DX Engineering DXE-RT4500HD Instructions manual

Heavy Duty Rotator

DXE-RT4500HD

DXE-RT4500HD-INS Revision 1b

© DX Engineering 2023

1200 Southeast Ave. - Tallmadge, OH 44278 USA

Phone: [phone] - Tech Support and International: [phone]

E-mail: [e-mail]

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DX Engineering RT-4500HD Rotator

Introduction

The RT4500HD Heavy-Duty Rotator has capabilities that surpass most rotators available on the Amateur
Radio market. In addition to an impressive list of features and benefits, it is especially noteworthy that this
rotator does not have mechanical limit switches. Soft rotation limits are set as desired in the controller, to the
limits of the installed antenna cables. If the antenna or the mast ever slips, simply reset the controller to the
new center of rotation and recalibrate the rotational range. Climbing or antenna mast repositioning is not
immediately required.

Install the DX Engineering RT4500HD Heavy-Duty Rotator in your tower to take advantage of these features
and benefits:

 Superior Rotational Torque > 4,400 in. lbs. with high ratio worm gear drive powered by an extra

heavy-duty 24VDC motor

 Exceptional Braking Torque >18,500 in. lbs. by high ratio gear reduction that prevents rotation of the

mast mounted antenna system due to wind

 Very High Vertical Load Capacity — internal needle thrust

bearing handles up to 2,000 lbs.

 High-compression Heavy-Duty Top Mount Mast Clamps

available for 2-inch OD or 3-inch OD masts

 Precision Movement — accuracy within +/-0.1 degrees with

high resolution magnetic pulse sensor controller

 Easy Maintenance — access panel allows service of the

magnetic pulse sensor assembly without removing the
rotator from the tower

 Built for Longer Life — all steel gears are hardened; high-

load gears are welded onto their shafts to prevent slippage;
larger main gear provides increased strength

 Weather-Protected — sloped powder coated cast

aluminum alloy body sheds water; seals at the output shaft,
intermediate plate and access panel keep moisture out;
weep holes make sure it stays dry

 Worry-Free Installation — four-bolt standard mount; this

triangular-shaped rotator is ideally sized to fit inside any G­series ROHN tower, including 25G (but the RT4500HD
easily handles larger antenna systems than 25G will
withstand). Note: Recommended for Rohn 45G and
larger towers. This rotator may overload a Rohn 25G tower.

 Works with High-Quality Controllers — Optional DX Engineering Green Heron Rotator Controller DXE-

RT21DXE or other 24VDC, Pulse Counting Programmable Controllers including Green Heron and the
MOH-ARCO-115V microHAM ARCO Advanced Rotator Controller

 Fully bench tested prior to packing to ensure rotator is functioning within design specifications

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General Information

The DX Engineering rotator is designed to rotate large tower mounted amateur and professional antenna
arrays under control from the station operating position.

The internal motor is variable DC coupled to a series of hardened gears to provide the turning power. A
magnetic pulse sensor sends the appropriate information to the rotator controller to indicate speed and
positioning. There are no starting capacitors, limit switches or positioning potentiometers that are normally
prone to failure in the DX Engineering rotator.

In the event of a nearby lighting strike, the pulse sensor may be damaged. Unlike other rotators, the DX
Engineering pulse sensor can be easily replaced by opening the pulse sensor assembly access panel without
having to remove the rotator from the tower.

The DX Engineering rotator is designed to fit Rohn 25, 45, 55 and
other large towers as well.

Note: Recommended for Rohn 45G and larger towers. This

rotator may overload a Rohn 25G tower.

The rotator should be mounted approximately 10 feet inside from
the top of the tower with an optional thrust bearing (DXE-TB-300
or DXE-TB-400) mounted on a thrust bearing shelf – or flat tower
top.

The rotator mounting shelf must be installed so it is level and
centered to the tower which will then be in-line with the rotator to
eliminate any undue stress. The Rotator is attached to the Rotator
Shelf using four single-use patch bolts for secure mounting.

An optional Mast Clamp (DXE-RTMC-2A or DXE-RTMC-3A) is
required to be mounted to the rotator top plate using four bolts
with single-use Nyloc hex nuts and flat washers.

An Important Note About Rotator Capacity – Antenna Wind
Area, expressed in square feet or square meters, is a
specification that applies for tower loading, but it does not
properly equate to rotator specifications. The appropriate specification for rotators is Rotational Torque.
Antenna system size, boom and element lengths, antenna balance, as well as total antenna and mast weight,
must all be considered to determine torque requirements. Total antenna wind area handling of the DX
Engineering RT4500HD may be expected to be greater than 35-40 sq. ft. for very well-balanced antenna
systems, while also using the appropriate torque calculations that account for total antenna system size and
weight.

If the antenna(s) used is (are) rated at a total of 18 square feet wind load or more, it is highly
recommended that a three inch mast be used.

PLEASE – Read the entire manual before starting installation to get familiar with the procedure and to

ensure you have the required tools and supplies needed for a successful and Safe installation.

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IMPORTANT SAFETY INFORMATION

The installation of a rotatable antenna system on a tower is a dangerous and potentially life-threatening task if
due care is not taken. DX Engineering shall not be held liable for any accident or injury involved in the
installation or operation of the RT4500HD rotator. It is the responsibility of the customer to ensure the
installation is completed by an experienced and reliable installation company complying with standard safety
practices and using the best practices for working on or near a tower.

SAFELY working on a tower system is THE MOST IMPORTANT thing. Your installation team must follow all
safety requirements to avoid any injury or possible death from an accident. If you and your team do not have
the experience or safety equipment required, you should contact a qualified tower/antenna installation team.

