Hy-Gain DCU-3 User manual

DCIJ-3
Digrtal
Antenna
Rotator
Controller
With Pro
gramm
able
Memory
For
the
HAM-IV and
T-zX
Model
DCtl-3 Instruction
Manual
fiA'gilin.
308Industrial
Park
Road
Starkville,
MS 39759USA

DCIJ-3 Digitul AntennoRolator Controller
Table
of Contents
Precautions........-. """"""""'3
DCU-3
Digital
Antenna
Rotator
Controller"""""" """""""5
DCU-3
Digital
Control
UnitSpecifications: """""'5
Installation.......... """"6
Rotator
Precautions..-..--.-. """"""""'7
Wiring
and
Check-Out-... """"""""'8
Operation
of
DCU-3
Controller""""" """"1I
$enuFunctions
.....-..-.- """"""""' l I
Menu
ltems,,'.. """""" 1
I
Menu
Details "'12
Manual
Operation
.....-..... """""' l3
MANUAL ROTATION """""""'13
HEADING
SET.. ...."I3
MEMORY
STORAGE..-..-. """"""""13
Computer
Operation
-.---... """""13
RS-232. """' 13
usB ""13
Software
Control """14
COMMAND
SET ...I5
Troubleshooting "" 16
Wiring.. """' 16
Antenna
Motion-. """ 16
Lack
of
Power
.-..-...--. "" 16
Checking
the
Control
UnitVoltages ""18
Checking
the
Rotator
Resistances
"""" "" 18
Heading
Notes """""I9
HowtoGet
Factory
Service' """"25
FigureI Front
Panel Figure
2 Back
Panel """' 5
Figure3 Control
cable connector
Attachment """' 8
Figure
4 LCDDisplay. "''|""""" ""' 9
Figure
5 RS-232
Wiring
Guide"" """"""' 14
Figure
6 Command
Set """"""" 15
Figure
7 DCU-3
BlockDiagram "" 19
Figure
8 L DCU-3
MainpCe Schematic """"" """""'"' 20
Figure
9 RDCU-3
MainPCB
Schematic
""""" "'21
TableI WireColor
List
Table
2 Recommended
Cables
Table
3 WireSize
Table4 Trouble
Shooting
Suggestions
Table
5 Voltage
Readings
Table
6 Rotator
Resistance
Readings
Table
7 Chassis
Parts
Table
8 Printed
CircuitBoard
Parts
8
9
9
t1
l8
l9
22
23
Version
1

DCU-3 Digilul Antenna Rotator Controller
Precautions
Towers and antennas require caution
during erectionand placement!
Extreme
care must be taken during erection so
that metrl tower and antenna
parts DO
NOT contrct power lines, even if the
partss[P, rotate,retract, fall or fracture!
Antenna pmition mechanisms(towers
and rotators) must be placedso that if
they farl theparts of the antenna
system
cannotcontact power lines,bea hazard
toindividualgor endanger
property.
TheDCU-3 ControlUnit isnotweatherproof
and
must
belocated
in ahouse
or other
protected
location.
Connectaground
wiretothell4"-2}
terminal
onttre
back
of theDCU-3.
Metal towersmustbe groundedproperly
at the tower locationbefore the tower is
erected. This is to minimize electrical
hazard and reducesthe possibility of
lightning damage.DO NOT bury bare
aluminumwiresor stakes
in theground.
Use copper or copper-clad ground
stakes. The senice entrance ground
should be checked. The household
electricaloutlet should be the 3-prong
type (grounded back to the service
entrance).Follow all local building codes
and the NFPA National Electric Codes
for grounding.
The DCU-3 has been carefully designed and
manufacturedto give many years of trouble-free
service
whencarefullyand professionally
installed.
It consistsof the strongestand bestcommercially
available components. This product is
manufacturedinthe
U.S.A.

