Hy-Gain 602 Installation instructions

ORDE8 NO.
=~., . ....
6 1
INSTALLATION
OPERATION INSTRUCTIONS,
HV-GAIN. ELECTRONICS CORloRATION
Rural Route 3 . Lincoln, Nebraska 68505
SECTION I
DESCRIPTION
The Model 602 DC Po~Supply is designed for use with the Hy-
Gain Model 600 Bi-linear Amplifier when used in a mobile in-
stallation. It is constructed on'an all aluminum chassis with heat
sinks for rapid transfer of heat from the heavy duty switching
transistors. An internal thermal-switch has been provided to
prevent damage to the unit by rendering it in inoperative during
periods of high ambient temperature.
The Model 602 DC: Power Supply is for use on negati ve ground
only automotive systems.
Size 8 1/2" x 6" x 4"
Weight 6 112 Ibs.
Transistor Complement 4 each - GDC-50
Diode Complement 10 each - IN 5054
Input Voltage 12 to 14 VDC @ 40 to 60 amps.
Output Voltage........................................ 800 VDC @ 600 ma
325 VDC @ 200 ma
100 VDC @ 35 ma
12 VDC @ 10 amps
SECTION II
UNPACKING
Carefully remove the Power Supply from the packing carton. Ex-
amine it closely for signs of shipping damage. This equipment
has been carefully packed for safe arrival IF PROPERLYHANDLED
EN ROUTE,
The responsibility for safe delivery rests with the carrier. The
responsibi Iity in obtaining 'reimbursement for damage rests with
YOU Prompt action on your part will speed adjustments. Our
warranty in no way covers malfunction or damage which is a re~
suit of improper handl ing by a carrier. Under no circumstances
should you return merchandise to your dealer before instigating
the necessary forms. To do so can jeopardize your investment
and the costs of necessary repairs may be a burden you will have
to assume.
Fill out the enclosed Warranty Registration Card and mail to in-
sure your warranty will be on file.
Save.the carton and pa.Qkingmateri al. Youmay need it at a later
date for storage or shipment:--
The system was fully tested prior to packing and operated per-
fectly in all respects. However, after satisfying yourself that
there has been no mechanical damage during shipment, the manu-
facturer recommends bench test of the system prior to installation
to insure no electrical damage occurred.

SECTION III
INSTAllATION
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as seen In Figure 1. Insert the heavy power cable through the
grommet adjacent to the terminal strip. After inserting the power
cable into the Power Supply, strip the outer vinyl jack back ap-
proximately three inches and then remove 3/8 inch insulation
from each individual wire. Connect the wires to the terminal
strip following the wiring code shown below. It is recommended
that the power cable wires be soldered to the lugs provided. By
soldering the power cable wires in place, future trouble with cor-
roded connections can be avoided.
The Model 6D2 Power Supply case design makes the unit sub-
stantially ~ash proof. but not completely water proof. It can be
~ounted wh(Jre water wi II occasionally spl ash on it without harm.
However, it should be mounted so that all cable entrances face
to the rear to minimize water entry arouhd the grommets.
I
The Model 602 Power Supply should be mounted in a position
where there is good air movement. J\ir movement in the motor
compartment .>;S best near the front and poorest near the rea r.
Placement sr,;~ be as far forward as possible. Do not place
the unit on t~iire wall under any circumstances. Many cars
have sufficiefl. 'space between the grill. and radiator for instal-
lation of the' ower Supply. However, If the unit IS placed be-
hind the grill; observe precautions regarding entrance of water.
For maximum cooling of the 602 Power Supply, it should be
placed in the flatest possible position to transfer as much heat
from the case to the automobile body. The mounting surface
should be cleaned thoroughly before attachment of the Power Sup-
ply to insure good heat transfer.
The heavy primary power cables which are furnished with the
Model 602 Power Supply cannot be lengthened or poor voltage
regulation will result with possible damage to the Power Supply.
This must also be taken into consideration when deciding place-
ment of the unit.
