Hy-Gain 640 Installation instructions

ORDER NO
64
INSTALLATION
OPERAI1:DN INSTRUCTiONs
SECTION I
GENERAL DESCRIPTION
. The Fqotlocker Linear Amplifier is a precision built
. amplifier of advanced design. It utilizes two tubes, six
transistors in a tuned grid tuned plate circuit for amplifi-
cation of AM, FM, CWand SSBsignals.
The Footlocker is designed for 12 DC negative ground
mobile installation and is supplied with a remote ON/OFF
switch which allows the operator to trunk-mount the Foot-
locker.
The Footlocker has a built-in automatic antenna change
over relay, which operates without special external con-
nections, making it perfect for operation with low power
transceivers having no external amplifier control circuits.
The Footlocker has been designed and constructed to sup-
press radiation that may cause television interference.
TVI problem has been given full consideration in the
design and the layout of the chassis. There are, however,
some types of TVI that cannot be prevented within the
amplifier. This is particularly true in weak signal areas.
In such cases, a good commercial low pass filter is recom-
mended.
SECTION II
UNPACKI NG
Carefully remove the Footlocker Amplifier from the carton.
Examine it closely for signs of shipping damage. If in-
spection shows damage, the del iveri ng carrier must be
contacted ·immediately and a claim filed.
The responsibility for safe delivery rests with the carrier.
The responsibi Iity of obtaining reimbursement rests with
Height (including feet) 59/16"
Width , , 14"
Depth . . . . . . . . . . . . . . . . •. . . . . . . . . . . . . . . . . . . . . . 11 1/2"
Net Weight , 9 Ibs.
Shipping Weight 10 Ibs.
Construction Lightweight aluminum chassis with
rugged steel cover
Frequency Range Amateur 10 meter band
Types of Emission AM, FM, CW, SSB, DSB
Power Output. 200 watts AM with full upward
modulation
Drive Required to Trigger Antenna Relay 1 watt
Max Drive (unmodulated carrier and FM) 5 watts
(amplitude modulated carrier) 3.5 watts
(amplitude modulated peak) ..•... 14 watts PEP
Input Impedance (unbalanced) 50 ohms nominal
Output Impedance (unbalanced) 50 ohms fixed
Antenna Switching , Automatic provided by
RFsensing circuit
Power Requirements 13.6 volts (12 v nominal)
50 amps
Cable Connector Data ..... Input & Output requires PL-259
you. Prompt action will speed adjustment. Our warranty
does not cover malfunction or damage which is a result of
improper handling by a carrier.

SECTION III
I NSTALLATI ON
The location of the mounting is not critical, however, the
Footlocker was designed to be mounted on the floor of the
trunk. Four support legs are provided to secure the Foot-
locker to the trunk floor. These support legs attach to the
Footlocker by means of the screws that hold the feet on.
Unscrew the feet, put the support legs on the screws and
put the feet back on.
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Cons.ideration must be given to provide adequate venti la-
tion and to enable the operator to set up and check the
Footlocker when it is installed.
The Remote Switch should be mounted in a convenient
position on the dash. The two wires should be routed
back to the Footlocker and connected to the terminal strap
marked "Remote". Make sure that the red wire goes to
the red terminal and the black wire to the black terminal.
A good ground should be made on the remote switch
through the mounting lugs, otherwise the ON/OFF indicator
lamp will not light when the Footlocker is switched to ON.
Before connecting the primary power cables to 'the supply
and the battery terminals, the voltage output of the gener-
ator or alternator should be checked." Turn on the car
headlights for five minutes without starting the motor.
This wi II discharge the battery sl ightly. Connect an ac-
curate voltmeter from the generator output terminal to
ground and start the motor. WITH THE MOTORAT A FAST
IDLE, THEGENERATORORALTERNATOROUTPUT VOLTAGE
SHOULD NOT EXCEED 14.5 VOLTS. If it does, the auto-
motive voltage regulator should be recalibrated for a
maximum output voltage from the generator or alternator of
14.5 volts. If the generator output voltage is between
13.5 and 14.5 volts, the regulator will not need adjustment.
