Hy-Gain AV-640 User manual

AV-640
8 Band Vertical Antenna
IN
S
TRU
C
TI
O
N
& 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
y
lines.

Table of Contents
AV-640
Vertical Antenna
Instruction Manual
Table of Illustrations
Topic Page
Introduction 3
Theor
y
of Operation 3
AV-640 Specifications 4
Antenna Location 5
Antenna Mast 6
Antenna Groundin
g
6
Antenna Guying 6
Customer Supplied Components 6
Tools Required for Assembly 7
Safety Precautions 7
Verification of AV-640 Parts 8
Assembl
y
Procedure 11
Installation Procedure 16
Tuning Procedure 17
Maintenance 18
Technical Assistance 18
Warranty 30
Illustration Page
Chart A 19
Chart B 19
Fi
g
ure A20
Fi
g
ure B 21
Figure C 22
Fi
g
ure D 23
Fi
g
ure E 24
Figure F 25
Fi
g
ure G 26
Fi
g
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
y
of O
p
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
g
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
p
ecifications
VSWR at Resonance: Less than 1.5:1 at antenna typical
Gain: 3 dBi nominal
Hei
g
ht: 25 ft 10 in
Wei
g
ht: 22 lbs
Horizontal Radiation Angle: 360 degrees
Vertical Radiation Angle: 16 degrees at 1/4 wavelength high
Wind Surface Area: 2.5 s
q
ft
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
g
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
y
in
g
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
pp
lied Com
p
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
S
p
oke Bundle
810-0640-24 1/8" 6" Aluminum Rod SP1 2
810-0640-25 1/8" 12" AluminumRod 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
g
Contents
Instruction Manual Ba
g
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
y
( ) 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
(
N5
)
. Do not ti
g
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
(
IN
)
. Leave rin
g
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
(
S8
)
and
(
2
)
1/4-20 n
y
lock nuts
(
NS
)
. Do not ti
g
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
g
section 6 inches
(
15 cm
)
into BC. Ti
g
hten hose clam
p
.
( ) 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
(p
19
)
.
(
)
Place 5/8"
p
lastic ca
p
(
C2
)
on end of tubin
g
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
g
rees from each other for
p
ro
p
er antenna assembl
y
.
( ) 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
y
(
)
Refer to Fi
g
ure F for the stub assembl
y
p
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
g
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
g
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
(
Pa
g
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
(
Fi
g
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.
1

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
g
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.
1

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
g
nificantl
y
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:
18

Hy-Gain Telephone [phone]
308 Industrial Park Road FAX [phone]
Starkville, MS 39759 email "hy-gain@hy-gain. com"
Telephone [phone] 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
g
ure AJJGJGG
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
p
er inch
30 Meters 50 KHz
p
er inch
20 Meters
100 KHz per inch
17 Meters 60 KHz
p
er ½ inch
15 Meters 100 KHz
p
er inch
12 Meters 150 KHz
p
er ½ inch
10 Meters 100 KHz
p
er ½ inch
6 Meters 300 KHz per ½ inch

FIGURE A
AV-640 Center Radiator Assembly