2: Referring to Figure 1, Control Console

Rear Panel, install a 2.5A fuse (1.5A

for 230 VAC) and a 12A fuse in the

riate fuse holders.

STEP 3: With the Control Console setting on a

suitable workbench, plug the power

cord into the a

riate wall socket.

STEP 4: Turn the power switch on. The switch

light should come on and stay lit until

turned off. The LED digital readout

should also come on. You will notice

that the digits will change for a

second or two until the system has

stabilized. Once stabilized, the display

should read between "-85" and "-99"

or "---". All of these are under-range

indicators showing that the control

cable has not been plugged in. The

over-range indicator is "EEE". This

will occasionally appear during

stabilization, but should not stay on

unless there is a wiring mistake. Turn

the

ower switch off.

Moisten the sheath with isopropyl al-

cohol. Align the contact with the back

of the cavity and insert it straight into

the appropriate cavity until bottomed.

Remove the sheath from the front of

the recetpacle and use on the other

contacts.

Repeat for each contact. pull back

lightly on each conductor to be sure

each contact is locked in each cavity.

Once locked in place, the contacts may

only be safely removed with an extrac-

tion tool. This tool consists of a tube

with an OD of 0.129 and an ID of

0.115. When inserted over the contact

from the front side, this tool compres-

ses the locking tabs, permitting easy

removal.

STEP 6: Plug the 8 pin connector into the rotator

rece

tacle.

STEP 5: Measure out the control cable required

for your installation. (See Specifica-

tions.) Stretch the cable out to its full

length when testing. Strip the wires on

both ends as shown in Figure 2.

Attach one end to the 10 pin

connector and the other end to the 8

Attach the other wire ends to the AMP

socket contacts, Figure 2. The maxi-

mum wire size that should be used

with these is 14 AWG, with a maxi-

mum insulation diameter of 0.135

inch. Crimp and solder these socket

contacts securely to each wire.

Before inserting a socket contact into

the receptacle, install the AMP seal

protector (sheath) (PN 650294) in the

socket portion of the contact as shown

in Fi

ure 2. Figure 2

Socket Contact A

lication

STEP 7: Plug the 10 pin connector into the con-

trol console. Turn on the control con-

sole power switch. The digital readout

should show a heading between -10

and 010 degrees. If it doesn't, refer to

Chapter 2, Section I, Troubleshooting

guide. Final calibration will take place

in Section V

STEP 8: Set the rotator so that the cover is facing

you. Move the brake switch on the

control console to the "FREE" posi-

tion. The switch should light up, indi-

cating that the antenna is free to turn.

You should also hear the solenoid re-

lease the brake and the solenoid will

make a humming noise which is nor-

mal.

STEP 9: Set the rotator so that the output shaft is

facing you. Move the rotate switch on

the control console to the ri

ht.

NOTE: The brake must be in the "FREE" position

efore the rotate switch will o

erate.

The output shaft should rotate clockwise. If not,

refer to Chapter 2, Troubleshooting. Move the ro-

tate switch back to the center position. The output

shaft should coast to a sto

Move the rotate switch to the left. The output

shaft should rotate counterclockwise.

North-Center Calibration:

Place the gearmotor assembly ( P/N 871159) on

your bench, and attach your control cable to both

the control unit and the gearmotor unit. Turn on

the control unit and rotate the gearmotor fully

CCW If South-centered, the display should read

rox. -15 de

rees.

If North-centered, the display should read approx.

165 degrees. If not, adjust the ZERO pot for this

value. Once you have the correct display, rotate

the gearmotor fully CW. If South-centered, the

display should read approx. 375 degrees. If

North-centered, the display should read approx.

195 degrees. If not, adjust the GAIN pot for this

value. If you are using South-centered operation,

this completes the adjustments on the bench.