(For regulator adjustment, refer to the shop service manual
for the automobile avai lable from your car dealer.)
Jhe Footlocker draws up to 50 amps of current when trans-
mitting. If the electrical system of your vehicle is not
capable of supplying this current at 13.6 volts, then full
RFpower output will not be achieved.
Connect the Footlocker directly to··the vehicleb~lttery
using #6 or heavier wire for both positive and negative.
The vehicle chassis is a poor ground return path at this
current and should not be used. As an added safety pre-
caution, it is strongly recommended that an additional 40
amp fuse and holder (the type obtainable from most elec-
tricalcontractor supply stores) be inserted in the line
directly at the positive terminal. This wi II protect battery
should a short circuit develop in the wires going to the
Footlocker.
OBSERVE POLARITY; positive to +12v termina/and nega-
tive to -12v terminal .. REVERSING POLARITY WILL CAUSE
DAMAGE TO VEHICLE AND FOOTLOCKER.
Connect a length of coaxial cable (RG 58/U or similar)
between the transceiver and XCVR socket.
The antenna system should be checked for VSWRof less
than 2: 1 before the Footlocker is used. For best perfor-
mance of your communication system the VSWRshould be
as low aspossible.
When the Footlocker is installed as outlined above, oper-
ation is simply achieved by switching the remote unit ON
and OFF. This controls the Footlocker. A built-in delay
in the automatic antenna change over holds the relay in
for about one second. This is to prevent chatter when
using SSB(single side band) transceivers.'
Set the sl ide switch on the rear panel to the TUNE posi-
tipn. Adjust the drive control for midway position. Apply
3.5 watts drive power by keyin"g the transceiv~r micro-
phone and quickly adjust the tune control for maximum
reading on the output meter. Removethe drive power after
adjustment.
Do not apply drive power for more than five ..seconds
without adjusting the tune control or damage to the tubes
can result.
Reapply drive power and adjust the drive control so that
the amplifier produces about 100 watts (about 5-6 on the
meter).

Adjustment of the input tuning coil (on the underside of
the Footlocker), using a hex shaped plastic al ignment
tool, may be necessary to achieve maximum power output.
Set the Tune-Operate slide switch to the Operate position.
Reapply drive power and adjust the drive control maximum
output, readjust the Tune and Input tuning coi I for maxi-
mumoutput.
The load capacitor is factory adjusted to provide maximum
output and should 12 . be adjusted.
Adjust the drive control until the. power output is about
150-200 watts. The amplifier is now adjusted to give 150
watts output with upward modulation to 300 watts.
Always use a good peak reading watt meter such as the
Hy-Gain 421A when adjusting an amplifier.
If the average output power decreases with modulation
then either the transmitter (exciter) is incapabl e of upward
modulation or the amplifier has not been tuned up correctly
and the above procedure should be rechecked. If this
does not correct the situation, the drive control (on the
rear panel) should be adjusted for a sl ightly lower power
level necessary to produce upward modulation than a
carrier power of a higher level with downward modulation,
this will increase your communication range and provide
a clearer signal with much less distortion.
For best AM operation the Iinear must be tuned according
to above procedures. Many misconceptions regarding
Iinear'operatioh exist among Iinear users. Reviewing a
few points regarding proper linear operation will help to
2. If the output signal reproduced is identical to the
input, except stronger, the amplifier is said to be linear.
If not, the amplifier is non-linear.
3. Non-I inear operation produces spurious outputs and
distortion of the signal.
5. All power used to produce distortion and spurious
signals is power not being used for communication.
6. The Footlocker provides a 300 watt RF envelope maxi-
mum power output.
7. Any attempt to operate AM at the 300 watt carri er
level will produce downward modulation with distortion
and spurious signa Is.
8. Distortion and spurious signals (lost power) will occur
in all Iinear amps of operation at maximum carrier power is
attempted.
9. All Iinear amplifiers should be operated at about one
half the maximum carrier output to allow for modulation
expansion of the carrier.