DCU-3 Digilal AntennaRotator Controller
DCU-3
DigitalAntennaRotator
Controller
The DCU-3 digital control
unit features
a
Large LCD display indicating the beam
heading,
manualand computer
controlled
beam heading selection,manual rotation
controls and 6 heading memory storage
positions.
Settings
inmemory include
brake
defay, rotator coast control, North and
South center headings,adjustablesleep
time,
andcallsigndisplay.
Your existing
rotator
unit(HAM IV, T2X, or
compatible)
must
beconnected
to thecontrol
unitwith an8-wirecable.
You mayuse
your
existing
cable,
you may assemble
your own
cablefrom the informationsupplied
in this
manual,oryoumay
purchasepre-assembled.
DCU-3Digital ControlUnit Specifications:
Size
Weight
Voltage
BrakeDelay
Coast
Delay
Sleep
Delay
4.125"x8.5"x9"
6.2s
lbs.
(2.8a
Ke)
I2OVAC
ar240YAC
(optional
DCU-3X)
0-8
seconds
0-10seconds
l-240minutes
orcontinuous ON
DEFAULT
3
DEFAULTO
DEFAULT20
HeadingMemories 6
POWER
LEFT
RIGHT
Figure1 FrontPanel
FrontPanel
Controls
Power
ON/OFF
Manuallyrotate
left/CCW
Manually
rotateright/CW
hgg,alin.
36 lfidrtlrbl P.tt Fd.
Sltrrvitlq |'S 39759 t SA
F9232 qrrPirr us6
cEe E cEc
FOTATOF OrrtPUr
G
[n*st .E
fi
HEADING SET/I\4ENU Setthe locally
controlled antenna heading or bearing.
Pushingin the"HEADING
SET"selectsany
menu or the menu function selectedor
executesthemenufunction.
ROTATE Instructs
the controllerto
rotatethe
antennatothelocally
set
heading.
Figure2 BackPanel
BackPanel
Connections
RS-232
INPUT InputCOM Port
GROUND Chassis
ground
RS-232OUTPUT Outputloopthrough
FUSE Protectivefuse
USB USB COM Port
ROTATOROUT Rotator connections
POWER 120VAC Input
(240VACInputoptional)
MI.M6 Memorystorage
buttons.
Version
1

DCU-3 Digitul AntennoRotator Controller
Installation
RotatorPrecautions
l. Unbalanced weight:
Weightshould
beas
closely balanced as possible.
Unbalanced
weight
in anantenna
creates
a.bendingmoment of force which is
concentrated
on the mast at the point
where
it isclampedtotherotator.
Wind Pressure:Balancedwind pressure
againstthe antenna
systemproducesa
bending force on the mast which can
causethe samestressesas unbalanced
weight. To minimize these forces, a
thrust bearing should be used where
possible,
the antennashould
be asclose
to the top of the tower as possibleand
the rotator shelf shouldbe as low as
possible
UnbalancedWind: If the antennahas
unequal
wind areas
andelement
spacing
on each side of the mast attachment
point, it could producetorque on the
support mast. This is similar to the
principle of a weather vane. If the
unbalanceis high enough
or the wind
velocity is high enough, this could
prevent rotation or could damagethe
limit switches.To minimizethis effect,
the antenna should be designed for
minimum mast torque or "torque
compensators" added to produce
minimummast
torque.
4. Mast Binding: If the antennasupport
mastbinds within the tower dueto ice
accumulationorother
reasons,
thiscould
prevent
rotation
5. Extreme Cold: If the ambient
temperatureisatorbelow-30degreesF,
thiscouldprevent
rotation.
Older
HAM-
M, II, III or IV and
older
TzX unitsmay
be sluggishat temperatureslessthan 0
degreesF.
The DCU-3 checksfor rotator movement
upongiving thecommandto rotateandif no
movement is detectedwithin 8 seconds, it
will stoptrying to rotate.If no movement
is
detected the display will flash MOTOR
abovethemainheading
display.
2.
3.
Version1

DCU-3 Digital AntennaRotutor Controller
Wiring and
Check-Out
l. Write down the colors
attached
to your existing
unit:
of the wires
rotatorcontrol
2. Disconnect
thewiresfrom your existing
control unit. Attach theseto the 8-pin
connector
to thesame
numbered
pins-
If thisisanew
installation,
assemble
the
rotator cable as shown in Figure 3, or
purchase
apre-assembled
cable.
Temporarily attach
themountingscrews
to the bottom of the rotor unit. These
will beused
to support
therotator
during
bench-testing. 9PIN
CONNECTOR
FOR
ROTATOR
END
OF
CONTROL
CABLE
(wrRE
slDE
VIEW)
.250'
Table 1 Wire Color List
a
J.
4.
S
PIN
CONNECfOR
FOR
CONTROL
CONSOLE
END
OFCONTROL
CABLE
(soLDER
SIDE
VIEW)
t
l-
j BLACK
BLACK
WHITE
GREEN
BLUE
ORANGE
YELLOW
BROWN
RFO
PIN
'
PIN
2
PIN
3
PIN4
PIN 5,
PIN6
PIN
7
Ptr\l
g
WHITE
GREEN
BLUE
ORANGE
PINT
nN2
Ptlt 3
PIN
I
PF{ 5
YELLOW PIN
6
BROWN PIN
7
RED PIN
T
CONTBOLCABLE
BELO€XE'l4t
BELDEII 9'x!5
IEWC186t2
ControlCable
ConnectorAttachment
CAUTION:
The new connector is numbered
differently than the terminal strip- Pay
close attention to the pin numbersl You
may wish to check Your wiring bY
measuring the rotator resistances as
shown in Table 6 Rotator Resistance
Readings.
Terminal Color
I
2
3
4
5
6
7
8
@o
@o.
9)
Figure
3
Version
1

