Hy-Gain CD-45IIX Instructions

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Starkville, MS 39759 USA

Ph. [phone] FAX: [phone]

INSTRUCTION MANUAL

GENERAL DES CR IPTION

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Antenna Rotator CD-451I
has 110 VAC Controller CD­45IIX has 220 V AC Controller

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The CD-45-II Rotator consists of a bell-type rotator,
a metered control unit and the necessary mount ing
hardware. The rotator is designed to mount on a
plate inside a tower or on a mast. The rotator unit
must be wired to the control unit w ith a 7 or 8 wire
cable. The control unit must be placed inside the
house or another

The CD-45-II now feat ures a NEW 8 pin connector
on the rear panel of the control unit for easy
connection to your cable.

Included with this product are the following:

A. Instruction Manual
B. Rotator Unit

C. Controller Unit

D. Mountin

rotected location.

Hardware Pack E.

Due to the wide variety of towers available, each
installation will have different requirements. The
gauge of the 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. For this reason, the owner must procure
the remainder of the ,components after checking
their com

A. The beam or antenna desire d and a suitable

B. A tower or other mechanism to position the

C. 7-wire cable to connect the control to the rotator

D. Coaxial cable to connect t h e beam to the

atibility. In general, these will be:

rotator and beam for safe and effectiv e rotation

see CAUTIONS):

see Section V).

communications e

ment.

E. Appropriate guy wi r es as r equired.
F. Ground Hardware.

Figure 1

SPECIFICATIONS

Input Voltage 120 VAC 50/60 Hz
Optional 220 VAC 50/60 Hz
Motor 24 VAC, 2.25 Amp, split phase
Power Transformer 120 VAC/26 VAC

10% duty, thermal switch protected

Optional 220 VAC/26 VAC

10% duty, thermal switch protected
Meter Transformer 120 VAC/23 VAC
Optional 220 VAC/23 VAC continuous duty
Meter DC Voltmeter 1000 ohms/volts

1 MA full scale

Meter Scale Direct Reading:

North centered, 5 degree increments

Optional Direct Reading:

South centered, 5 degree increments
Maxumim Ante nna Si ze :
A. Tower mounted as per Figure 3 8.5 square feet (.79 sq. m) of wind surface area
B. Outside tower or mast mounted as per Fig. 5 or 7 5.0 square feet (.46 sq. m) of wind surface area

Operational Temperature Range -30 degrees to 210 degrees F (-34 to 99 degrees Celsius)
Maximum Int erconnect Cable Resistance:
A. Terminal 1 1.0 ohms
B. Terminals 3, 4, 5, 6, 7, 8 2.5 ohms
Rotation Time 45-60 seconds with 60 Hz input
Brake Automatic Disc Type
Rotator Size 8 inches (20 cm)

Maximum diameter by 17 3/8 inches (44 cm) high
Maximum Antenna Mast Size 2 1/16” O.D. (52 mm)
Mounting Hardware Plated Steel Hardware and Plated Steel Clamps
Control Unit Size 8.5 inches (21.6 cm) wide by 9.0 inches (22.8 cm) deep
Shipping Volume 2411.02 cubic inches (0.0395 cu. M)
Shipping Weight 22.0 pounds (9.98kg)

• Towers, often the highest metal parts in the vicinity, require extreme 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

• Metal towers or other position mechanisms must be platted so that if they fracture or blow over in
high winds, they cannot contact power lines, be a hazard to individuals, or endang er proper ty .

• When not mounted within a tower with a thrust bearing as shown in Figure 4, the rotutor must be
DEBATED.

• Metal towers must be grounded properl y at the tower location befo re the tower Is erected.

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This
bare aluminum

to minimize electrical hazard and the possibility

is

or stakes in the ground. Use copper ground stakes. The service

wires

lightning damage. Do not bury

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entrance ground should be checked. The household convenience outlet should be the 3-

rong type (grounded back to the service entrance).

• The Control Box is not weatherproof and must be located in the house, ham shack or other
protected location.

The CD-45II Rotator has been ca refully designed and m anu factur ed to give many years of
trouble-free service when carefull y and prof essionall y installed. It consist s of the st rongest
and best commercially available components.