If you are using North-centered operation, rotate

CCW until you reach a display of `000'. As you

rotate further CCW the display should change to

`359','358', etc. You can expect some ambiguity

near the switchover from `359' to `000'. Try ro-

tating both directions near this point, and watch

the display. If there is a large jump (e.g. from

`355' to `002') or an overlap (e.g. from `359' to `-

007'), you will need to adjust the two lower pots

marked "-01/3XX" and "3XX". Rotate to where "-

O1" is displayed. If "-O1" can not be obtained,

rotate to the closest positive heading (e.g. "00" or

"O1"). This may require quick reflexes on the

brake switch. Adjust the new pot marked "-

01/3XX" until "-O1" is replaced by "3XX", where

"X" may be any digit. Adjust the new pot marked

"3XX", so that "359" is displayed.

You may now rotate plus and minus a few de-

grees to check the operation of the 359/000

switchover. You may notice that the operation is

slightly different between CW and CCW (hyster-

esis). Occasionally you will see either "360" or "-

O1". This is normal! This completes the bench

adjustments for North-centered operation.

Leave your gearmotor at the center of rotation,

and install it within your tower.

Figure 3

Control Cable Connector Attachments

DETAIL A

Actuator Shown in the "000" position.

Figure 4

Control Cable-Rotator Wiring Guide

Figure 5

Solenoid and Potentiometer Wirin

Guide

Section IV Volta

e Conversion

CAUTION:

Dangerous and lethal voltage exist inside

this unit. Remove the power cord from the

socket before servicing this unit.

To convert the voltage of this unit, follow the

procedure below and Figure 5 for 115 VAC, or

ure 6 for 230 VAC.

Refer to Figure 1 and install the fuse indicated for

the volta

e that will be used.

Replace the power cord's plug with the appropri-

ate one for the power system requirements in your

area.

Arrange the three white wires indicated with A

and B to the configuration shown for the desired

volta

115

Figure 6 Wiring for

115 VAC

AA-0300-9-011

230

Figure 7 Wiring for

230 VAC

Section V Calibration and Installation Procedures

Calibration Installation

The HDR-300/A is shipped from the factory

with two calibration steps completed. The 3-turn

potentiometer is matched to the rotator assembly

and the di

ital dis

is calibrated to zero.

It these items are replaced or become un-

calibrated, refer to Chapter 2, Section III for

calibration procedures.

Only one calibration step should normally have

to be performed. This is a gain adjustment to the

digital voltmeter incorporated into the display

circuitry. This adjustment can be made either

with the rotator installed or on the bench. The

best method is to adjust it on the bench first, then

check it again on the tower!

Set the rotator on the bench with the output shaft

parallel to the bench top. Assemble the mast

clamps and platform as shown in Figure 7. Insert

the key into the keyway in the platform, and

slide the mast clamp assembly onto the output

shaft. This may unbalance the rotator, so you

may wish to tip it back on the plastic housing.

Turn on the control console and turn the rotator

so the display reads "00". Line up the mast

clamp assembly on a distant object, so that after

turning the rotator through 360°, the mast clamp

assembly is again lined up on the same object.

Turn the rotator clockwise until this alignment is

obtained. Using a small screwdriver, adjust the

gain potentiometer so that the display reads

"360", See Figure 1.

Remove the mast clamp assembly from the out-

put shaft. At this time, coat the platform hole

with heavy grease to prevent corrosion. If your

rotator mounting plate is not permanently

attached to the tower, it should be removed at

this time. Assemble the rotator to the rotator

mounting plate. (For Hy-Gain towers see Figures

7 and 8.) The rotator requires four (4) mounting

holes, each 3/8 inch in diameter, four (4) inches

apart on a 5.656 inch (5 21/32") diameter circle.

Refer to the template for mounting hole locations

on the mounting plate which is furnished in this

manual. For small towers, the mounting holes

must be arranged on the mounting plate so that

the output shaft is centered within the tower ant

that the gear housing doesn't interfere with a

tower leg or bracing.

Turn the rotator back to "000" to check the align-

ment again. If "360" cannot be obtained by ad-

justing the gain potentiometer, refer to Chapter 2,

Troubleshooting. Turn the rotator both

counterclockwise and clockwise until each limit

switch is found. The counterclockwise limit

switch should be between -10 and -25 degrees.

The clockwise limit switch should be between

370 and 385 degrees. Return the rotator to "000".

If everything checks out, the HDR-300/A is now

read

for installation.

