General Description
The 3501BA is a medium duty, azimuth rotating system designed to rotate and hold
large communication antenna arrays. It can be mounted in various positions on most
towers. The entire mechanism is protected from weather by a ruggedly constructed
housing.
The rotator is supplied complete. (The cable is not supplied.) The control unit
includes an ON/OFF switch, directional rotation switch, and a selsyn operated,
compass-rose indicator, calibrated in degrees for azimuth information. Mating control
connectors are supplied for the rotator/indicator connection.
Specifications
Mechanical
Rotating torque ...........................9000 in. lbs.
Braking torque .............................(in excess of) 23,000 in. lbs.
Maximum vertical load ...............1000 lbs.
Maximum bending moment
at top bearing ...........................................................................................2 0 0 0 f t. lbs. lateral thrust
Mast size range ...........................1-1/4" to 3"
Weight ............................................2 5 0 l b s .
Output shaft speed ....................1 rpm
Size .................................................19" wide x 24" long x 14.5" high
Electrical
Power requirement, indicator..110/120 V, 50 - 60 cycle, 2 amp
Fuse, indicator ........................... 3 AG, 3 amp
Power requirement, rotor ...........1 1 0 / 1 2 0 V , 5 0 t o 6 0 c y c l e ;
220/240 V, 50 - 60 cycle, single phase
Fuse, rotor (110/120 VAC) .. Fusetron FNM-8 (cartridge)
Motor ................................................1/4 hp, single phase, 110/120 or 220/240 V
Control system ............................manual with remote power relays
Indicating syste m .......................Selsyn motor, 50 - 6 0 c y c l e , 1 1 0 1 2 0 V
Cable (indicator control) .... six-conductor, #16 AWG minimum
Positioning accuracy ..................±50
Unpacking
Remove the rotator and indicator from the shipping carton. Save the carton for
any future shipping. Unpack the rotator and check it for damage. Remove the side
panels and check for damage. Unpack the indicator and inspect for damage. This
equipment has been carefully packed for safe arrival if properly handled en route.
The responsibility for safe delivery rests with the carrier. The responsibility
for getting reimbursed for damage rests with you. Prompt action on your part will speed
adjustments. Our warranty does not cover malfunction or damage which results from
improper handling by a carrier. You should not return any merchandise to your dealer
before filling out the necessary forms. To do so can jeopardize your investment and incur
upon you the costs of necessary repairs. The system was fully tested prior to packing.
It operated perfectly in all respects. Howe ver, after you are satisfied that there has been
no mechanical damage during the shipment, we recommend bench testing of the system
prior to installation to insure that no electrical damage has occurred.
2
Installations
Lubrication WARNING
The gear box is shipped dry. Do not operate without oil.
For normal operating conditions where surrounding temperatures are between 40 and
120 degrees Farenheit, "MOBILE Super Cylinder Oil 600W" or an oil of equal
viscosity and composition is recommended. Below 40 degrees, this oil should be
diluted with a lighter oil "SAE 30W Motor Oil" until the desired viscosity is
obtained. Fill both sump units to the oil level mark and maintain this level. After
the first 100 _hours of operation, drain the coil, flush out the case, and refill it to
the proper level. Thereafter, under normal operating conditions, oil should be
replaced at intervals of 1000 hours of operation.
The selsyn shaft on both selsyns should be oiled once a year on each end with two
drops of light oil. Do not use more than two drops.
AA-3501-C-012
CAUTION
Both primary and secondary reducers have individual oil reservoirs. Each unit
must be filled to and maintained at its individual oil level. For additional
suitable oils, see the listing of Typical Manufactu rer's Worm and Worm Gear
Reducer Oils meeting A.G.M.A. Standards 250.02A.
2
Cable Requirement Six wires are required to control the rotator and indicate its position. For best
operation, the voltage drop should not exceed 2%. However, the rotator will o perate
with greater voltage drop with slight degradation of performance.
Belden #8621 seven conductor #16AWG cable can be used for runs up to and
slightly exceeding 300 ft. (One conductor is unused.)
Cable connectors for attachment of the cable to the rotator and indicator are
furnished with the system.
Wire Harness from Relays
brown
violet
orange
blue
red
black
Motor Terminal (T) Board
T #6
T #1
red
black
T#4
T #6
Wire Harness from Relays
brown
violet
orange
blue
red
black
Motor Terminal (T) Board
T #1
T #4
red
black
T #3
T 44
Power Requirements The indicator will operate only from 110/120 V, 50 - 6 0 c y c l e p o w e r . I t i s s u p p l i e d with a
power cord and wall plug which fits a standard outlet.