TYPES OF INSTALLATIONS

There are three general types of installation (see Fig­ures 4, 6, and 7).

1. The recommended installation is an "Inside"
Tower Mount, as shown in Figure 4, with a top
bushing or bearing to provide l ateral support and
resist hi

h wind loads.

When the rotator is properl y mounted this way, it
can be rotated to turn an antenn a or beam of 8.5
square feet 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 overturning force induced in a
high wind ( see "Unbalance d Weight" and "Wind
Pressure"

.

2. An "Outside" Tower Mount, as per Figure 7, is the

best type of installation when not using an inside
tower mount. The rotator is not as well protected
but the installation is simpler.

3. A telescoping or other type mast, as shown in
Figure 6, can also be used. The lower mast
support is required for this installation.

There are variations o f mounting, generally into one
of the above categories. For ex ample, the rot ator may
be mounted lower in the tower than shown in Figure

4. In that case, more than one bushing or thrust

bearing for the beam mast may be required and
longer coast down time allowed in operation. These
factors are interrelated and the components must be
matched together.

UNBALANCED WEIGHT AND WIND

PRESSUR

1. Unbalanced Weight: Weight should be as closely
balanced as possible. Unbalanced wight creates a
bending moment of force which is concentrated
on the mast at the point where it is 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
and gear train. Unbalanced 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 installation
to withstand unbalanced weight and pressure the
top mast should be as short and as strong as
possible. In multiple arrays the heaviest should be
closest to the rotator. In order to distribute the
bending stress and prevent fracture of the mast,
the CD-45-1I Rotator includes two specially
designed steel clamps to secure the mast to the
rotator.

After procuring the type of tower or other
positioning mechanism of the owner 's choice, the
next step is to wire the rotator to the control box
and check out its operation prior to installation.

WIRING AND CHECK-OUT

A preliminary operation check should be made prior
to installation. We recommend the following

NOTE: The CD-45-1I requires only 7 wires to
operate properly since Terminal 2 in the rotator is
unterminated. However, if an 8-wire cable is used,
the Ham IV rotator can be installed at a later time
without changing the cable or control.

C. With the Control Unit and Rotator on the work

table, connect the cable between the Rotator
and Control Unit using the full length ofcable
that will be used in the installation.

important that Terminal #I on the Rotator is
connected to Terminal #1 on the Control Unit

and so on. Attach and solder the ends
cable to the 8 pin connector supplied in the
connector parts pack Plug this connector into
the control unit when done.

of

It is

the

If the Hy-Gain Ham IV is required, due to a larger
antenna being installed, it will only be necessary to
purchase the Ham 1V Rotator, Part Number

5137201. The control units and cable requirements
are identical, therefore, only the installation of the
heavier duty rotator will be necessary.

A. Decide the wire gauge (size) required and obtain
the number of feet of the proper cable (see Table 1).

B. Strip and tin 3/8" on each wire end after removing

about 4 inches of the jacket from one end of
cable. Tinning can be accomplished, after
twisting the strands together, with an ordinary
soldering iron and radio solder, being careful not
to melt the insulation. On the end to be
connected to the control unit, strip the jacket
about 2 inches and strip the insulation from each
wire end 3/8".

NOTE: The specifications call for heavier gauge
wire on Terminal #1. Lead #1 must be heavier
gauge and less total lead resistance (see
Specifications, page 2). Wire the control to the
rotator as shown in Figure 3.

CAUTION

Shorts between terminals or grounded leads may
damage the rotator.

Figure 2 Rotator Wiring

(control)

Figure 3 Rotator Wiring

(Base)

D. Install four 1/4"-20x 11/4" bolts in the four

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mounting holes in the bottom of the bell
housing. Run them in about a 1/2" and leave
them as close to equal length as possible.

E. With the rotator sitting in the upright position,

resting on the four 1/4"-20 x 1 1/4" bolt heads
and connected to the control unit by the cable,
plug the power cord into a 120 VAC 50/60 Hz
or 220 VAC 50/60 Hz wall socket, depending
on which unit you have.

MOUNTING INSIDE THE TOWER

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
angle, or upside down.