Before connecti ng the pri mary power cabl es to the suppl y and the
battery terminals, the voltage output of the generator or alter-
nator shOuld be checked. Turn on the G<lrheadlights-forfivemii1:=
utes without starting the motor. This will discharge the battery
sl ightly. Connect an accurate volt meter from the generator out-
put terminal to ground and start the motor. WITH THE MOTORAT
A FAST IDLE, THE GENERATOROR ALTERNATOR, OUTPUT VOL-
TAGE SHOULD NOT EXCEED14.5 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 wi II not need adi,ustment. (For regular adjustment,
refer to the ship service manual for the automobile available
from your car dealer.
The Model 602 Power Supply is mounted by" heavy sheet metal
screws or bolts passed through the four holes in the bottom of the
flange. The exact mounting position should be selected keeping
in mind the considerations of paragraph 3.1.
The unit is furnished with a heavy duty power cable for connec-
tion to the Model 60oBi-Linear Amplifier. This power cable in-
cludes a pre-wired 12 pin plug. After deciding upon the exact
placement of the Powu Supply, route the power cable from the
the Model 600 Bi-Lin¢'1r Ampl ifier to the Power Supply. Allow
some slack in the power cable at the Power Supply. The excess
cable may be cut off. Be sure to cut from the end that wi II con-
nect the Power Supply and do not cut the power piug off.
To expose the terminal strip Ior connection of the power cable,
you must remove six ~.crews. Two on each end and one on each
side to release the tC'~'l::over. Thiswill expose the terminal strip
No.1 - Red +800 VDC @ 600 ma HIGH VOLTAGE
No.2 - Blue....................••. 325 VDC @ 200 ma LOWVOLTAGE
No.3 - Purple & fellow V,'ires +12 VDC @ 6 amps
FILAMENTS & TRANSISTORS
No. 4 - Orange 100 VDC @ 35 ma tllAS
No.5 - Brown Relay Control Vt'ire
(Ground to turn supply ON)
No.6 - Black & Green V ires............•....................... Ground
;:n
After wiring the terminal strip, replace the top cover and secure
the Model 602 Power Supply in operating position utili:cing the
four mounting holes in the bottom flange. Route the primary power
cables from the supply to the battery.
NEVERconnect the primary power cables to the starter so-
lenoid or any other voltage source on the car. The primary
power cable must always be connected directly to the bat-
tery terminals or clamps. Take care to insure that the po-
larity of the Power SuWly power cables is not reversed
when rrmnecting to the battery.
AftE'lr.the pr.imary-povli1l1'"si.JpPlycables are installed, check to in-
sure that the Model 600 Bi-Linear Amplifier is turned off and con-
nect the power supply cable to the rear of the amplifier.
The separate power supply concept provides maximum efficiency
by utilizing the shortest low voltage high current power leads
possible. By transforming the car's 12 volts to operating vol-
tages near the battery and routing to the amplifier, power trans-
mission losses are minimized.
If the power supply is mounted on the same chassis as the am-
plifier, the long 12 volt power leads required will cause a
voltage drop of 2-3 volts. This wi II cause a loss of 20-30% in
power. This loss is not encountered with a separate power
supply and short 12 volt leads. Additionally, remote control
problems are also easier because it is not necessary to switch
the rnain 12 volt power leads.
To remotely control the 600-602 combinations. attach 2 wires,
#18 AWG size, to terminals No.5 and 6 of the 602 power supply
connection strip. Route these wires to a remote control switch
under the dash. Whenever the switch is closed, the primary
control relay will close and turn-on the 600-602 combination.
The 600 Linear can now be placed in any convenient location
after tun ing and setting the controls.
The front panel power switch should be left in the OFF posi-
tion when using a remote control switch.

