Hy-gain Tailtwister t-2x User manual

®

308

Industrial

Park

Road

Starkville,

MS

39759

USA

Ph:

(662)

323-9538

FAX:

(662)

323-6551

T-2X

/

T-2XX

TAILTWISTER™

9Rotator

T-2X

has

110

VAC

Controller

T-2XX

has

220

VAC

Controller

INSTRUCTION

MANUAL

_

GENERAL

DESCRIPTION

The

Tailtwister

rotator

consists

of

an

extra

heavy

duty

rotator

and

the

control

unit.

The

rotator

is

designed

to

be

mounted

on

a

plate

inside

a

tower.

A

mast

to

support

and

turn

large

communications

beams

is

then

attached

to

the

top

of

the

rotator.

However,

in

some

instances,

mast

mounting

is

desired.

The

Lower

Mast

Support

Kit,

PN

5146710,

contains

a

lower

mast

support

and

the

necessary

hardware

to

facilitate

mounting

the

Tailt-

wister

rotator

on

top

of

a

mast.

New

features

in

the

Tailtwister

include

an

8

Cinch®

connector

on

the

rear

panel

of

the

control,

a

chassis

ground

connection

on

the

120

VAC

model,

a

high-strength

drive

gear,

a

weather

proof

AMP

connector

at

the

rotor

unit,

and

RF

beads

on

the

potentiometer

lines.

Cinch™

a

Division

of

Labinal

Components

&

Systems,

Inc.

The

rotator

unit

must

be

wired

to

the

control

unit

with

an

8-wire

cable.

The

control

unit

must

be

placed

inside

the

house

or

other

protected

location.

Included

in

the

shipping

box

are:

.

Instruction

Manual

Rotator

Unit

.

Controller

Unit

.

Mounting

Hardware

Pack

Connector

Parts

Pack

hon

mre

Due

to

the

wide

variety

of

towers

available,

each

installation

will

have

different

requirements.

The

gauge

of

the

8-wire

cable

to

connect

the

control

unit

to

the

rotator

depends

upon

the

distance

between

the

rotator

and

control.

The

longer

the

distance,

the

larger

the

diameter

of

the

wire

required.

Various

antennas

or

beams

require

different

installation

methods.

(See

Table

1).

Figure

1

Control

Unit

-

Front

Panel

PECIFICATIONS

7

Doe

ation

ee

Ringe

-

Maximum

Interconnect

Cable

Resistance:

=

A.

Pins

1

ang

2.

oe

diblie

Voluine

©

a

. |

|

~aiipoe

ven

ee

a

eos

ee.

oe

CAUTIONS

e

Install

properly

and

safely

.

e

Towers,

often

the

highest

metal

parts

in

the

vicinity,

require

caution

during

erection

and

placement.

Extreme

care

must

be

taken

during

erection

so

that

metal

towers

and

beams

do

not

contact

power

lines

even

if

the

beams

slip

or

rotate,

towers

fall

or

fracture

or

metal

wires

blow

in

the

wind,

etc.

¢

Metal

towers

or

other

position

mechanisms

must

be

placed

so

that

if

they

fracture

or

blow

over

in

high

winds,

they

cannot

contact

power

lines,

be

a

hazard

to

yu

yiduals,

or

endanger

property.

e

When

not

mounted

within

a

tower

with

a

thrust

bearing,

as

shown

in

Figures

6

and

7,

the

rotator

must

be

DERATED.

e

Metal

towers

must

be

grounded

properly

at

the

tower

location

before

the

tower

is

erected.

This

is

to

minimize

electrical

hazard

and

the

possibility

of

lightning

damage.

DO

NOT

bury

bare

aluminum

wires

or

stakes

in

the

ground.

Use

copper

ground

stakes.

The

service

entrance

ground

should

be

checked.

The

household

convenience

outlet

should

be

the

3-prong

type

(grounded

back

to

the

service

entrance).

e

The

Control

Box

is

not

weatherproof

and

must

be

located

in

the

house,

ham

shack

or

other

protected

location.

e

Read

this

manual

completely

before

proceeding.

The

Tailtwister

rotator

has

been

carefully

designed

and

manufactured

to

give

many

years

of

trouble-free

service

when

carefully

and

professionally

installed.

It

consists

of

the

strongest

and

best

commercially

available

components.

TYPES

OF

INSTALLATION

There

are

three

general

types

of

installations

(see

Figures

4,

5

and

6).

1

The

recommended

Installation

is

an

“Inside”

Tower

Mount

with

a

thrust

bushing

or

bearing

to

provide

support

and

resist

high

wind

loads.

When

the

rotator

is

properly

mounted

this

way,

it

can

be

rotated

to

turn

an

antenna

or

beam

of

20

square

feet

(1.86

m2)

wind

surface

area.

The

wind

loading

during

storms,

the

rotational

inertia

of

the

beam

and

unbalanced

weight

are

more

important

than

the

dead

weight

of

the

beam.

It

is

important

to

minimize

the

height

of

the

beam

above

the

rotator

to

minimize

the

overtuming

force

induced

in

a

high

wind

(see

“Unbalanced

Weight”

and

“Wind

Pressure”).

An

“outside”

Tower

Mount

(see

Figure

6)

is

optional.

The

rotator

is

not

well

protected

but

the

installation

is

simpler.

With

an

“Outside”-

Tower

Mount,

the

rotator

must

be

derated

to

10

square

feet

(.93

m2).

.

A

telescoping

or

other

type

mast

(see

Figure

7)

can

also

be

used.

This

installation

is

similar

to

Number

2

above

and

requires

the

optional

Heavy

Duty

Lower

Mast

Support

Kit

and

must

be

derated

to

10

square

feet

(.93

m2).

UNBALANCED

WEIGHT

AND

WIND

PRESSURE

1.

Unbalanced

Weight:

Weight

should

be

as

closely

balanced

as

possible.Unbalanced

weight

creates

a

bending

moment

of

force

which

is

concentrated

on

the

mast

at

the

point

where

itis

clamped

to

the

rotator.