The rotator is mounted inside a tower (see Figure 3)
to the flat tower plate by means

furnished in the hardware kit. Use the following

rocedure:

it is mounted horizontally, at any

if

of

four bolts

F. Turn the power switch on. The meter should be

illuminated.

G. Depress the "Brake Release" (Center) lever, hold

it, and simultaneously depress the CCW
direction switch (left). The rotator should turn
CCW (looking from the top). This is S-E-N-W­S: Release the CCW direction switch; the
rotator will coast down and stop. Now release
the brake switch. The rotator is now locked into
position.

H. Repeat Step G for CW direction by depressing

the brake switch first, then the CW direction
switch (Right).

CAUTION

It is best to release the direction switch just prior
to the end of rotation (extreme CW or CCW
position) in order not to cause undue stress on
the stop arm and/or the gears.

1. Locate the rotator in the tower directly under the
bushing. Note that the tower plate must be cut out
to allow the connecting cable to pass through the
plate

2. Reattach the wires in the same mann er as used in

the trial assembly and secure the wires to the
tower in such a manner that the wires will not be
strained.

3. The rotator is attached to the tower plate by

means of fourbolts and lockwashers (see Figure

3). Spacer washers must be used between the
rotator and plate for clearance of the rotator
housing bolt heads. The flat tower plate must be
drilled in four places using the template
provided with this manual unless the tower plate
is already properly drilled. A fifth hole must be
drilled or cut to clear the control cable.

4. Tighten the four bolts, but not to final tightness.

Observe how the rotator turns. It must rotate in
such a manner as to turn the mast concentric ally
to the top bushing.

I. Return the rotator to full CW

FOR CUSTOMER'S USE ,

Enter the number/color of each lead connected to the
terminals, and pins of the plug.

1234

5678

osition.

5. Trial assemble the mast to the top of the rotator
using the U-bolts, nuts and lockwashers through
the rotator and clamps as shown in Figure 3. 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 standard wall thickness
of .145". For stacked arrays or very large beams,
we recommend extra heavy-duty wall
thickness.200". Both steel pipes can be
purchased to specification ASTM-120.

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" (21/16")
(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. If

the rotator, top bushing and mast are properly
aligned, there should be unrestricted rotation
through

360°. If

be moved slightly on the flat plate.
quality bearing is used in the top

(recommended),

not, the rotator may have to

If

of

the shimming procedure must
be done more carefully as closer tolerances are
required.

It is important that the rotator does
not try to turn the mast eccentrically with the
top bushing or bearing.

a high

the tower

7. Tighten the four bolts carefully-to approximately
100 inch-pounds of torque.

Return the rotator to the full CW "S" position.

8.

Mount the beam pointing South. The coaxial
cable should be looped in such a manner that it
will not foul or tangle when the beam turns
around in a circle to the full

360

counterclockwise position. (The antenna rotates
"S" to "F' [counterclockwise] on the first turn,
therefore slack should wrap counterclockwise
around the mast.) Tighten the U-bolts

securely.

0

Item

No.

51

52
53
54

55
56
57

Screw, Pan head,
Bolt, 1/4 -

Clamp 4
U-bolt 4

Flat washer 4
Grommet 1
Terminal cover 1

58 Nut, 1/4" -

Description

1 1/4" 4

20 x

20

6-32 x 3/8"

59 Lockwasher, split, l/4" 1

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2

8

Figure 4

Rotator Mounted Inside Tower

MAST MOUNTING

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1. Mount the rotator to the lower mast support and to
the mast. (See Figures 5 & 6.

2. Attach one end of the control cable to the rotator
terminals. Use the same sequence as used on the
pre-installation check. The cover and grommet
must be slipped over the cable prior to attaching
it to the terminals on the rotator. (See Figure 4.

3. Tape the rotator control cable to the mast at points

18" to 24" apart.

4. Connect the antenna cable to the antenna (follow
manufacturer's recommendation). Make sure
you have enough slack for the 360° rotation.
(The antenna rotates "S" to "E"
[counterclockwise] during its first turn,
therefore, slack should wrap counterclockwise
around the mast.) See Figure 6.

5. Attach the mast guy wires to the rotator lower
mast support or mast ring

Figure 5

Rotator Mounting with Lower Mast Support