SECTION IV
OPERATION
Should a fuse bloVli instantly, it indicates a high current short in
the 12VDC Iine. Either in the supply, the poV\,ercable to the am-
plifier, or in the amplifier itself. The first step should be to un-
plug the power cable from the amplifier, remove the top cover
from the power supply for access to the terminal strip and with the
aid of a short jumper wire, connect terminal No.5 in the supply
to the car frame. This will normal'ly start the supply (replace fuse
blown in above test). If the supply does start when shorting ter-
minal I~O. 5 to the frame and the voltage output~is as it should
be, it v;ouldindicate the short is in the Bi-Linear Ampl ifier. If
the supply' blows another fuse, you can isolate the cable as a
source by disconnecting all cable wires at the supply terminal
strip and again starting the supply by jumping terminal No.5 to
the car frame (replace the blown fuse). If the supply operates
normally, then the trouble is in the cable. If another fuse is blown
, _ , . ,.' the trouble is in the supply. Removethe supply and very care-
A specIal hermal Rel~l-ncmded+"tbL'L J 1.' ~o_o_ffe~ __, fully look for components that might be touching the case and
the user maximumprotection from temperature failure of compon- ------cau-sing'En;fturt-.-----1+--RoAELQ[-.EJob2..erved,then itis reasonably cer-
ents, especially transistors. If a nominal temperature of 176 de- tain the trouble is a bad transistor-~-------
grees is exceeded, this protective device will open the primary
relay 1<1and render the supply inoperative until the temperature
drops to a safer level, at which time it will automatically reacti-
vate the supply.
Operation of the Model 602 Power Supply is controlled by the aNI
OFFSwitch of the Model 600 Bi-Linear Amplifier. Whenthe Mod-
el 602 Power Supply is operating properly, there will be a slight-
ly 'audible. tone of approximately 400 cycles heard near the
Power-S·upply. Due to the heavy power drain on the automotive
electrical system by this Power Supply when (>perating only use
it when the motor is in operation. Usage of the Power Supply
without the engine in operation can cause damage to the transis-
tors due to low voltage conditions.
Power SURplydamage is most likely to occur by continuing oper-
ation or usage after driving the vehicle for a considerable period
of time and then stopping and turning off the motor. The temper-
ature rise within the motor compartment is rapid and wi II cause
transistor failure or operation of the thermal relay. Under such
conditions the Power Supply should be turned off unti I the car is
moving again or until the motor compartment has cooled down.
The majority of transi stor fai Iures are traceable to usage of the
equipment after extended driving periods while the car has stop-
ped for refuel ing, etc.
Loss of operation during a transmission due to this relay is cer-
tainly more desirable than loss of operation due to transistor
failure. Proper mounting in a well ventilated area will prevent
loss of operation due to either of the above causes, barring other
factors of unusual natural heat. .
The 602 power s~1' fl'y is further protected from over load damage
by a fuse in the negative return load of the high and low voltage
sections. This fuse is located on the side opposite the primary
40 amp fuse. It is a size AGe 0.5 amp fuse. Failure of this
fuse while tuning up or operating indicates an overload which
could cause 602 power supply fai lure or secondary component
failure.
DO NOT use a larger fuse. Use onlv type AGe 0.5 amp.
An occasional fuse failure is much less inconvenient than
transistor or torroid transformer failure.
Use onlv AGU-40 fuses in the primary Power SupplV line.
A higher amperage fuse will not protect the supplV from
damage.
In most cases, when the 40 ampere fuse blows, it indicates a
strong probabiIity of a shorted transi stor. However"-sometimes a
surge can blow a fuse without damage occuring an~Ja new fuse
should be installed and tried before further investigation is made.
If the supply operates normally, then it indicates nO,damagewas
done. If it instantly blows the new fuse, it is most likely an in-
dication of a bad transistor, a short in the primary cables, or a
short in the power cable.
The following ohecks can be made to isolate va}ious problems
that might be encountered and speed servicing in tr:iefield. How-
ever, V',e suggest that no work be done in the field unless you
anticipate completing the work in the field.
When a bad transistor is the conclusion of the tests made, it can
be verified with a simple VOM test, using a low ohm scale which
will read 5 ohms or less. To make the test. disconnect the two
wir~s to the lugs of the transistor (use long nose pliers to hold
the lugs near the case and prevent overheating the transistor) and
measure resistance between the two lugs. It should be at least
3 ohms. A bad transistor will show a direct short. If good, im-
mediately reconnect the wires, taking care not to reverse them,
use the pliers again for a heat sink. Check the other transistors
and replace the one found shorted. While replacing the defec-
tive transistor, aIways check the four 1.5 ohm I 5 watt base
drive resistors for proper value. If all transistors are found to
be good, it would indicate a short circuit in the other power sup-
ply components, such as a diode, capacitor or toroid transformer.