The rotator must be supplied either 110/120 VAC or 220/240 VAC single -phase power
from a separate source independent of the indicator. This source should be both fused
(30 amp) and switched or provided with 30-amp circuit breakers for 110/120 VAC
operation. When operated from a 110/120 VAC source, run current is 4.2 amps, starting
surge is 20 amps.
The power cable to the rotator should be a minimum of #12 AWG. A safety ground is also
desirable. Maximum voltage drop to the rotator should be 2%. A greater voltage drop can
be tolerated, but should not exceed 4%. Motor winding failure can result from
overheating.
The rotator circuit is wired for 110/120 VAC operation when it is shipped. If it is to
operate from a 220/240 VAC source, remove the end plate on the motor and change
wiring to conform with the illustration for 220/240 VAC operation. Change the rotator
fuse to type FNM-4 cartridge style when using 220/240 VAC
Mounting The 3501 BA may be mounted in many ways. Five methods of mounting are
described in the following paragraphs:
1. Side of tower mount. Place the side of the rotator against a flat side of the tower
and as near to the top as possible. Clamp or bolt the angles to the legs, then
attach the rotator to the angles. Support the outer side of the rotator by
forming knee braces and bolting steel angles to the outside and attaching the lower
end angles to the tower legs. Attach the angles with U-bolts (preferred method) or by
bolting (if the legs are large enough where a bolt will not weaken
them 1.
2 . S i d e o f p o l e m o u n t . This alternate mounting should only be used under special
circumstances. Position the rotator at the top of the pole with the side of the rotator
touching the pole. Straps must be attached to the mounting channel and formed around
the pole. (Straps and mounting channel are not provided.) The outer side of the rotator
is supported by angle braces to the bottom of the channel.
3. Inside of large towers. This may be done in towers which have a crossbracing
platforms. The rotator may be seated on one of these platforms. Bolt the shipping hold down angles to the cross arms of the tower at the appropriate positions and secure
them to the rotator with bolts.
Mounting on Interior of Tower
A. Center rotator on cross brace of tower and mark the
position on cross brace where rotator angles touch the
cross braces.
B. Drill and bolt holding brackets to the cross braces. C.
Bolt angle holding brackets to the rotator angles.
Alternate Method
If inside of tower is too large for rotator, a large plate
or additional angle irons must be used to span the
distance between cross braces. These angles or plate
may then be bolted to rotator angles or holding brackets.
4. On top of large towers. Where a large, flat-topped tower is available, the rotator
may be installed directly on top. This m ay be secured by bolting directly and
securing the four corners with four angles supports to the legs of the tower as shown
in the illustration.
AA-3501-A-006
NOTE: Mast clamps and hardware are part of Prod. 3792AA.
Product 3792AA contains mast clamps and hardware which are
used when mounting the 3501BA to the LP-1007 or antennas other
than Hy-Gain models.
The LP-1017CA antenna does not require these clamps;
it mounts directly to the rotator output flange. For direct
mounting of LP-1017, see "Mast Installation" instructions.
5. Ground mounting. This is desirable where you want the rotating mechanism at
ground level while it rotates a long mast on which the antenna is mounted. This
may be done two ways. The rotator may be mounted securely to a concrete slab and a
small structure built up and around the rotator to secure it to the tower. (Many
towers are large enough at the bottom to house this rotator directly.)
AA-3501-A-007
The mast may also be held in a bearing as shown above and the rotator housed
outside the tower. The rotator drives the mast by using two sprocket gears and
a chain. This requires two identical #50 sprocket gears and a length of #50 roller
chain.
Mast Installation
The LP-1017 CA antenna is constructed so that the boom-to-mast plate, on the mast
assembly, can be mounted directly to the output flange of the rotator.
The portion of the mast assembly, below the boom-to-mast plate must be cut off before
it can be mounted to the output flange.
P r o d u c t 3 7 9 2 A A i s r e q u i r e d f o r a t t a c h i n g a n y o t h er antenna to the rotator.
It provides a set of mast clamps and hardware to secure the mast of your antenna to
the rotator. Center the mast of the antenna on the flange and adjust the clamps so that
it will rotate without any eccentricity. This adjustment is important to prevent uneven
bearing loads and undue wear.