This

moment

tends

to

strain

the

mast

at

that

point

and

also

to

bind

the

ball

bearings

by

creating

excessive

downward

pressure

on

one

side

and

upward

pressure

on

the

other.

Such

unbalance

places

additional

stress

on

the

motor

gear

train.

Unbal-

anced

weight

becomes

critical

as

the

distance

from

the

antenna

boom

to

the

clamping

point

at

the

rotator

is

increased.

2.

Wind

Pressure:

Wind

pressure

against

the:

boom

and

elements

produces

a

bending

force

on

the

mast

which

can

cause

the

same

stresses

as

unbalanced

weight.

To

strengthen

the

instal-

lation

to

withstand

unbalanced

weight

and

wind

pressure

the

top

mast

should

be

as

short

and

as

strong

as

possible.

In

multiple

arrays

the

an-

tenna with

the

most

wind

area

should

be

closest

to

the

rotator.

In

order

to

distribute

the

bending

stress

and

prevent

fracture

of

the

mast,

the

T2X

rotator

includes

a

specially

designed

steel

clamping

plate

to

clamp

the

mast

to

the

rotator;

After

procuring

the

type

of

tower

or

other

position-

ing

mechanism

of

the

owner’s

choice,

the

is

to

wire

the

rotator

to

the

control

box

and

check

out

its

operation

prior

to

installation.

WIRING

AND

CHECK-OUT

A.

Decide

the

wire

gauge

(size)

required

and

pro-

cure

the

number

of

feet

of

the

proper

cable(see

|

E.

Tum

the

power

switch

on.

The

meter

should

Table

1).

be

illuminated.

Maximum

Gauge

for

Gauge

for

F.

Depress

the

“Brake

Release”

(center)

lever,

Length

Terminals

1&2

Terminals

3-8

then

release

it.

An

audible

click

should

be

So

eae)

ees

en

ee

eee

heard

in

the

rotator.

This

is

the

solenoid

oper-

eae

(38m)

#18(1.19mm)

#20(.97

mm)

ating

the

brake

wedge.

200’

(61m)

#16(1.42mm)

#18

(1.19

mm)

300°

(91m)

#14(1.75mm)

#16

(1.42

mm)

Table

1

9

CONNECTOR

OF

CONTROL

CABLE

FOR

CONTROL

CONSOLE

END

OF

CONTROL

CABLE

2?

LS

aN

2.4

6

(WIRE

SIDE

VIEW)

(SOLDER

SIDE

VIEW)

-250°

378"

mane

=]

=—

wie

2

=

re

Sra

arranged

‘Same

ae

5

eo

re

RED

PING

SUNROW

CABLE

RED

&

Figure

2

Control

Cable

Connector

Attachments

G.

Depress

the

“Brake

Release”

(center)

lever,

NOTE:

The

specifications

call

for

heavier

hold

it,

and

simultaneously

depress

the

CCW

gauge

wire

in

two

locations.

Leads

#1

and

#2

direction

switch

(left).

The

rotator

should

turn

must

be

heavier

gauge

and

less

total

lead

resis-

CCW

(looking

from

the

top).

This

is

S-E-N-W-

tance.

S.

Release

the

CCW

direction

switch;

the

ro-

tator

will

coast

down

and

stop.

Now

release

the

B.

Assemble

the

rotor

cable

as

shown

in

Figure

1.

Geile

euch:

“Thesroptine

Seng

lacked

(ais

seeese

see

cucua

ecuw

mess

ce

one

sae

cas

occ

Serre

een

ee

et

ee

ieee

posi

ti

on.

Ht

CAUTION

:

——

Shorts

between

terminals

or

grounded

leads

::

H.

Repeat

the

for

CW

direction

by

may

damage

the

rotator.

Pay

strict

attention

depressing

the

brake

switch

first,

then

the

CW

to

the

numbers

on

the

connectors!

i

direction

switch

(right).

The

red

lamps

should

CE

ee

eee

ooo

indicate

direction

of

rotation.

C.

Temporarily

attach

the

6

5/16"-18

x

1

5/8"

I.

Return

the

rotator

to

full

CW

position.

Item

140)

to

the

bottom

of

the

rotor

:ii*t!tttteeveresersssaseeeenenseneunvesesaceneeneanenseeneeneeeeneas

oo

:

CAUTION

D.

With

the

rotator

sitting

in

the

upright

position

5

It

is

best

to

release

the

direction

switch

just

i

and

connected

to

the

control

unit

by

the

8-wire

#

Prior

to

the

end

of

Sones

(extreme

etal

i

cable,

plug

the

control

unit

power

cord

intoa

CCW

position)

in

order

not

to

cause

undue

=:

**

stress

on

the

stop

arm

and/or

the

gears.

‘s

receptacle.

eee

andes

atria

eee

Be

ci

stat

rs

ATTACHING

CONTACTS

TO

WIRES

AND

CONNECTOR

_

Since

these

contacts

will

be

inserted

into

connector

blocks,

their

tabs

must

be

carefully

rounded.

Unless

you

have

a

crimpinmg

tool

for

installing

connec-

tors,

use

the

following

procedure.

1.

CUT

WIRE

TO

SPECIFIED

LENGTH.

REMOVE

1/8"

OF

INSULATION

FROM

END.

|

j-—1/8"

ot

ae

2.

INSERT

WIRE

BETWEEN

TABS

IN

CONTACT.

3.

BEND

TAB

TIGHTLY

AROUND

BARE

WIRE

END.

Repeat

for

each

contact.

Pay

close

attention

to

the

numbered

holes

in

the

connector!

Pull

back

lightly

on

each

conductor

to

be

sure

each

contact

is

locked

in

each

cavity.

Once

locked

in

place,

the

contacts

nl

fely

remov

ith

an

extraction

tool

(Extraction

tool

not

included).

This

tool

consists

of

a

tube with

an

O.D.

of

0.129

and

an

LD.

of

0.115.

When

inserted

over

the

contact

from

the

front

side,

this

tool

compresses

the

eCe

tabs,

permitting

easy

removal.