Figure 8

HDR-300 Rotator Mountin

Hardware

Item Item

No. Description No. Description

10 Platfor

Plate 20

ut, hex, 5/16", stainless steel

11 Platform 21 Flatwasher, 5/16", stainless steel

12 Mast Clamp 22 Lockwasher, split, 3/8", stainless steel

13 Key, 1/4 sq. x 15/8", plated 23 Lockwasher, split, 5/16", stainless steel

14 Bolt, hex head, 3/8"-16 x 3 1/2", stainless steel 24 Flatwasher, 3/8", stainless steel

16 Bolt, hex head, 5/16"-18 x 1", stainless steel 68 Screw, pan head, #10-24 x 6"

17 Bolt, hex head, 5/16"-18 x 1 1/2", stainless steel 69 Screw, pan head, #10-24 x 13/4"

18 Setscrew Allen, 1/4"-20 x 3/8", stainless steel 70 Screw, pan head, #10-24 x 3/8", stainless steel

19 Nut, 3/8"-16, stainless steel 71 Flatwasher, #10

72 Receptacle, 8 pin

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

For towers that must be climbed for installation,

follow these instructions:

Make sure that the rotator will match the holes

in your mounting plate per previous informa-

tion. Under NO circumstances should the

rotator be lifted by the mast clamp assembly.

The rotator may be pulled up the tower by

first attaching the mounting plate to the

rotator. The rope can ben be attached to

mounting plate. Another method is to secure a

5/16"-18 eyebolt into one of the mounting

holes and attach the rope to it for lifting. A

rope cradle may also be used. Once the rotator

is mounted securely within the tower, the mast

clamp assembly can be installed and the

control cable ta

ed to the tower.

Tighten the setscrew into the platform. Lower

the mast into the mast clamp. Tighten the four

(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

platform. The antenna should be oriented so that

it is pointing north when the readout shows

"000".

Route the control cable down the tower using

appropriate strain relief. Route the control cable

to the control console and plug it in. Using the

same calibration steps as before, line the antenna

up with a distant object. Rotate the antenna until

the antenna is again lined up with the same

object. Check the digital readout and adjust if

necessary.

CAUTION:

If using a crank-up tower, do not

completely nest the tower with the HDR-

300/A installed. Because of the shape of

the gear box, a portion of the rotator

extends out of the tower.

Section VI. O

erations and Maintenance

erations

The HDR-300/A brake release feature is

designed to decrease the effects of torsional

forces caused by rapid deceleration and instant

stopping of large antennas and beams. By

releasing the rotate switch slightly before the

point of intended antenna position, letting the

unit coast to a full stop, then locking the brake,

the torque on both the tower and rotator is held

to a minimum. This will prolong the life of your

rotator system and will maintain the maximum

CAUTION:

Although operation of the HDR-300/A at

its rated capacity of 25 square feet in

strong winds (50 mph plus) is not recom-

mended, it is possible as long as certain

precautions are taken.

Always allow the antenna to coast to a stop

efore lockin

the brake.

NOTE: When the rotator is not in use, the brake

switch should be set in the "lock" position. The

brake switch incorporates a light to remind you

that the antenna is free to turn.

The brake switch must be in the "FREE"

position before the rotator will turn.

Always keep the brake locked when the

rotator is not bein

turned.

Avoid rotating near the ends of rotation. Do

not depend on the limit switches to stop

rotation of a large antenna in strong winds.

These precautions should also be followed when

rotating medium size antenna (7 to 15 square

feet) in light winds. When followed, the life of

the rotator system will be prolonged.

Use the Digital Readout System

The HDR-300/A incorporates a very accurate

digital display of azimuth bearing information.

This display will always indicate the exact direc-

tion of the antenna once calibrated. A readout of

"000" degrees indicates that the antenna is point-

ing due North. A readout of "090" indicates East,

"180" indicates South, "270" indicates West, and

"360" indicates North again.

Because of the type of digital readout system

used, overtravel in the clockwise direction is

indicated by 360 to 385 which would correspond

the 000 to 025 degrees. Overtravel in the

counterclockwise direction is indicated by nega-

tive numbers such as -01 to 125 degrees.