The maximum allowable bending moment at the top bearing is 2,000 ft-lbs. This is equal
to an antenna with a wind load of 500 lbs. at 80 mph placed four feet above the
rotator.
IMPORTANT: Proper installation of the mast clamps requires a torque wrench. Tighten
the six 3/8" bolts in the mast clamps to 19 ft-lbs. then tighten the four 1/2" x 2"
bolts through the flange to 40 ft-lbs. Tighten the 3/8" bolts securely before
tightening the 1/2" bolts, otherwise damage will occur to the clamps. Do not
overtighten. The serrations in the clamps are sharp and will bite into the mast
securely. The output shaft of the rotator is hollow and the feedline may be passed
through it. RF rotary joint assemblies are available from Hy-Gain as optional
accessories.
Cable Attachment
Indicator
Installation
The 3501BA system is furnished with mating cable plugs for the control cable and
power input connectors. After installing the rotator and routing the cable, attach the
plug, type MS 3106A-18-12S, to the cable following the color code shown on
the wiring diagram. Install the power plug MS 3106A-20-23S on the power cable and
connect it to the rotator.
Place the indicator in the operating position and attach the plug, Jones-type
P406CCT, to the cable according to the color code shown on the wiring diagram.
Plug the indicator into a 110/120 VAC source. Depress the ON/OFF switch.
The indicator lamp should light. The indicator will synchronize with the rotator.
The indicator dial will usually require slight adjustment for accurate readings.
Remove the chassis as shown above. Loosen the three Allen screws in the dial
frame holding the selsyn and carefully rotate the selsyn in the frame until the dial
indicates the proper direction. Tighten the Allen screws and replace the cabinet.
CAUTION
Do not allow the selsyn to be pulled out of its housing or the arrow pointer will
detach from the selsyn shaft.
Depending on requirements, the limits of rotation may be reset after installation. The
limit switches are operated by the pin in the drive gear of the rotator selsyn. To reset
limits, loosen the rotator selsyn in its mounting and rotate the drive gear until the Iimit
switches are actuated at the desired heading (preset prior to loosening the selsyn). Remesh the gears on the output shaft and selsyn and retighten the selsyn in its mounting.
After this adjustment, realign the indicator as described in Indicator Installation.
WARNING
Before climbing the tower and/or performing any maintenance or system
adjustments, make certain all power is disconnected from the rotator and
indicator. This is a necessary precaution against electrical shock.
Operation
Depress the ON/OFF switch to actuate the CW -CCW switch and rotate the antenna to
the desired heading. After severe wind conditions, if the antenna drifts in heading, the
i n d i c a t o r wiII display the new heading after power has been re-applied.
CAUTION
Do not switch directly from CW to CCW or serious damage to the rotator could
result. When switching from CW to CCW (or vice-versa), always stop at center o f f
position for at least five seconds.
Parts List
Qty
1
1
1
1
2
2
1
1
1
2
1
1
1
Part No.
172297
740001
741021
375900
872335
872339
882337
875035
701025
701099
747124
270019
Description
switch bracket
selsyn
motor painted
reducer
gear
frame
shaft with selsyn gear
Indicator Assembly
ON-OFF switch
CW-CCW switch
selsyn
adapter
Qty
1
1
1
1
1
1
1
1
1
1
1
1
RETURNING EQUIPMENT FOR SERVICE
Do not ship equipment to the manufacturer without prior authorization. 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 you. When a shipment is
expected, even the time of sending the labels is less than that lost when an unexpected
shipment is received.
The shipment must be well packed and fully insured. Damage claims must be settled
between you and the carrier, which greatly delays any returns. Proper packing normally
avoids this problem.
All shipments must be sent to us prepaid. We do not accept collect shipments. All returns
should be made in our standard cartons. 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. If there are any charges not covered by warranty, we will hold the shipment and
advise you of costs, which you can then send.
3. Upon your written authorization, we will ship COD for any charges not covered by
warranty. The carrier will collect these charges and the transportation costs on
arrival. Unclaimed or refused COD shipments will not be reshipped until payment of
service and transportation charges are received. Shipment will then be made collect for
reshipment transportation charges. Unclaimed equipment automatically becomes
the property of Hy-Gain Electronics sixty days after the date of refusal or return and will
be disposed of for payment of charges due.