4,

BEND

OPPOSITE

TAB

AROUND

FIRST

TAB.

5.

APPLY

SOLDER.

DO

NOT

ALLOW

SOLDER

aN

TO

FLOW

INTO

THE

CONTACT

END.

HOLD

THE

CONTACT

END

UPWARD

WHEN

YOU

SOLDER.

SOLDERING

SOLDER

6.

WHEN

SOLDER

COOLS,

CAREFULLY

SHAPE

END

TABS

AROUND

THE

INSULATION

ON

THE

aay

A

iy

Ly

7.

PUSH

CONTACT

INTO

HOLE

IN

CONNECTOR

SHELL

UNTIL

CONTACT

CLICKS

INTO

PLACE.

CONNECTOR

SHELL

eo

SOCKET

CONTACT

Figure

3

wee

Attaching

Contacts

to

Wires

and

Connector

MOUTING

INSIDE

TOWER

The

rotator

is

mounted

inside

a

tower

(see

Figure

4)

to

the

flat

tower

plate

by

means

of

six

(6)

bolts

furnished

in

the

hardware

kit.

Use

the

following

procedure:

1.

Locate

the

rotator

in

the

tower

directly

under

the

bushing.

Note

that

the

tower

plate

must

be

cut

out

to

allow

the

connecting

8-wire

cable

to

pass

through

the

plate.

Use

the

template

in

the

back

of

the

manual.

Plug

the

cables

together

and

secure

the

cable

to

the

tower

in

such

a

manner

that

the

cable

will

not

be

strained.

The

rotator

is

attached

to

the

tower

plate

by

means

of

six

(6)

bolts

and

lockwashers

(see

Figure

4).

The

flat

tower

plate

must

be

drilled

in

six

(6)

places

using

the

template

provided

with

this

manual

unless

the

tower

plate

is

al-

ready

properly

drilled.

ae

4.

Tighten

the

six

(6)

bolts,

but

not

to

final

tight-

ness.

Observe

how

the

rotator

turns.

It

must

rotate

in

such

a

manner

as

to

tum

the

mast

concentrically

in

the

thrust

bearing.

.

Trial

assemble

the

mast

to

the

top

of

the

rotator

using

the

U-bolts,

nuts

and

lockwashers

through

the

rotator

and

clamp

plate

as

shown

in

Figure

4.

The

maximum

mast

diameter

that

may

be

used

is

2

1/16"

O.D.

We

recommend

1

1/2"

nominal

steel

pipe

with

1.9"

O.D.

in

stand-

ard

wall

thickness

of

.145".

For

stacked

arrays

or

very

large

beams,

we

recommend

extra

heavy-duty

wall

thickness

of

.200".

Both

steel

pipes

can

be

purchased

to

specification

ASTM-

120.

NOTE:

Apply

a

coating

of

heavy-duty

motor

oil

or

grease

to

the

threads

of

the

stainless

steel

bolts

and

U-bolts

to

prevent

seizing.

THRUST

BEARING

;

Pe

Pascal

eS

_

LT

TOP

TOWER

PLATE

160.

|<

'

A

MAST

136

—

a=

bi

N137

Figure

4

137

eae

A

140

|

.TOWER

160

[perry

|

eo

TOWER

MOUNTING

PLATE

161

Item

No.

Description

136

Nut,

hex,

5/16"-18,

ss

Lockwasher,

split,

5/16",

ss

Bolt,

hex

head,

5/16"-18

x

1

5/8",

ss

Plate,

Mast

Clamp

U-Bolt,

5/16"-18

x

3

1/4"

x

4"

Rotator

Mounting

in

a

Tower

6

On

any

inside

tower

installation,

care

must

be

exercised

to

get

the

antenna

mast

shimmed

to

the

exact

rotational

center

of

the

rotator.

The

geometry

is

such

that

a

mast

of

2.062"

(2

1/16"

[52

mm])

O.D.

pipe

will

be

exactly

centered.

If

the

O.D.

of

your

mast

is

less

than

this,

you

should

shim

out

to

these

dimensions.

6.

Ifthe

rotator,

top

bushing

and

mast

are

properly

aligned,

there

should

be

unrestricted

rotation

through

360°.

If

not,

the

rotator

may

have

to

be

moved

slightly

on

the

flat

plate.

If

a

high

quality

bearing

is

used

in

the

top

of

the

tower

(recommended),

the

shimming

procedure

must

be

done

more

carefully

as

closer

toler-

ances.are

required.

It

is

important

that

the

rota-

tor

does

not

try

to

turn

the

mast

eccentrically

with

the

top

bushing

or

bearing.

7.

Tighten

the

mounting

bolts

carefully

-

to

ap-

proximately

175

inch-pounds

of

torque.

8.

Drill

through

the

antenna

mast

and

rotator

cast-

ing,

using

a

5/16"

drill.

Locate

the

hole

in

the

clamp

plate

that

is

furnished.

Insert

the

bolt

through

the

clamp

plate,

mast,

and

rotator

and

tighten

all

bolts

to

150

inch-pounds.

Refer

to

Figure

4.

BEAM

NOT

TO

EXCEED

10.0

SQUARE

FEET

(.93

m7)

WIND

SURFACE

AREA

LOAD.

BEAM

TO

TOP

OF

ROTATOR

NOT

TO

EXCEED

2

FEET

(607

mm)

COAMIAL

CABLE

-

LOOP

TO

PERMIT

FULL

360°

ROTATION

OF

BEAM

‘av,

i

9.

Retum

the

rotator

to

the

full

CW

“S”

position.

Mount

the

beam

on

the

mast

pointing

South.

The

coaxial

cable

should

be

looped

in

such

a

manner

that

it

will

not

foul

or

tangle

when

the

beam

tums

around

in

a

circle

to

the

full

360°

counterclockwise

position.

OUTSIDE

TOWER

Referring

to

Figures

5,

6,

and

7,

an

outside

tower

or

pole

mount

is

made

in

the

same

manner

except

that

the

rotator

is

fastened

by

four

(4)

bolts

only

(not

six)

to

the

Lower

Mast

Support,

PN

5146710.