The HDR-300/A has numerous features to

prevent water entry. The output shaft uses a spe-

cial V -shaped )-ring to prevent water entry at

this point. The mast clamp assembly uses an

aluminum plate to keep the platform from

damaging the O-ring and to prevent water from

runnin

throu

h the mast clam

assembl

Also, a new plastic housing is provided to keep

the motor, capacitor, limit switches, and poten-

tiometer dry. A drain hole is provided to

eliminate condensation water. Periodically check

the O-ring and the plastic housing to insure

moisture resistance.

During normal rotation, the display will incre-

ment in steps of approximately 4 degrees. This is

because the rotation is faster than the display

system. Once the rotator is allowed to coast, the

increments will be in steps of 1 degree. The

conversion rate of the digital display system is 4

Hz. This prevents a rapid flickering of the

dis

durin

rotation.

The digital display system also incorporates two

filters that eliminate both 50/60 Hz and RF

modulation of the dis

Maintenance

Rotator Assembly: The gears are lubricated with

a special low temperature grease that is stable

from -60°F to +280°R After three to five years of

service, the gears should be checked to insure

adequate lubricant. This grease can be obtained

through Hy-Gains's Customer Service Depart-

ment for a nominal charge.

The output shaft of the rotator is stainless steel to

prevent corrosion; however, after many years of

service, some rusting may occur in the platform

hole. You should coat this hole with grease

efore installation to

revent corrosion.

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.

"---" (Step 7, Chapter l, Section III). Potentiometer wired incorrectly.

10 pin connector wired incorrectly.

8 pin connector wired incorrectly.

Potentiometer not installed correctly.

Digital display reads between "-99" and "- Potentiometer not installed correctly.

10" (Step 7, Chapter 1, Section III).

Digital readout not zeroed.

Potentiometer wired incorrectly.

10 pin connector wired incorrectly.

8 pin connector wired incorrectly

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.

"FREE" position.

10 pin connector wired incorrectly.

8 pin connector wired incorrectly.

Control cable not plugged in.

12 Amp fuse not installed.

Brake solenoid buzzes but doesn't release Too much voltage drop in control cable.

brake.

Use a heavier cable.

Rotate switch has no effect. Brake still in lock position.

Control cable not plugged in.

10 pin connector wired incorrectly.

8 pin connector wired incorrectly.

Limit switch stuck.

End of rotation - Switch direction.

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.

ut motor won't turn. Loosen the two lon

screws holdin

the moto

housing and recenter it.

Rotator able to go less than -50 or greater Rotator has coasted past one of the limit

than 450 degrees. switches.

Output shaft runs opposite the direction in- Limit switches wired incorrectly.

dicated b

the rotate switch.

10 pin connector wired incorrectly.

8 pin connector wired incorrectly.

Digital display runs opposite the direction in- Potentiometer wired incorrectly.

dicated by the output shaft.

10 pin connector wired incorrectly.

8 pin connector wired incorrectly

"360" can not be obtained by adjusting the Potentiometer not installed correctly

ain

otentiometer

(

Cha

ter 1, Section V

)

Digital readout not zeroed.

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.

degrees with brake switch locked.

Brake system failed.

Very high RF field near control cable.

250 j.tF capacitor not working.

Rotator able to go less than -25 degrees Limit switches) broken.

and/or greater than 385 degrees.

Limit switch actuator loose or misadjusted.

Gain control not calibrated.

Digital readout not zeroed.

Rotator will turn with no load but will not Mast is binding in tower.

turn a large antenna.

Control cable is too small.

Winds are too strong.

Antenna is too large.

Thrust bearing is not used.