NOTE: We will not ship by means of any carrier that will not fully insure the shipment.
Some carriers have a $200 limit. The exception to this is when parcel post is the only
means of shipment (APO-FPO, etc.). We will ship by this means with your written
agreement that you will assume any loss over that which the carrier will insure. COD
shipments cannot be made to APO-FPO addresses.
ONE YEAR LIMITED WARRANTY
Hy-Gain Electronics Corporation warrants all products manufactured by it and bearing the Hy-Gain
model numbers to be free from defective material and workmanship and agrees to repair such products under
normal use and service, if investigation discloses the defect to be the fault of our manufacture. Hy-Gain's
obligation under this warranty is limited to repairing any such product which, upon our examination,
proves to be so defective. All products repaired under such warranty must be returned to the Hy-Gain
factory or any authorized field service station, transportation prepaid by the purchaser, within one year
from the date of original purchase from Hy-Gain or authorized Hy-Gain distributor.
This warranty applies only to the original purchaser.
Upon receipt of equipment, the purchaser is responsible for checking the contents for damage.
Any shipping damage claims should be referred to the carrier.
This warranty does not apply to any Hy-Gain products which have been repaired, worked upon, or
altered by persons not authorized by Hy-Gain to do so, or products to which the repair has injured the stability
or reliability of such product, or which has been the subject of mis-use, negligence, or accident, or the
serial number of which has been removed, altered, effaced, or in any other way rendered unidentifiable.
Neither does this warranty apply to any of our products which have been connected, installed, used, or
otherwise adjusted other than in accordance with instruction furnished by Hy-Gain. Nor does Hy-Gain
Electronics Corporation assume any liability for consequential damages, and in any event, our liability shall
in no case exceed the original purchase price of the product.
Accessories supplied by, but not manufactured by Hy-Gain Electronics shall carry only such warranty as is
available from the manufacturer of such goods and are specifically excluded from Hy-Gain warranties.
This warranty is void if Hy-Gain shall inspect equipment and find it to have been modified, improperly
installed, or used. This warranty is expressly in lieu of all other warranties expressed or implied, and all other
obligations or liabilities on the part of Hy-Gain, and no person including any dealer, agent, distributor, or
representative of Hy-Gain is authorized to assume for Hy-Gain any liability on its behalf, or in its name,
except to refer purchasers to this warranty.
All claims of defect or shortage should be addressed to:
Warranty Service Department HyGain Electronics Corporation 4900
Superior Ave. Lincoln, Nebraska
68504
You must furnish model number, date, place, and proof of purchase, such as a copy of the sales receipt, to
establish warranty. Your letter should include all pertinent details along with part or item numbers
involved. Do not return anything until requested to do so. No warranty card is furnished. You must
supply the above information.
Any returned items must have prior authorization. Unexpected returns are greatly delayed in handling. These
delays can be avoided by writing in advance and furnishing the necessary information.
DESIGN: Hy-Gain reserves the right to make changes in design and improvements on its products
without assuming any obligation to install the same on any of its products previously manufactured.
Further, Hy-Gain reserves the right to ship new and/or improved products which are similar to the form, fit,
and the function of products originally ordered.
Typical Manufacturer's Worm and Worm Gear Reducer Oils
NAME OF MANUFACTURER
AMERICAN OIL COMPANY
ARKANSAS FUEL OIL COMPANY
ATLANTIC REFINING COMPANY
CARTER OIL COMPANY
CATO OIL & GREASE COMPANY
AMBIENT TEMP. 15°-60°F
Amolite Worm Gear'Comp #4
Optimus #6
Mogul Cyl. Oil
Cylesstic T140
Cyl. Oil B
CITIES SERVICE OIL COMPANY
CONTINENTAL OIL COMPANY
ESSO STANDARD OIL COMPANY
FISKE BROS. REFINING COMPANY
GULF OIL CORPORATION
Optimus #6
Inca Cyl. Oil
Cylesso T140
Lubriplate #:8
Acorn Cyl. Oil "B"
HOUGHTON & CO., E.F.
HUMBLE OIL & REFINING COMPANY
KEYSTONE LUBRICATING COMPANY
NATIONAL REFINING COMPANY
NEW YORK- NEW JERSEY LUBRICATING CO.
Mod. Worm Gear Oil
Cylesso T140
AG #7
Enarco Dark Cyl. Oil
D#17A Comp
OHIO OIL COMPANY
PENNZOIL COMPANY
PENOLA, INC.