CAUTION:
Shorts between terminals or grounded
leadsmay damage
the rotator. Checkthe
numbered pins on each connector with
an Ohmmeter!Pin I is connected
to pin
1,
etc.
DCU-3 Digitul AntennaRotator Controller
5.
Belden
8448
Belden
9405
IEWC
#8612
Table2 Recommended
Cables
With the rotator sitting in the upright
position (eitheron the benchor on the
tower) andconnected
to the controlunit
by the8-wirecable, plugthecontrol
unit
power cord into a receptacle
andturn it
on.
The DCU-3 display
should
look similar
to the display shown in Figure 4. The
_numeric
displayin the centerindicates
the current bearingof your rotator. The
numericdisplay
in thelower right corner
indicates the target bearing that is
manuallyset. Thenumericdisplayin the
lower left indicates
target
bearingthatis
computer set. The characterdisplay in
the upper right corner indicates the
compassheadingin "NESW" format.
The alphanumeric
display in the upper
left corner is where the call sign is
displayedif programmed.
If the center
displayreads
a steady"999",disconnect
your controlcable
and checkthe cable
wiring with an ohmmeter. See the
section "Checking the Rotator
Resistancesfrom the Ground".Proceed
if the cable checks OK. 999 also
indicatesthatthe cable
may not be not
plugged
in orthe
right stophas
notbeen
set.
NOTE:
The specifications call for heavier
gauge
wire in two locations. Leads #1 and #2
must be heavier gauge and less total
lead resistance
Maximum
Length
Gauge
for
TerminalsI &
2Gauge
for
Terminals3-8
125'(38
M) #18
(1.19
mm) #20
(0.97
mm)
200'
(6r
M) #16
(l.42mm\ #18(l.l9mm)
300'(91
M) #14
(1.75
mm) #16
(l.42mm)
Table 3 Wire Size
i.;i{i;i[l T f,.ii-l'T'iri:i'
fi4=
t.1-!t..1 l-..!{!:;L-l:
Figure4 LCDDisplay
NOTE:
MOTOR is displayed when there is no
indication of rotator movement and
CABLEalso indicatesa cable problem.
7. If the current bearing display shows a
number
between
"000" and "359", then
proceed. Twist the HEADING SET
knob, The LOCAL HEADING display
should
change.
Usingtheknob,select a
targetbearingat least30 degreesfrom
the current bearing. Push the
"ROTATE" button. The brake in the
rotator should release,
the rotator will
turn a few degrees in the opposite
direction, reverse direction, and then
turn to the target bearing. The rotator
shouldturnto theheading
plusor minus
2 or 3 degrees.The brake
solenoid
will
"hum" for 3 seconds
or what the menu
brakesetting
wasset
to if changed,then
the brakewill engage.
During rotation
thedisplay will showtheactualheading
1... t
6.
Version1

DCU-3 Digitul Antenna Rolotor Controller
8.
9.
asit turns.If operation
doesnotwork as
described,
immediately
unplugthe unit
from the AC line and check cable
wiring!
You may wish to repeat step 6 to
confirm operationover a widerangeof
bearings.If the operation
is consistent,
proceed
to thenextstep.
Calibratetherotation
stopsof theDCU-
a
J.
a. Rotateto the left manuallyby
pressing
the LEFT button until
the rotator reaches the left
mechanical
stopthenrelease.
b. Pressandhold theMENU button
untilthemenuisdisplayed.
c. Turn the
necessaryHeading Set knob if
..1.CALIBRATE
Headingsetknob
function.
d. Turn the knob to select "1.
LEFTSTOPSOUTH"then press
theHeading
Set
knobintoselect.
You may seethe display
change
to l8l or 182
andthe
display
will
sayLEFT STOP.
e. Next rotate the rotator to the right
mechanical
stop using the RIGHT
button. Thedisplaymaydisplay
the
antenna heading of "999" when
initially rotation to the right stop.
This is OK as long asthe left stop
did not also display the antenna
headingof "999".
f. Press and hold the MENU button
untillthe
menuisdisplayed.
g. Turn the Heading Set knob if
necessaryto select
"1.CALlBp7qfE"
thenpress
theHeadingset
knobin to
selectthefunction.
h. Turn the knob to select
,,2. RIGHT STOP SOUTH'' then
press the Heading Set knob in to
select. You may see the display
changeto 179 or 180andthedisplay
will sayRIGHTSTOP.
10.If this is a new installation,rotatethe
systemto the centerof rotation.You are
nowreadyto installtherotatorsystem
in
yourtower or on yourmast.
Referto the
instructionsin your rotator manual for
complete
installationinformation.
to select
then press the
in to selectthe
Version1