Section II. Voltage and Resistance Measurements

Volta

e and Resistance Charts

Control Unit, 10 pin socket:

Between Pin Numbers Voltage or 1hlerance

Resistance

1-3 (with rotate switch to the right) 24 VAC f 10%

2-3 (with rotate switch to the left) 24 VAC t 10%

4-3 (with brake "Free") 24 VAC ± 10%

8-10 +5 VDC t %

9-10 180KL2 t 20%

10-chassis zero ohms

Rotator Unit, 8 Pin Socket:

Between Pins Resistance

Excluding Control Cable

1-3 1.0 ohm

2-3 1.0 ohm

1-2 2.0 ohms

3-4 32 ohms

5-7 1000 ohms

6-7 150-550 ohms

5-6 450-850 ohms

Section III. How to Get Factor

Service/Calibration

Service Information

Do not ship equipment to the manufacturer with-

out prior authorization. We prefer to send special

shipping labels which will avoid the delay of an

unex

ected shi

ment.

If time is extremely important, wire or call for

approval and we will rush labels to you. When a

shipment is expected, even the time of sending

the labels is less than that lost when an unex-

ected shipment is received.

It is very important that the shipment be well

packed and fully insured. Damage claims must be

settled between you and the carrier and will

greatly delay any returns. Proper packing nor-

mall

avoids this trouble.

NOTE: we will not ship by means of a carrier that

will not fully insure the shipment. Some carriers

have a $200.00 limit. The exception to this is

when there is no other means (APO-FPO-etc.) of

shipment than parcel post, then we will ship by

this means with your written agreement that you

assume any loss over that which the carrier will

insure. C.O.D. shipments cannot be made to

APO-FPO addresses.

All replacement parts orders must be prepaid or

C.O.D. only. Replacement part price quotes will

be furnished on request for those who desire pre-

paid shipment or cannot accept C.O.D. shipments.

Calibration

ALL SHIPMENTS MUST BE SENT TO US

PREPAID. We do not accept collect shipments.

All returns should be made in our standard car-

tons only - so save our carton when unpacking the

unit. When a shipment is returned, it will be

handled in one of three wa

1. Where all service is in warranty, the ship-

ment will be returned prepaid by a carrier of

our choice. Warranty claims must be accom-

panied by a copy of the bill-of-sale.

2. If there are any charges not covered by war-

ranty, we will hold the shipment and advise

ou of costs

which

ou can then send.

3. Or, upon your written authorization, we

will ship C.O.D. for any charges not

covered by warranty, then the carrier will

collect these charges and the transportation

costs on arrival. Unclaimed or refused

C.O.D. shipments will not be reshipped

until payment of service and transportation

charges is received. Shipment will then be

made collect for reshipment transportation

charges.

Most replacement parts do not need adjustment or

calibration. The two exceptions are the 3-turn po-

tentiometer and the main P .C. board.

To Recalibrate The Pot Within The Gearmoto

Assembl

Place the gearmotor assembly (P/N 871159) on

your bench, and remove the black plastic cover.

Attach your control cable to both the control unit

and the gearmotor unit. Place a voltmeter across.

pins 9 and 10 (A digital VOM is best to use). Turn

on the control unit and rotate the gearmotor to it's

center of rotation. (Watch the plastic limit switch

actuator while turning the rotator) With the

gearmotor at the mechanical center of rotation,

loosen the screws which hold the pot assembly to

the gearmotor. It is easier to remove one screw,

then pivot this assembly so that the plastic gears

unmesh. When loose enough so that the pot's

plastic gear turns freely, adjust the position of this

gear until the voltmeter reads 3.07 volts. Carefully

re-mesh the plastic gears and tighten the two

screws. The voltmeter should read within the

range of 3.05 to 3.10. If not, repeat this

adjustment.

Rotate the gearmotor CCW until the limit-switch

actuator is approximately 1/8" from the limit-

switch arm, and has not opened the circuit. The

actuator should "point" to the pivot-post of the

limit switch arm. (The voltage should read ap-

prox. 2.25 volts) Adjust the "Zero" potentiometer

so that the digital display reads "000". Mark this

position with a pen or pencil on the gearmotor.

Rotate the gearmotor a full revolution CW until

your mark is reached again. (The voltage should

read approx. 3.89 volts) Adjust the "Gain" pot

until "360" is shown on the digital display. The

rotator is now calibrated for South-centered op-

eration.