Since

the

eccentricity

of

the

rotator

turning

in

ref-

erence

to

the

tower

is

no

longer

important,

the

shimming

procedure

is

not

necessary.

The

four

(4)

screws

must

be

torqued

to

the

same

specification

and

the

8-wire

cable

securely

fastened.

The

lower

mast

should

be

pinned

with

the

5/26"-18

x

4"

bolt

as

shown

in

Figure

6.

wanes

an

CAUTION

The

rotator

is

designed

for

vertical

operation

with

the

bell

shaped

housing

in

the

up

position.

Water

and

other

contamination

will

get

into

the

motor

unit

if

it’s

mounted

horizontally

or

upside

down.

ORMONDE

MN

ARHHEEHT

FEAT

EHRHODHHKMOEM

HBO

TTFAHBE

EDT

HHO

eananenoona

é

//

\

F

bf

»

es

ROTATOR

Ps

}

8-WIRE

CONTROL

CABLE

/

WAN

A

<—

Rotator

Mounted

On

Tower

Top

Plate

OPTIONAL

KITS:

HEAVY-DUTY

LOWER

MAST

SUPPORT

KIT

(51467-10)

(Optional)

The

stock

Tailtwister

T2X

is

intended

to

mount

on

the

base

plate

inside

of

the

tower.

However,

in

some

instances,

outside

tower

or

mast

mounting

is

desired

as

per

Figures

5

and

6.

This

kit,

P/N

5146710

contains

a

heavy-duty

lower

mast

support

and

the

necessary

hardware

to

facilitate

mounting

the

T2X

on

top

of

a

tower

stub

or

mast.

item

No.

Part

Na.

Description

3-1

51423800

Clamp,

lower

mast

..........cccceecscseseseecneseee

5-2

3142700

U-Bolt,

$/16"-18

x

3

W/4"

K

4"

cee

5-3

5142401

Bolt,

5/16"-18

x

4),

hex

head,

ss...

5-4

555747

nUT,

5/16"-18,

hex,

SS

occ

cccssee

sees

5-5

564792

Lockwasher,

5/16",

split,

ss

00...

3-6

3142602

Support,

lower

mast

..0.....

cc

cccceecceeseeeronees

5-7

107632061

Screw,

#6-32

x

3/8",

round

head.....0..000.....

5-8

5033900

Cover,

terminal

oo...

cccccccccccceccesccecsceeccerecs

5-9

5091400

Grommet

heii

Sade

ames

tenes

i

NOTE

:

:!

THIS

IS

AN

ACCESSORY

KIT

AND

SHOULD

BE:

i:

PURCHASED

FROM

YOUR

DISTRIBUTOR/DEALER

‘

PMS

NTO

RHE

NATHAN

EM

EHR

TERED

HHHCTTEKRCSSe

DE

dane

eee

meee

Seancccecccscaguscuacccaansacascaucaccsccnasaacauaas

Seeaaanea

ee

SEO

EE

OME

MORE

CHM

O

NERO

RE

HEE

SEM

ET HH

HERE

MORSE

RT

we

EG

CAUTION

i!

When

the

rotator

is

installed

using

the

lower

mast

i

:!

support

kit,

the

antenna

size

must

be

restricted

ito

10

square

feet

(.93

m2)

of

wind

surface

area.!!

SOSSCSASFT

SS

SHAH

AGTSTSOHHMANE

OMS

ETDARTEETHETOH

HH

AMBER

EKHE

BONE

HOTEEDAs

/;

BEAM

TO

TOP

OF

ROTATOR

_

NOT

TO

EXCEED

2

FEET

(607

ware)

wl

2

5-5

(5

PLACES}

es

wl

5-4

(5

PLACES)

5

™

:

ac

=n

pare

5-2

9

~--4-

peemaby

3

|

1

(4

PLACES)

BOLTS,

(5/16"-18

X

1

5/8"),

AND

5/16"

SPLIT

LOCKWASHERS

THAT

CAME

WITH

THE

ROTATOR

~

WIRE

CONTROL

CABLE

/

Figure

6

Rotator

Mounting

with

Lower

Mast

Support

BEAM

NOT

TO

EXCEED

7.6

SQUARE

FEET

(0.7

rm”)

WIND

SURFACE

AREA

LOAD

HAM

IV

ROTATOR

ie

Loop-ra

Fe

nu

euCuae

ROTATION

OF

BEAM

‘im

LOWER

MAST

SUPPORT

(agen

yey

PN

51487-10

ONLY

ill

[3

|

ae

ee

CONTROL

CABLE

p=

<5

APPROPRIATE

GUY

WIRES

He

Ee

NG

oA

a

\

ork

Figure

7

Pole

Mounted

Rotator

8

PRELIMINARY

CHECK

AND

CALIBRATION

IMPORTANT

THERMAL

PROTECTION:

If

the

rota-

tor

fails

to

turn

after

4

or

5

minutes

of

continuous

operation,

the

thermal

switch

has

come

into

play.

This

protective

device

in

the

transformer

automatically

shuts

off

power

if

the

rotator

is

used

continuously

for

too

long.

It

will

automatically

reset

after

10

minutes.

1.

Turn

the

Control

Unit

Power

“ON”

with

the

upper

right

“ON-OFF”

switch.

The

meter

should

be

illuminated

and

the

needle

should

be

to

the

right.

2.

Depress

the

brake

lever

(center)

and

hold.

De-

press

the

CCW

lever

(left)

and

operate

the

rotator

to

its

full

CCW

position.

If

the

meter

does

not

move

from

the

right

to

the

left

hand

position,

press

and

release

the

“Calibrate”

switch.

3.

With

the

rotator

in

its

full

CCW

position,

if

the

meter

is

not

at

its

full

left

position,

carefully

adjust

the

zero

(CCW

South)

position

with

the

screw

directly

under

the

meter

to

exactly

South.

4.