DCU-3 Digital Anlenno Rotalor Controller
OperationofDCU-3
Controller
Menu Functions
MenuItems
I. CALIBRATE
a. l. LEFT
STOPSOUTH
"b. Z.ruCgT STOPSOUTH
2. OFFSET
a. Encoder
setstheoffsetfromtheoriginalsetup.
Dialintheamountand
press
the
encoder
toselectthechange
b. 0to360degrees
3. CALLSIGN
a. Turn
theencodertodisplaythecharacter
then
press
theencoder
toselectand
advancetothenext
character.
Press
asecondtimetosave
thecallsign.
4. DEFAULTS
a. Resets
backtooriginalsettings.Select
YESorNOto
reset.
b. All memory
settings
areretainedtill itis
set
backto
Default.
5. BRAKEDELAY
a. Defaultis3seconds
b. Turn theencoderfor
0to8secondsin0.1secondsteps.
6. NORTHSTOP
a. Default isNO
b. UsetheencodertoselectYESorNOthen
press
theencoder.
7. SLEEP DELAY
a. Defaultis 10minutes
b. SetI to255minutesor0foralways
on.
8. COAST
SET
a. Default 0
b. Setstheheadingthat
willturn
offthemotorbefore
itreachesthe
heading
so
itwill
coast
tothatheading.
0to l0 degrees. Use
this
inconjunction
with
the
Brake
Delay.
9. REVERSELCD
a. Default isNORMALwhere
the
charactersarelightand
thebackground
is
blue/dark.
b. REVERSE
isblue/darkcharactersandlightbackground.
Version 1

DCU-3 Digitul Anlenno Rototor Controller
Menu Details
OFFSET is usedto compensate
for any
mechanical
errors
that
maybein theantenna
heading.
Forexample:
if theantenna
isset
to
360 degrees
and it is found to be actually
pointing
at355
degrees,
theOFFSET
can
be
set
to compensate
forthiserror-
IinaXn DELAY has
adefaultof 3 seconds
.Forantennas
that
have
alarge
mass
adjust
it
to allow the antenna
to quit moving before- -
thebrake
engages.
COAST SET is used to comPensate
for
overshootof the heading.The inertia of
largemass
antennas
will cause
themto pass
the desired heading and setting this
adjustment will help by turning off the
motor and let the antenna coast to the
desired spot. This will have to be tried
experimentallyto find the best settingfor
your antenna.
This in conjunctionwith the
Brake Delay will set the requiredtime to
insure the antenna has stopped before
lockingdown
the
desired
heading.
CALLSIGN isused
to set
up thecallsign
displayon thescreen
if desired. Select
the
menu function then enter the characters
by
turning the Heading
Setknob to thedesired
characterthen pressthe knob in to allow
selection
of thenextcharacter-
Once
all the
characters
have
been
entered
presstheknob
again
to exitthe
mode.
NORTHSTOP In some
cases
youmay
want
your antenna
centered
toward
thesouth
with
thestops
atthe north.
If thisisthecase
put
up the antennapointed to the south, and
once
installed
and
ready,
select
thisfunction
and
turntheHeadingSet
knobto select
YES
then
press
theknob in.
SLEEP DELAY is used
to put the control
into asleep
modewhere
theLCD backlight
turns
off andthe microprocessor
goes
into a
low powerstate.
It will wakebackup with
thepress
of any buttonor anycommand
on
the COM port. Selecting
this menu will
allow you to setthe time from 0 to 240 in
minutes.
0 is alwayson.Whentheunit goes
to sleep
theback light will tum off. Pushing
any button,turning the Heading Set, or a
computer
command
will wake
it uP-
REVERSE LCD changesthe characters
. andbackground
from dark blue background
andwhite letters
to a white background
and
dark letters as viewed from straight on'
When
viewedfrornaside
angle
or above
the
display
at the display viewing limits, the
characters
in normal mode may look dark
with a light background. To select the
reverse
mode
select
thismenu
itemthenturn
theHeading
Set
knobto say
YES for reverse
or NO for normal then press
the knob to
select.
10 Version
1