PHILLIPS PETROLEUM COMPANY
PURE OIL COMPANY
598 Worm Gear Comp
Pennzoil Cyl. Oil #12
Cylesstic T140
Hector S.6008 Steam Cyl. Oil
Red Clipper
RICHFIELD OIL CORPORATION
SHELL OIL CORP. (CAL.)
SHELL OIL CORP. (N.Y.)
SINCLAIR REFINING COMPANY
SKELLY OIL COMPANY
Valve Oil Light
Valvata J78
Valvata J78
Moduc Cyl. Oil Lt.
13536 Spec. Gear Oil
STANDARD OIL COMPANY, (CAL.)
STANDARD OIL COMPANY, (IND.)
STANDARD OIL COMPANY, (KENT.)
STANDARD OIL COMPANY, (OHIO)
SOCONY MOBILE OIL COMPANY
Calol Gear Comp 130
Standard Worm Gear Oil
Cylesso T140
Sohicyl C150
Mobil Cyl. 600 W
SWAN FINCH OIL CORPORATION
TEXAS COMPANY
TIDEWATER ASSOCIATED OIL CO., (N.Y.)
TIDEWATER ASSOCIATED OIL CO., (CAL.)
UNITED OIL COMPANY
Safco Worm Gear Med.
Honor Cylinder Oil
Tycol Atwoter 83
Tycol Atwater 83
United Gear Oil #7 Comp.
VALVOLINE OIL COMPANY
WAVERLY OIL COMPANY
Volvene Dark
Comp. 600 Stock
POUR
POINT
AMBIENT TEMP. 50 °-125°F
20°F
25°F
25°F
20°F
15°F
Amolite Worm Gear Comp #5
...................................
Bessemer Oil
Cantons LK150
Cyl. Oil C
25°F
20°F
20°F
20°F
10°F
15°F
20°F
45°F
40°F
10°F
15°F
20°F
20°F
25"F
25°F
20°F
25°F
25°F
20°F
5°F
10°F
35°F
20°F
15°F
40°F
Penn Optimus #5
Zuni Cyl. Oil
Cantons LK150
Lubriplate #8
Senate Cyl. Oil "C"
M.E. Worm Gear Oil
Cylesso T160
AG #8C
Enarco Dark Valve
D#18A Comp
POUR
POINT
10°F
35°F
20`F
10°F
35°F
15°F
20°F
30°F
15°F
15°F
30°F
50°F
45°F
10°F
...................................
Pennzoil Cyl. Oil #2
Cantons LK150
Andes "S" Steam Cyl. Oil
...................................
45°F
20°F
25°F
Steam Cyl, Oil Comp.
Valvata J83
Valvata J83
Superheat Valve Oil
...................................
35°F
20°F
20°F
40°F
Calol Gear Comp. 150
Calumet SH Cyl. Oil
Cantons LK150
Sohicyl 650
Mobil Super Cyl. 600W
35°F
30°F
60°F
30°F
40°F
Safco Worm Gear Hvy.
650T Cyl. Oil
Tycol Atwater 87
Tycol Atwater 90
United Gear Oil #8 Comp.
35°F
60°F
#4431 Gear Oil
Comp. C600 Flash Stack
30°F
50°F
25°F
15°F
Ideal #1 Cyl.
White Rose Valmor 80K
Penn Optimus #5
M.E. Worm Gear Oil
Cylesso X185
13°F
35°F
30°F
30°F
50°F
25°F
35°F
50°F
35°F
40°F
40°F
35°F
CANADIAN COMPANIES:
BRITISH AMERICAN OIL COMPANY, LTD.
CANADIAN OIL COMPANY, LTD.
CITIES SERVICE, LTD.
HOUGHTON, CANADA, LTD.
IMPERIAL OIL, LTD.
McCOLL FRONTENAC, LTD.
SHELL OIL COMPANY CANADA, LTD.
TIDEWATER ASSOCIATED OIL CO.,
CANADA, LTD.
British #1 Cyl.
White Rose Valmor 75K
Optimus #6
Mod. Worm Gear Oil
...................................
Regal K
Valvata J78
Tycol Atwater 83
10°F
25°F
60°F
Texaco 650T Cyl. Oil
Valvata J83
Tycol Atwater 87
30°F
50°F
35°F
15°F
35°F
35°F
20°F
50°F
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