Meter

Calibration

Procedure:

Operate

the

rotator

to

its

full

clockwise

position.

Adjust

the

calibration

potentiometer

until

the

meter

indi-

cates

full

scale

to

the

right.

The

meter

is

now

calibrated.

Do

not

adjust

the

calibration

poten-

tiomgter

when

the

rotator

is

in

any

position,

other

than

full

clockwise.

When

the

control

unit

is

turned

“OFF”,

the

meter

needle

will

fall

to

the

left

“S”

position

and

return

to

indicate

the

rotator

position

as

soon

as

the

control

unit

is

turned

“ON”

again.

It

will

not

damage

the

unit

to

leave

it

turned

“ON”

for

extended

periods.

NORMAL

OPERATION

To

operate

the

rotator,

it

is

necessary

to

understand

the

T2X

Brake

Release

Lever

and

its

function.

The

brake

lever

(middle

lever)

on

the

Control

Unit

operates

a

brake

wedge

mechanism

in

the

rotator

which

locks

the

rotator

into

position

mechanically.

The

rotator

cannot

tur

unless

the

wedge

is

re-

tracted

by

depressing

the

middle

lever.

The

normal

operation

is

as

follows:

1.

Retract

the

brake

wedge

by

holding

down

the

“Brake

Release”,

middle

lever.

(Green

light

on.)

NOTE:

The

brake

wedge

will

be

retracted

only

while

the

Brake

Release

lever

is

held

down.

2.

Turn

the

rotator

to

the

compass

location

by

pushing

down

and

releasing

either

the

left

hand

or

the

right

hand

lever.

Allow

a

few

seconds

for

the

rotator

to

coast

down.

Then

re-engage

the

brake

wedge

by

releasing

the

“Brake

Release”

(middle)

lever.

OPERATING

PRACTICE

The

rotator

has

several

mechanisms

to

protect

it

from

misuse,

but

the

following

precautions

are

advisable.

1.

If

you

have

a

very

large

beam,

the

rotator

can

be

“nudged”

to

exactly

the

desired

position

by

alternately

working

the

left

and

right

control,

allowing

it

to

coast

down

before

the

brake

wedge

is

allowed

to

engage.

2.

It

is

advisable

not

to

run

it

full

speed

into

the

end

of

rotation.

3.

Upon

completion

of

turning,

always

allow

the

rotator

to

coast

down

by

keeping

your

finger

on

the

“Brake

Release”

after

you

have

released

the

rotation

lever.

This

procedure

will

allow

the

rotator

to

stop

before

you

re-engage

the

brake

wedge.

Observing

this

sequence

prevents

the

rotator

from

stopping

suddenly

thus

preventing

undue

stress

on

the

rotator,

beam,

and

tower.

The

motor

has

an

internal

brake

which

controls

the

coast

down

time

and

deceleration.

The

internal

mo-

tor

brake

is

usually

strong

enough

to

prevent

pin-

wheeling

during

operation.

GROUNDING

The

tower,

or

other

metal

support

device,

must

be

grounded

to

an

earth

ground

at

its

location.

Use

heavy

copper

cable

looped

so

that

if

the

tower

comes

down

for

any

reason,

there

will

be

adequate

slack

to

prevent

the

ground

wire

from

breaking.

Use

one

or

more

8

foot

copper

jacketed

steel

stakes

driven

into

the

moist

earth

and

fasten

the

wire

securely

at

the

stake

and

at

the

tower.

As

mentioned

in

the

“Cautions”

portion,

the

steel

chassis

of

the

control

box

should

be

either

grounded

to

a

metal

cold

water

pipe

in

the

house

or

back

to

the

electric

service

entrance

box

where

the

power

comes

into

the

house.

This

normally

is

ac-

complished

with

the

wire

of

the

3-prong

plug

which

then

depends

on

the

wall

outlet

being

adequately

grounded

back

to

the

service

entrance

as

to

the

utility

ground.

If

there

is

any

doubt,

have

this

checked

by

a

licensed

electrician.

SOUTH-CENTER

METER

SCALE

CONVERSION

The

stock

Tailtwister

Control

Unit

is

shipped

with

the

meter

scale

installed

for

“North”

center

opera-

tion;

ends

of

rotation

are

at

the

“South”

position.

Some

geographic

locations

and/or

popular

working

areas

may

favor

having

the

meter

“South”

center;

ends

of

rotation

are

at

the

“North”

position.

We

have

provided

the

Tailtwister

with

an

interchange-

able

meter

scale.

We

recommend

the

following

procedure:

1.

Disconnect

the

power

cord.

2.

Remove

the

8-wire

control

cable,

carefully

la-

beling

each

wire

with

its

corresponding

termi-

nal

number.

This

operation

may

be

omitted

if

the

control

box

can

be

worked

on

easily

without

removing

the

leads.

3.

Remove

the

top

and

bottom

covers.

4.

Slip

the

lamp

and

holder

off

the

lamp

holder

bracket.

Loosen

the

hex

nut

on

the

transformer

that

is

holding

the

lamp

holder

bracket

and

swing

the

bracket

clear

of

the

wires

leading

to

the

printed

circuit

board.

5.

Carefully

remove

the

hex

nuts

on

the

meter

studs

to

free

the

printed

circuit

board.

Slip

the

P.C.

Board

off

the

studs

and

pull

it

down

under

the

chassis.

SPSCHOSM

TAHA

BEHTHEKHR

SRS

TEACHHTCHOHAHMEHEATHABHBOTARHHRAHHOSHAHHAHOSBA

HO

mMOn

Bg

CAUTION

}

It

is

good

practice

to

use

a

short

test

lead

or

jumper

wire

to

short

the

meter

studs

when

it

is

not

in

the

circuit.

SOOM

RODEO

RHHOD

HOC

EHHOHENDEEKORETE

MEH

EORaN

eee

nenneaewaeumaawnoe

a

SSAREKERAHCHAKHEKRTEAHEHREHAOHERAGHEKHASTHRHHHRECHETRAAAMRABEHBAHBAHEEEKEHHahHeaane

6.