The DXE-RT4500RT weighs approximately 22 pounds – ensure no one is located below the tower working
area either on the ground or on the tower. If the rotator it is accidently dropped while working on the tower
injury or death may occur if someone is struck by the falling rotator.

NOTE: The lifting handle must always be used when transporting the rotator and

when raising it up the tower.

Do NOT lift the rotator by the top round rotator plate.

A snap ring holds the top plate in position and it is not designed to hold the

weight of the rotator. If you hold the rotator by the top plate, you risk having the

snap ring fail and the rotator will then drop away from the top plate.

A tower must never be installed in a position where it could fall across power lines in the event of a
catastrophic failure during a windstorm or other environmental disaster. Follow all safety related items when
installing or working on a tower – Safety First.

The control cable attached to the DX Engineering rotator could, in the event of a nearby or direct lightning
strike carry lethal voltages down the cable and into your radio room. DX Engineering strongly recommends the
installation of suitable lightning arrestors on all rotator control lines and coaxial cables entering your radio room
from your antenna installation. Additionally a thrust bearing by-pass kit and lightning rod should be installed to
further help mitigate lightning damage.

If an electrical storm should be approaching your area, quickly disconnect the control cable from the rear of the

rotator’s control box and disconnect the AC cable from the wall outlet. Disconnect the coaxial cables from the

antennas as well. Only do this if the lightning is NOT in your immediate area, as you could be killed instantly if
lightning should strike while you are holding a cable.

NOTE: If you have any doubts about your ability to install this

rotator, seek out the services of a professional antenna – tower

installation company.

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Combinations Available

DXE Combination

Part Numbers

DXE-RT4500HD

Rotator

DXE-RTMC-2A

2” Mast Clamp

DXE-RTMC-3A

3” Mast Clamp

DXE-RT21-DXE

Green Heron

Controller

MOH-ARCO-115V

microHAM

Controller

DXE-RT4500HD-2

X X

DXE-RT4500HD-3

X X

DXE-RT4500HD-2DX

X X X

DXE-RT4500HD-3DX

X X X

DXE-RT4500HD-2MH

X X X

DXE-RT4500HD-3MH

X X X

Included Parts List

Part Number

Description

Qty

DXE-RT4500HD

Rotator

(1)

1

DXE-ROT-MTG-HWK

Patch Bolt

(2)

, 5/16-18 (18-8) x 3/4” Stainless Steel

4

Flat Washer, #18, Stainless Steel

4

DXE-LP20-F

4 pin control female cable connector with 6mm and 8-12mm water tight grommet

1 - Rotator Lift Strap – Aluminum

(3)

5-1/4” x 1” x 1/4”

1

-

Rotator Lift Strap Bolt

(3)

5/16-18 x 3/4”, Socket Head Cap, Stainless Steel

2

-

Rotator Lift Strap Flat Washer

(3)

5/16”, Stainless Steel

2 - Rotator Top Plate Snap Ring, spare, External 3/4” shaft, .704 groove, Black Phosphate

1

DXE-RT-UB-INS

Unboxing Information Sheet

1

DXE-RT4500HD-INS

Instruction Manual

1

(1)

Rotator Weight: With no mounting hardware and no clamp: Approximately 22 pounds

With all mounting hardware and 2” mast clamp: Approximately. 27 pounds

(2)

Single-Use Thread Lock Patch Bolts

(3)

For transport only – will be removed when rotator is installed

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Required Parts

JTL-12555 - Jet-Lube® SS-30™ Anti Seize – for all stainless steel hardware to avoid galling

LCT-37477 - Loctite® - 242 Medium Strength Threadlocker (blue)
TES-06143 – 3M Scotch® Super 88 Premium Vinyl Electrical Tape – to secure the rotator control cable to a

tower leg as needed and also to weatherproof the rotator cable connectors
TES-2155 – 3M Temflex™ 2155 Rubber Splicing Tape - to weatherproof the rotator cable connectors

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Rotator Control Box – Select One

DXE-RT-21DXE - Digital Universal Controller, manufactured by Green Heron
MOH-ARCO-115V – MicroHam ARCO Rotor Controller

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Tower Accessory Shelf – Select One

DXE-AS25G – Tower Accessory Shelf for Rohn 25 tower
DXE-AS455G – Tower Accessory Shelf for Rohn 45 and 55 tower

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Mast Clamp – Select One*

DXE-RTMC-2A – DX Engineering Rotator Top HD Mast Clamp for 2 in. OD mast
DXE-RTMC-3A – DX Engineering Rotator Top HD Mast Clamp for 3 in. OD mast

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Thrust Bearing – Select One*

DXE-TB300 – Advanced Design Thrust Bearing for 2 in. OD masts
DXE-TB400 – Advanced Design Thrust Bearing for 3 in. OD masts

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DX Engineering Chrome-Moly Mast – Select one*

DXE-ST200CM-22 - 2 in. OD Mast, Chrome-Moly 4130 Steel Tube, 100K PSI Min. Yield, 0.250 in Wall, 22 ft. L
DXE-ST300CM-22 - 3 in. OD Mast, Chrome-Moly 4130 Steel Tube, 100K PSI Min. Yield, 0.250 in Wall, 22 ft. L

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Bearing By-Pass Kit – Select One

DXE-BBGK-2-25-P - Bearing Bypass Ground Kit, for 2 in. OD Mast, 25G/45G Tower Leg
DXE-BBGK-3-25-P - Bearing Bypass Ground Kit, for 3 in. OD Mast, 25G/45G Tower Leg
DXE-BBGK-3-55-P - Bearing Bypass Ground Kit, for 3 in. OD Mast, 55G Tower, Leg

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* NOTE: If the antenna(s) used is (are) rated at a total of 18 square feet wind load or more,

it is highly recommended that a three inch mast be used.