To calibrate for North-centered operation, adjust

the slide switch to the left (closed) position. Ro-

tate CCW to where "-O1" is displayed. If "-O1"

can not be obtained, rotate to the closest positive

heading (e.g. "00" or "01"). This may require

quick reflexes on the brake switch. Adjust the

new pot directly under the "Gain" pot until "-O1"

is replaced by "3XX", where "X" may be any

digit. Adjust the new pot centered between the

"Zero" and "Gain" pots and two inches lower, so

that "359" is displayed. You may now rotate plus

and minus a few degrees to check the operation of

the 359/000 switchover. You may notice that the

operation is slightly different between CW and

CCW (hysteresis). Occasionally you will see

either "360" or "-O1". This is normal!

New PCB 871165-2

Switch South-Center

right (open) North-Center

left closed

Voltage at Center of Rotation 3.07 3.07

Voltage at full CCW 2.25 2.25

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 De

artment.

All requests, inquires, warranty claims, or

for orderin

lacement

arts

contact:

Hy-Gain

308 Industrial Park Road Starkville,

Mississippi 39759 USA Phone: 662-

323

9538

CHAPTER 3

HDR-300/A PARTS LIST AND SCHEMATICS

PARTS

NOTE: Item numbers ma

not necessaril

be in numerical order.

No. Part No. Description Qty

1 870511 Gear Motor Assembly..............................................................................1

2 250117 Gear, 1T2-32038..................................................................................1

3 470643 Cover, black plastic..............................................................................1

4 (Not Used)

5 722958 Potentiometer, 3-turn

(

1 K ohm

)

.........................................................1

6 *740200-2 Gear Motor, VW47..............................................................................1

64 500350 Screw,

anhead, #4-40 x 5/8"..............................................................4

65 559612 Nut, hex, #4-40....................................................................................4

66 561166 Flatwasher, #6......................................................................................4

67 569613 Lockwasher, internal, #4......................................................................4

68 500346 Screw, pan head, #10-24 x 6"..............................................................2

69 500347 Screw, pan head, #10-24 x 13/4 ".......................................................2

70 500348 Screw, pan head, #10-24 x 3/8" ..........................................................7

71 561165 Flatwasher, #10..................................................................................11

72 650290 Connector, AMP 208677-1..................................................................1

650291 Contact, AMP 66602-1........................................................................7

450581 Wire seal foryin contact, AMP 207565-2.................................................. 1

871161 Parts Pack, Fuses .....................................................................................1

7 710043 Fuse, 1.5A/3AG slo-blow....................................................................2

8 710044 Fuse, 2.5A/3AG slo-blow....................................................................2

9 710045 Fuse, 12A/3AG slo-blow.....................................................................2

871532 Parts Pack Box, HDR-300.......................................................................1

10,170429 Platform Plate ......................................................................................1

11 375917 Platform................................................................................................1

12 375918 Clamp, mast .........................................................................................2

870512 Parts Pack, AMP Plug..............................................................................1

652292 AMP plug, 208678-1...........................................................................1

650293 AMP socket, 66601-1..........................................................................8

650294 AMP sheath, 208338-1........................................................................3

871533 Parts Pack, Hardware...............................................................................1

13 385928 Key, plated, 1/4" sq. x 15/8 "..............................................................1

14 500155 Bolt, hex head, 3/8"-16 x 3 1/2", stainless steel .................................4

15 (Not Used)

16 505842 Bolt, hex head, 5/16"-18 x 1", stainless steel ...................................... 4

17 509712 Bolt, hex head, 5/16"-18 x 1 1/2", stainless steel ...............................4

18 536395 Setscrew, Allen, 1/4"-20 x 3/8" ss, with nyloc patch .......................... 2

19 555694 Nut, hex, 3/8"-16 stainless steel .......................................................... 4

20 555747 Nut, hex, 5/16"-18 stainless steel ........................................................4

21 560024 Flatwasher, medium, 5/16", stainless steel .......................................... 4

22 561016 Lockwasher, split, 3/8", stainless steel ................................................ 4

HDR-300

A PART

(co

Item

No. Part No. Description Qt

23 564792 Lockwasher, split, 5/16", stainless steel .............................................. 8

24 567180 Flatwasher, 3/8", stainless steel...........................................................4