Loosen

the

meter

retaining

clips

and

remove

the

meter

from

the

chassis.

7.

Insert

a

small

knife

blade

between

the

clear

meter

cover

and

black

housing

at

either

corner

of

the

top

edge

and

gently

pry

the

cover

loose

from

that

corner.

Repeat

for

the

other

corner.

The

meter

cover

should

pop

off.

8.

Carefully

slip

a

knife

blade

under

each

corner

of

the

lower

edge

of

the

white

meter

scale

and

twist

slightly

until

the

scale

clears

the

two

small

indexing

pins.

Remove

the

scale

and

install

the

new

one.

Make

sure

the

scale

fits

over

the

indexing

pins

and

that

it

is

flush

and

tight

against

the

black

housing.

This

will

assure

free

movement

of

the

indicator

needle.

9.

Reinstall

the

meter

(remove

the

temporary

jumper),

the

P.C.

Board

and

lamp

hardware.

Check

for

pinched,

shorted

end,

or

overstressed

Wires.

10.

Reinstall

the

top

and

bottom

covers.

l

—"

.

Reconnect

the

8-wire

control

cable

in

the

exact

sequence

as

they

were

removed.

If

your

beam

was

installed

originally

using

the

T2X

with

a

“North”

center

scale,

the

antenna

mast

must

be

loosened

and

repositioned.

In

order

for

the

meter

to

indicate

properly,

the

front

of

your

beam

must

point

“North”

when

the

rotator

is

at

the

ends

of

rotation.

Recalibrate

the

meter.

NOTE:

In

the

past

the

South

Centered

meter

scale

was

on

the

reverse

side

of

the

factory

installed

North

Centered

scale.

The

unit

is

now

provided

with

a

separate

South

Centered

scale.

This

will

help

to

avoid

damage

to

the

face

of

the

meter

scale

during

removal

of

the

North

Centered

scale.

10

TROUBLESHOOTING

GENERAL

DESCRIPTION

Most

operational

difficulties

with

rotators

are

traceable

to

broken,

shorted

or

grounded

wires

usually

at

the

rotor

connections.

Time

spent

in

cutting

the

leads

to

exact

lengths,

tinning,

and

clamping

to

prevent

strain

on

the

control

cable,

will

pay

dividends.

BE

MOSKMEMEDEHERRESHSHRHTEHESHSHHHEET

AE

EHEKHEMABeAeeHEetenaanmHNEG

CAUTION

t

This

unit

has

been

thoroughly

tested

andi

cycled

before

shipment.

Follow

thei

:!connector

wiring

carefully

between

Rotator

and

Control

Box.

Incorrect

wiring

will

burn:

out

the

rotator

potentiometer

and

void

thei:

iiwarranty.

Re

sure

Rotator

and

Control

Units

are::

compatible.

Do

not

intermix

models

with!:

:!

different

operating

voltages.

This

results

int:

sluggish

or

non-operating

performance,:

s:

;:

burned

out

motors,

overheated

transformers

Ss

CR

we

se

MOK

NHB

SETS

THHEHTOCKH

END

HHHMEMeResoAawetH

EET

ONH

Mae

wae

Hawes

SOSHATAASHORHERTAECAHEHHAHETAHRATKHEABHHOKETANHEHBHAHAHAeARKBeNtInAe

a

ee

MECHANICAL

PLAY

Frequently

the

slight

motion

of

the

antenna

array

in

gusts

of

wind

is

due

more

to

the

natural

flexing

of

the

elements

and

mast

than

itis

due

to

actual

play

in

the

rotator

mechanism.

A

slight

amount

of

“play”

is

built

into

the

rotator

to

avoid

binding

due

to

environmental

changes.

ANTENNA

ROTATES

IN

HEAVY

WIND

This

is

ysually

a

matter

of

the

mast

slipping

in

the

support.

For

large

arrays,

it

is

often

necessary

to

drill

a

5/16"

hole

through

the

clamping

plate,

mast

and

mast

supports

and

them

together

with

the

stainless

steel

bolt

supplied.

If

“slipping”

or

“turning”

is

suspected,

return

the

rotator

to

the

end

of

rotation

and

visually

check

to

be

sure

that

the

antenna

is

in

the

original

stop

location

as

installed.

11

LACK

OF

POWER

If

the

antenna

rotation

is

slow

or

sluggish

or

hard

to

start,

check

for

proper

voltages.

If

the

voltages

are

correct,

the

130-156

MFD

motor

start

capacitor

could

be

at

fault.

It

is

recommended

that

a

new

capacitor

be

tried

before

any

other

action

is

taken.

Also,

check

proper

wire

size

per

Table

1,

page

4.

If

the

electrical

circuit

is

okay,

then

check

for

mechanical

binding.

Pay

particular

attention

to

bearings

and

alignment

of

the

mast

of

an

inside

tower

mount.

If

the

temperature

is

less

than

-30°

F

(-349

C),

the

rotator

will

be

very

sluggish

and

hard

to

start.

This

is

normal.

Hold

down

on

the

rotation

switch

until

movement

is

seen

on

the

meter.

If

the

capacitor

is

good,

the

temperature

is

well

above

-30°F,

and

there

is

no

mechanical

binding

above

the

rotor,

the

rotor

may

not

be

receiving

the

proper

voltage

levels

to

achieve

maximum

torque.

Check

the

cable

resistances,

and

wire

sizes.

For

cable

runs

over

300’,

move

the

motor

capacitor

to

the

tower.

IMPROPER

METER

INDICATION

The

brake

and

motor

operate

independently

of

the

indicating

system.

If

the

pilot

light

burns

at

proper

brilliancy,

the

instrument

transformer

is

okay

and

the

output

is

not

shorted.

Check

the

1/8

amp

meter

circuit

fuse

with

the

ohmmeter.

Check

for

about

13

VDC

across

Terminals

No.

3

and

No.

7

with

the

switch

operated.

If

the

proper

voltage

is

not

ob-

tained,

check

the

individual

components

in

the

meter

circuit.