10. Operation without leaving room for modulation expan-
sion will not provide good communication. The carrier
contributes nothing toward intelligibility, only good modu-
lation can carry intelligence. Running higher carrier power
and lower modulation is a detriment rather than an asset.

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SECTION IV
SERVI CE INFORMATION
DO NOT ship equipment to the Manufacturer without prior
authorization. We prefer to send special shipping labels
which willavoid the delay of unexpected shipment.
If time is extremely important, wire or call for approval
and we will rush labels to you. When a shipment is ex-
pected,even the time of sending the labels is less than
that lost when an unexpected shipment is received.
It is VERY IMPORTANTthat 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 normally avoids this trouble.
ALL SHIPMENTSMUST BE SENTTO US PREPAID. We do not
accept collect shipments. All returns should be made in
our standard cartons only - so save your carton when un-
packi ng the unit. When a shipment is returned it wi II be
handled in one of three ways ...
1 - Where all service is in warranty the shipment will be
returned prepaid by a carrier of our choice.
2 - If there are any charges not covered by warranty we
wi II hold the shipment and advi se you of costs, which you
can then send.
3 - Or, upon your written authorization, we will ship COD
for any charges not covered by warranty, then the carri er
wi II coil ect these charges and the transportation costs on
arrival. Unclaimed or refused COD shipments will not be
reshipped until payment of service and transportation
charges is received. Shipment wi II then be made collect
for reshipment transportation charges. Unclaimed equip-
ment automatically becomes the property of the Manufac-
turer 60 days after date of refusal or return and wi II be
disposed of for payment of charge due.
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.j of shipment than parcel post; and then we
will ship by this means with your written agreement that
you aSSume any loss over that which the carrier will
insure. COD shipments cannot be made to APO-FPO ad-
dresses.
All replacement parts orders must be prepaid or COD only.
Replacement part price quotes wi II be furni shed on request
for those who desi re prepaid shipment or cannot accept
COD shipments.
All requests, inqui ries, warranty claims or equipment
returns should be madeto:
Hy-Gain Electronics Corporation
8601N.E. Highway 6
Lincoln, Nebraska 68507
Attn: Customer Service Manager

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SECTION V
WARRANTY
Hy-Gai n Electronics Corporation warrants each new product
manufactured to be free from defects in material and work-
manship and agrees to remedy any such defect, or to fur-
nish a new part, in exchange for any part of any unit which
under normal installation, use, and service discloses such
defect within ninety days from the date of purchase by
original owner. The unit serial number must be registered
by the original owner at the time of purchase to val idate
the warranty.
This warranty does not extend to any of our products which
have been subjected to mis-use, neglect, accident, in-
correct wiring not our own, improper installation or to use
in violation of instructions furnished by us. Nor does it
extend to units which have been repaired or altered out-
side of our factory nor to accessori es used therewi th not
of our own manufacture, nor to any cases where the serial
number has been removed, defaced, or changed.
Hy-Gain Electronics Corporation reserves the right to make
any changes deemed necessary or desi rable without ad-
vance notice or incurring any obi igation to make like
changes in units previously manufactured or sold.
This warranty does not cover transportation or instal-
lation costs that may be incurred. HY-Gain Electronics
Corporation's sole liability is the remedy of any defect for
ninety days.Hy-Gain Electronics Corporation is not respon-
sible for personal injury or property damage resulting from
improper or careless installation not intended by the manu-
facturer.
No person is authorized to assume for us any other lia-
bility in connection with the sale of our products.
All warranties are void and terminated one year after the
last unit of its type and design has been manufactured by
us.

PARTS LIST
Symbol Description Part No. Symbol Part No.