25 640024 Plug, 10 pin..........................................................................................1

(

Not Used

)

27 871869 Control Console Assembly ......................................................................1

28 51845039 Screw, Philips, #4-40 x 3/8".............................................................. 2

29 250105 S

acer

hex head

#8-32 x 3/8"............................................................4

30 179808 Cover, console......................................................................................1

31 451623 Strain Relief .....................................................................……………1

32 460293 Front Panel...........................................................................................1

33 350834-1 Back Plate ............................................................................................1

34 450375 Front Panel Label.................................................................................1

35 506460 Screw

Rround head

#10-24 x 3/4" ....................................................4

36 506650 Screw, round head, #6-32 x 1/2...........................................................4

37 506665 Screw, round head, #6-32 x 1/4" .........................................................2

38 506800 Screw

round head

#8-32 x 3/4" .........................................................6

39 509234 Screw, round head, #8-32 x 1/2" .........................................................6

40 511577 Screw, Type A, pan head, #6 x 5/16" ..................................................4

41 556970 Nut, hex, #10-24..................................................................................4

42 556990 Nut, hex,#8-32 ...................................................................................12

43 557000 Nut, hex, #6-32....................................................................................2

44 557010 Nut, hex, #4-40....................................................................................2

45 567125 Lockwasher, internal, #10.................................................................. 4

46 567135 Lockwasher, internal,#8.......................................................................8

47 600221 Power Cord ..........................................................................................1

48 640026 10 Pin Receptacle ................................................................................1

49 660020 Terminal Strip ......................................................................................1

50 700088 Power Switch .......................................................................................1

51 700092 Brake Switch............................................................................…………….1

52 700089 Rotate Switch.......................................................................................1

53 710044 Fuse, 2.5A/3AG slo-blow....................................................................1

54 710045 Fuse, 12A/3AG slo-blow.....................................................................1

55 718105 Fuse holder, 3AG.................................................................................2

56 52158025 Capacitor, disc, ceramic, .lpf..............................................................2

57 730063 Transformer, 24 VAC...........................................................................1

58 870994 Jumper Cable Assembly ......................................................................1

59 871165-2 Main PC. Board Assembl

(Refer to Figures 18, 19, & 20)...........................................................1

60 871166-1 Display PC. Board Assembly

(

Refer to Fi

ures 21, 22, and 23

)

........................................................1

61 871275 Bezel and Lens Assembly....................................................................1

62 871870 Main Chassis w/feet.............................................................................1

63 04890 Cable Tie 4" .........................................................................................6

64 59000111 Screw, M4-.7 x 10, pan head, Philips .................................................4

65 51845039 Screw, #4-40 x 3/8" pan head............................................................ 2

GEAR MOTOR PARTS

Item

No. Part No. Description Qty

6 740200-2 Gear Motor, VW47..................................................................................1

6A 740200-A Gear Housing, aluminum casting (upper) ...........................................1

6B -B Gear Housing aluminum casting (lower) ............................................1

6C -C Solid Output- Gear Shaft Output Assembly (358810)........................1

6D -D Machined Steel Gear #2 ......................................................................1

6E -E Machined Steel Gear #3 ......................................................................1

6F -F Steel and Fiber Combo Gear #4..........................................................1

6G -G Motor Assembly, 24 VAC, including end plate and

mounting hardware ..............................................................................1

6H -H Solenoid, 24 VAC, and mounting bracket and screws ........................ 1

61 -I Solenoid Plunger..................................................................................1

6J -J Brake Lockin

Arm, S

rin

, Mountin

Screws, and Washers ...........1

6K -K Clutch/Brake Assembly 2/Allen setscrew ...........................................1

6L -L Motor Capacitor...................................................................................1

6M -M Limit Switch and Insulator and hardware ...........................................2

6N -N Jumper Wire.........................................................................................1

60 -0 Jumper Wire.........................................................................................1

6P -P Plastic Paddle Arm and Push-Out .......................................................1

6Q -Q Plastic Limit Switch Actuator w/Allen setscrew................................. 1

6R -R Plastic Gear (knurled shaft) .................................................................1

6S -S (Not Used)