If

the

13

VDC

is

present,

check

for

500

ohms

across

rotator

leads

No.

3

and

No.

7.

If

500

ohms

is

present

from

No.

3

and

No.

7,

see

if

the

readings

from

No.

3

to

ground

and

No.

7

to

ground

total

500

ohms.

NOTE:

An

intermittent

condition

in

any

component

in

the

rectifier

or

meter

circuits

within

the

control

box,

as

well

as

in

the

cable

or

potentiometer

circuit

in

the

rotator

itself

can

cause

meter

fluctuation

or

error.

Possible

cause

of

such

trouble

may

be

localized

by

placing

a

test

DC

meter

across

Terminals

No.

1

and

No.

3

or

No.

1

and

No.

7

comparing

the

action

of

the

test

meter

with

the

panel

meter.

NO

ROTATION

-

INDICATION

OK

Either

the

thermal

cut-out

in

the

power

transformer

has

opened

or

there

is

actually

trouble

in

the

motor

circuit.

After

allowing

time

for

the

thermal

cut-out

to

restore

service,

proceed

to

“Checking

the

Con-

trol

Unit”

and

“Checking

the

Rotator

from

the

Ground”.

GROUND

WIRES

Ground

on

cable

leads

can

burn

out

either

the

line

fuse

or

the

small

fuse

in

the

meter

circuit.

If

lead

No.

3

or

lead

No.

7

is

grounded,

it

shorts

out

part

of

the

potentiometer

so

that

as

rotation

progresses

to

the

other

end,

the

full

DC

voltage

is

applied

across

a

decreasing

portion

until

current

becomes

so

high

that

the

potentiometer

burns

out.

Note

also

that

any

grounds

may

put

an

overload

on

the

power

transformer

which

could

cause

the

line

fuse

to

blow

or

overload

the

rectifier

circuit

so

that

the

1/8

amp

fuse

blows.

HELPFUL

SUGGESTIONS

Be

sure

to

check

your

rotator

cable

for

shorting,

open

circuits,

incorrect

wiring,

intermittent

con-

nections,

shorted

terminals,

rodent

damage,

and

mast

support

or

thrust

bearing

binding.

CHECKING

THE

CONTROL

UNIT

1.

Voltages

with

Unit

Plugged

In.

To

check

the

control

unit,

plug

the

line

cord

into

AC

power.

With

no

connections

to

the

termi-

nals,

turn

the

“ON-OFF”

switch

to

the

“ON”

position,

the

meter

light

will

illuminate.

The

meter

needle

will

remain

on

the

left

hand

“S”.

-Terminals

1

and

2

should

show

30

volts

AC

(approximately)

when

the

brake

level

is

de-

pressed.

Terminals

1

and

5

should

show

30

volts

AC

with

brake

release

lever

depressed

and

CW

lever

depressed.

Terminals

1

and

6

should

show

30

volts

AC

with

brake

release

lever

depressed

and

CW

lever

depressed.

Terminals

3

and

7

should

show

approximately

13

VDC.

2.

Resistances

with

Unit

Not

Plugged

In.

Disconnect

the

AC

power

source

and

discon-

nect

the

8-wire

control

cable.

The

control

box

can

be

checked

without

remov-

ing

the

cover

by

using

a

volt-ohmmeter

to

check

values

across

terminals.

Resistance

across

Terminals

1

and

2

should

read

4

ohms.

Read

same

value

across

Terminals

1

through

5

with

clockwise

switch

lever

(right

hand)

de-

pressed

and

across

Terminals

|

through

6

with

counterclockwise

switch

lever

(left

hand)

de-

pressed.

Resistance

across

input

line

cord

with

“ON-OFF”

switch

in

the

“ON”

position

and

the

brake

lever

depressed

should

read

3.8

ohms

CHECKING

THE

ROTATOR

FROM

THE

GROUND

You

may

possibly

avoid

bringing

the

rotator

down

by

making

electrical

checks

from

the

control

box

position.

This

is

done

by

disconnecting

the

eight

wire

control

cable

from

the

control

unit.

From

the

schematic

diagram,

itis

apparent

that

the

resistance

of

the

lead

wires

will

be

added

to

the

resistance

of

the

motor

windings

and

potentiometer

strip

in

mak-

ing

the

resistance

checks

as

shown

in

Table

2.

Read

Between

To

Check

Resistance

Terminals

Brake

Solenoid

,

-/5

ohms

+

leads

]-2

1/2

Motor

Winding

2.5

ohms

+

leads

1-8

1/2

Motor

Winding

—.2.5

ohms

+

leads

1-4

1/2

Motor

+

Switch

2.5

ohms

+

leads

1-6

1/2

Motor

+

Switch

2.5

ohms

+

leads

1-5

Entire

Motor

5

ohms

+

leads

8-4

Right

Limit

Switch

O

ohms

+

leads

8-5

Left

Limit

Switch

0

ohms

+

leads

4-6

Entire

Pot

500

ohms

3-7

Pot

Arm

to

+

End

0

to

500

ohms

3-1

Pot

Arm

to

-

End

0

to

500

ohms

7-1

Table

2

ADDITIONAL

CHECKLIST

1.

Check

continuity

of

control

wires

for

loose

connections

caused

by

wind.

2.

Tape

down

control

cable

securely

all

the

way

to

rotator.

3.

Check

motor

winding

through

control

cable

as

outlined

in

Table

2.

4.

Check

cable

between

leads. Static

lightning

charges

or

direct

hits

will

cause

carbon

arcs

in

control

cable

at

numerous

spots

along

the

cable

that

cannot

be

seen.

This

resistive

path

will

break

down

with

voltage

applied

to

rotator.

(Replace

cable.)

Ed

5.

Check

both

control

and

rotator

connectors

for

shorts.

6.

Rotation

in

one

direction

usually

indicates

a

loose

or

broken

cable

wire,

bad

relay,

and

bad

sensing

transistors

in

some

units.

7.

Be

sure

cable

is

of

proper

size

for

length

used.