If the emitter current equalizing wires, R9- R12, have been
damaged, do not replace with any other size and length
wire or improper current distribution will cause transistor
failure again. Use 6 of #22 AWG wire onlv.
If the fuse does not blow and the lamp and fi laments light.
but the power supply does not start osci lIating, the type
111495 bulb should be checked to insure the filament has
not burned out. The type 111495 is an aircraft lamp avail-
able from most aircraft repair shops. If not locally avail-
able, type 111458 can be substituted, but the filament is
not as rugged as the type 111495. ;

SECTION V
SERVICE INFORMATION
DO NOT sh~equipment to the Manufacturer without prior authori-
zation. We prefer to send special shipping labels which will avoid
the delay of unexpected shipment.
If time is extremely important, wire or call for approval and we will
rush labels to \lOU. When a shipment is expected, even the time of
sending the la~ls is less than that lost when an unexpected ship-
ment is receiveo.
It is VERY IMPORTANT that the shipment be well packed ana fully
insured. Damageclaims must be settled between you and the car-
rier and will greatly delay any returns. Proper packing normally
avoids this trouble.
ALL SHIPMENTS MUST BE SENT TO US PREPAID. We do not
accept collect shipments. All returns should be made in our standard
cartons only - so save your carton when unpacking the unit. When
a shipment is returned it will 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-lf there are any charges not covered by warranty we will hold
the shipment and advise you of costs, which you can then send.
3-0r, upon your written authorization, we will ship C. O. D. for any
charges not covered by warranty, then the carrier will collect these
charges and the transportation costs on arrival. Unclaimed or re-
fused C. O. D. shipments will not be reshipped until payment of
service and transportation charges Isrec_eL'ffid.Ship.rner;twtll"1fien
be rT1~.(jecolJect·for reshipment transportation charges. Unclaimed
SECTION VI
WARRANTY
Hy~aln Electronics Corporation Wilrrants each new product manu-
factured to be free from defects in material and workmanship and
agrees to remedy any such defect. or to furnish a new part, in ex-
change 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 regis-
tered by the original owner at the time of purchase to validate the
warranty.
Thiswarranty does notextend to anyof our products which have been
subjected to mis-use, neglect, accident, incorrect wiring not our
own, improper installation or to use in Violation of instructions fur-
nished by us. Nor does it extend to units which have been repaired
or altered outside of our'cfactory nor to accessories used therewith
not of our own manufactu're,nor toany caseswhere the serial number
has been removed, defaced, or changed.
Hy~ain Electronics Corporation reserves the right to make any
equipment automatically becomes the property of the Manufacturer
60 days after date of refusal or return and will be disposed of for
paymentof charges due.
WeWILL NOTship by meansof 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.l of shipment
than parcel post, and then we will ship by this meanswith your writ-
ten agreement that you assumeany loss over that which the carrier .
will insure. C. O. D. shipments cannot be made to APO-FPO ad-
dresses.
A.II replacement parts orders must be prepaid or C. O. D.only.
Replacement part price quotes will be furnished on request for those
who desire p,t:lpaid shipment or cannot accept C. O. D. shipments.
All requests, inquiries. warranty claims or equipment returns should
be made to:
Hy-Gain Electronics Corporation
Rural Route 3
li l1 coln, Nebraska·~8505-·".
changes deemed necessary or deSirable WlthoUl advance notice
or incurring any obiigation to make like changes in units prevously
manufactured or sold.
This warranty does not cover transportation or installation costs that
may be incurred. Hy-Gain Electronics Corporation's sale liability
is the remedy of any defect for ninety days. Hy-Gain Electronics
Corporation isnot responsiblefor personal injury or property damage
resulting from improper or careless installation not intended by the
manufacturer.
No person is authorized to assumefor us any other liabilitv in con-
nection with the sale of our products.
All warranties are void and terminated one year aft~r the last unit
of ItStype and design has been manufactured by us.