C1 Capacitor 2. 2'pf Cer Disc 721609 Q3 Transistor GDC-50 760259
C2 Capacitor 20 pf Cer Disc 725717 Q4 Transistor GDC-50 760259
C3 Capacitor 0.1 uf Flat Film 721574 Q5 Transistor GDC-50 760259
C4 Capacitor-Load 326 pf Variable 720015 Q6 Transistor GDC-50 760259
C5 Capacitor-Tune 50pf Variable 721157 R1 Resistor 18 ~ 1/2 watt 721339
C6 Capacitor. 001 uf 2.5 KV 721660 R2 Resistor
270 1\ 1 watt 720016
C7 Capacitor 10pf 3KV 721613 R3 Resistor
18 1\ 2 watt 720017
C8 Capacitor. 001 uf 721158 R4 Resistor
270 1\ 1 watt 720016
C9 Capacitor. 390 pf 721700 R5 Resistor
100 1\ 1/2 watt 721285
C10 Capacitor. 001 uf 721158 R6 Resistor 22 K..I\..1 watt 721373
C11 Capacitor 2200 pf 721161 R7 Resistor
100 1\ 1/2 watt 721285
C12 Capacitor . 003 uf 3 KV 721159 R8 Pot Linear 7.5 K..I\.. 721451
C13 Capacitor 6800 pf 721160 R9 Resistor 4.7
K..I\..l watt 721367
C14 Capacitor 10 uf Ele 721121 RIO Resistor 15K
1\ 1/2 watt 721340
C15 Capacitor 500 uf Ele 721120 R11 Resistor
330 1\ 1/2 watt 721305
C23 Capacitor 20 pf Cer Disc 725717 R12 Resistor
270 1\ 1/4 watt 721112
C17 Capacitor . 001 uf 721158 R13 Resistor
33 1\ 1/4 watt 721103
C18 Capacitor, 001 uf 721158 R14 Resistor
33 1\ 1/4 watt 721103
C19 Capacitor 40uf 450VDC Ele 721156 R15 Resistor 3.5 K
1\ 10 watt 721515
C20 Capacitor 40uf 450VDC Ele 721156 R16 Resistor 2K
1\ 10 watt 721527
C21 Capacitor 40uf 450VDC Ele 721156 R18 Resistor 220K..I\..l watt 721383
C22 Capacitor 200uf 150VDC Ele 721779 R19 Resistor 220
K..I\..l watt 721156
D1 Diode 1N270 765722 R20 Resistor 220K..I\..l watt 721156
D2 Diode 1N270 765722 R21 Resistor 10K..I\..2watt 721418
D3-D11. Diode 1N5054 765713 R22 Teflon Wire 6 in 22 Ga Str 620001
F1 Fuse 3/4 amp AGC 3AG 710009 R23 Teflon Wire 6 in 22 Ga Str 620001
F2 Fuse 40 amp AGU-40 710227 R24 Teflon Wire 6 in 22 Ga Str 620001
K1 Relay 4PDT 730006 R25 Teflon Wire 6 in 22 Ga Str 620001
K2 Relay SPST 12VDC 730238 R26 Resistor
0 68 1\ 5 watt 722224
L1 Coil-Tank 270014 R27 Resistor
0 68 1\ 5 watt 722224
L2 Choke 800uh 721902 R28 Resistor
0 68 1\ 5 watt 722224
L3 &4Choke-Plate 721124 R29 Resistor
0 68 1\ 5 watt 722224
L5 Coil Z144 728025 Sl DPDT Slide Switch 700206
M1 Meter 0-1 mA Relative Power 795680 T1 Coil- Input 720018
N1 Lamp Bayonet Base
:# 1495 710222 T2 Toroid Power Transformer 730217
N2 Lamp Bayonet Base
:# 1495 710222 VI Beam Pentode Tube 760004
PI Parasitic Choke 721950 V2 Beam Pentode Tube 760004
P2 Parasitic Choke 721950 TH1 Relay Thermal 722167
Q1 Transistor MPS 6516 761115 TB1 Terminal Locking 540226
Q2 Transistor 2N696 761114 MOl Motor 12VDC 740004
D12 IN5054 Diode 765713 R30 Resistor
33 1\ 1/4 watt 721103
NOTE
For best results, always use matched pairs of type
8908 output tubes available from Hy-Gain Customer
Service.