6T -T Potentiometer Mountin

Bracket and mountin

hardware .................1

6U -U Output Shaft Bearing and Washers ...................................................... 1

6V -VG Ear Housing Hardware ........................................................................1

6W -W Low Temperature Grease.....................................................................1

6X -X V-Ring Seal..........................................................................................1

COMPLETE ASSEMBLY

Figure 11

Gear Motor Assembl

with Cove

Figure 12

Output Gear and Shaft Assembly

o. Descriptio

o. Descri

tion

3 Cover, black plastic 6C Solid Output Gear and Shaft Assembly #1

5 Potentiometer, 3-turn 6G Motor Assembly, 24 VAC, including end plate

6 Gear Motor mounting hardware

6A Gear housing, aluminum casting (upper) 6L Motor Capacitor

613 Gear Housing, aluminum casting (lower) 6U Output Shaft (PN 358810)

6V Gear Housing Hardware

Figure 13

Gear Motor Assembl

-Side

Figure 14

Gear Motor Assembl

-To

View

Ite

No. Description No. Description

5 Potentiometer, 3-turn (1K ohm) 6L Motor Capacitor

6 Gear Motor 6M Limit Switch and Insulator and Hardware

6G Motor Assembly, 24 VAC, including end plate and 6N Jumper Wire

mountin

hardware 60 Jum

er W iere

6H Solenoid, 24 VAC, and mounting bracket and screws 6P Plastic Paddle Arm and Push-Out

61 Solenoid Plunger 6Q Plastic Limit Switch Actuator w/Allen setscrew

6J Brake Locking Ann, Spring, Mounting Screws 6R Plastic Gear (knurled shaft)

and Washers 6T Potentiometer Mountin

Bracket and mountin

hardware

6K Clutch/Brake Assembly w/Allen setscrew 6V Gear Housng Hardware

Figure 15

Gear Motor Schematic

Figure 16

Steel and Fiber Gears

Figure 18

Interior View of Control Console

Figure 19

Schematic Main P .C. Board

Figure 20

Main PC. Boar

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 Ca

acitor, dis c, ceramic, .1

F, 25V

Cl and C2 722463 Capacitor, electrolytic, l000pF, 16VDC

C3 and C4 52158025 Capacitor, disc, ceramic, .1pF, 25V

C5 51821016 Capacitor, electrolytic, 220pF

C6 722465 Ca

acitor, .22

F 12VDC, disc,

R1 54046100 Resistor, 100K, 1/4W 1%

R2 54045110 Resistor, 11 K, 1/4W 1 %

R3 52154269 Resistor, 3.3K, 1/4W 1%

R4 722469 Resistor, 150K, 1/4W 1 %

R5 722975 Resistor, 42.2K, 1/4W 1 %

R6 52154195 Resistor, 3.9M, 1/4W, 1%

R7 54044576 Resistor, 5.76K, 1/4W 1 %

R8 54046237 Resistor, 237K, 1/4W, 1 %

R9 54044681 Resistor, 6.81K, 1/4W 1%

RIO 54044953 Resistor, 9.53K, 1/4W 1%

VRl 722467 Variable Resistor, 50K

VR2 723441 Variable Resistor, 1 K

VR3 723421 Variable Resistor, 2.5K

VR4 722468 Variable Resistor, IO

D1-D4 58678000 Diode, IN5817, low voltage turn on

U1 760098 A/D IC CA3161E

U2 760099 Driver IC, CA 3161E

U3 and U4 760097 LM348AT 5.0

U5 53284000 LM393

S1 70000 Switch, 2-position

F1 710076 Fuse, 1 amp, 3AG, Fast acting

NOTE: All designators correspond with Figures

Com

onents and Wirin

of Main PC.

Figure 22

Schematic of Dis

P .C. Board

Figure 23

Dis

PC. Board

Figure 24

Ite

No. Description

40 Screw, Type A, pan head, #6

x 5/16" 50 Power Switch

51 Brake Switch

52 Rotate switch

60 Display PC. Board Assembly Figure 25

Rear Mounted Com

onents-Front Panel of Control Console

HY GAIN HDR 300AX ROTATOR

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