Refer

to

Table

1.

is

8.

Substitute

a3

foot

piece

of

new

rotator

cable

to

bench

test

unit.

Proper

operation

will

indicate

a

defective

rotator

cable

on

the

mast

or

tower,

or

a

cable

not

large

enough

to

create

proper

turning

torque.

9.

Low

line

voltage

and

cold

weather

will

slow

rotation.

Using

an

extra

long

or

small

wire

extension

cord

can

lower

line

voltage.

How

To

Get

Factory

Service

If

service

is

required,

the

unit

must

be

packed

securely

and

sent

prepaid

to:

hy-gain

308

Industrial

Park

Road

Starkville,

MS

USA

13

For

units

that

are

in

warranty,

no

charge

will

be

made

for

any

repair

work

required.

Include

a

copy

of

your

sales

receipt.

For

out-of-warranty

units,

call

the

Warranty

Service

Department

for

prices.

The

price

includes

rebuilding

the

unit,

replacing

all

defective

and/or

worn

parts,

and

return

freight

charges.

Hy-Gain

reserves

the

right

to

change

prices

atits

option.

When

returning

items

for

repair,

a

check,

money

order,

Visa

or

Mastercard

number

for

the

repair

charges

must

be

included.

Be

sure

to

include

your

name,

address,

zip

code,

and

tele-

phone

number.

Also,

give

a

brief

description

of

the

problem.

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Part

No.

5140302

5140300

5139200

5056300

5143000

5143001

1034403

5056300

5089501

710053

§138500

5140600

5140601

5018700

640076

520057

5088400

450403

560068

5141100

5141200

5152700

1073301

5017700

1073501

5020200

5151500

5086100

5079800

5147701

710061

5103600

5175200

723406

10563000

1034403

710054

5137300

5089102

5105000

10563205

1

450431

506325

550029

556960

567110

567120

5140700

PARTS

LIST

T2XControl

Unit

Replacement

Parts

Description

Qty

Control

Unit,

220

VAC,

complete

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Read

Tous

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Socket

Cinch

S308

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Boca

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eserives,

ceiasani

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lense

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Screws

76-32%

3/8".

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34

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35

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and

13

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Version

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43

and

16

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FIGURE

11

f

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29

or

31

+

30

or

32

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CIRCUIT

BOARD

ASSEMBLY,

29

ITEM

3

(SEE

DETAIL

A)

5

SECTION

AA

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FI

3

17

39

38

36

Figure

9

T2XControl

Unit

Inside-Top

View

is

11

(RED)

411

(RED)

Printed

Circuit

Board

Detail

A

16

35

41

or

43

This

label

on

220V

version

only

(EUROPEAN

PLUG

SHOWN)

Chie

er}

DETAIL

A

50,

51,

52,5

48

(BOTTOM

VIEW)

Figure

10

Rear

View

of

T2X

Control

Unit

40

-

CALIBRATE

POTENTIOMETER

36

POSITION

METER

CALIBRATION

SCREW

CCW

SWITCH

Figure

11

Front

View

of

T2X

Control

Unit

17

T2X

Rotator

Replacement

Parts

Item

Part

No.

Description

Qty

101

5137700

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102

5136201

Upper

Mast

support

(Bell

Casting)

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5136301

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5011300

Bearing

Retainer

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MOTOR

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(118)

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Figure

12

Inside

View

of

T-2X

Rotator

19

hy-2

dino

LIMITED

WARRANTY

hy-gain

Warrants

to

the

original

owner

of

this

product,

if

manufactured

by

hy-gain

and

purchased

from

an

authorized

dealer

or

directly

from

hy-gain

to

be

free

from

defects

in

material

and

workmanship

for

a

period

of

12

months

for

rotator

products

and

24

months

for

antenna

products

from

date

of

purchase

provided

the

following

terms

of

this

warranty

are

satisfied.

The

purchaser

must

retain

the

dated

proof-of-purchase

(bill

of

sale,

canceled

check,

credit

card

or

money

order

receipt,

etc.)

describing

the

product

to

establish

the

validity

of

the

warranty

claim

and

submit

the

original

or

machine

reproduction

of

such

proof-

of-purchase

to

hy-gain

at

the

time

of

warranty

service.

hy-gain

shall

have

the

discretion

to

deny

warranty

without

dated

proof-of-purchase.

Any

evidence

of

alteration,

erasure,

or

forgery

shall

be

cause

to

void

any

and

all

warranty

terms

immediately.

hy-gain

agrees

to

repair

or

replace

at

hy-gain’s

option

without

charge

to

the

original

owner

any

defective

product

under

warranty,

provided

the

product

is

returned

postage

prepaid

to

hy-gain

with

a

personal

check,

cashiers

check,

or

money

order

for

$8.00

covering

postage

and

handling.

Under

no

circumstances

is

hy-gain

liable

for

consequential

damages

to

person

or

property

by

the

use

of

any

hy-gain

products.

.

Out-of-warranty

Service:

hy-gain

will

repair

any

out-of-warranty

product

provided

the

unit

is

shipped

prepaid.

All

repaired

units

will

be

shipped

COD

to

the

owner.

Repair

charges

will

be

added

to

the

COD

fee

unless

other

arrangements

are

made.

This

warranty

is

given

in

lieu

of

any

other

warranty

expressed

or

implied.

hy-gain

reserves

the

right

to

make

changes

or

improvements

in

design

or

manufacture

without

incurring

any

obligation

to

install

such

changes

upon

any

of

the

products

previously

manufactured.

_

All

hy-gain

products

to

be

serviced

in-warranty

or

out-of-warranty

should

be

addressed

to

hy-gain,

308

Industrial

Park

Road,

Starkville,

Mississippi

39759,

USA

and

must

be

accompanied

by

a

letter

describing

the

problem

in

detail

along

with

a

copy

of

your

dated

proof-of-purchase.

This

warranty

gives

you

specific

rights,

and

you

may

also

have

other

rights

which

vary

from

state

to

state.

Hy-Gain TAILTWISTER T-2X User manual

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