HY GAIN CD 45IIX ROTATOR

User Manual: Pdf HY-GAIN--CD-45IIX-ROTATOR

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hy-gain

308IndustrialParkRoad

Starkville, MS 39759 USA

Ph. (662) 323-9538 FAX: (662) 323-6551

4511 / CD

4511X

Antenna Rotator CD-451I

has 110 VAC Controller CD-

45IIX has 220 VAC Controller

INSTRUCTION MANUAL

GENERAL DESCRIPTION

The CD-45-II Rotator consists of a bell-type rotator,

a metered control unit and the necessary mounting

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 with a 7 or 8 wire

cable. The control unit must be placed inside the

house or another

rotected location.

The CD-45-II now features 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

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

atibilit

. In

eneral

these will be:

A. The beam or antenna desired and a suitable

antenna mast

B. A tower or other mechanism to position the

rotator and beam for safe and effective rotation

(

see CAUTIONS

)

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

(

see Section V

)

D. Coaxial cable to connect the beam to the

communications e

ment.

E. Appropriate guy wires as required.

F. Ground Hardware.

Figure 1

Rotator and Control Unit

CAUTIONS

• 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

the wind, etc.,

• Metal towers or other

osition mechanisms must be

latted so that if the

fracture or blow over in

high winds, they cannot contact power lines, be a hazard to individuals, or endanger property.

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

DEBATED.

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 Antenna Size:

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 Interconnect 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)

• 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-

ron

rounded 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 carefully designed and manufactured to give many years of

trouble-free service when carefully and professionally installed. It consists of the strongest

and best commerciall

available com

onents.

TYPES OF INSTALLATIONS

There are three general types of installation (see Fig-

ures 4, 6, and 7).

UNBALANCED WEIGHT AND WIND

PRESSUR

1. The recommended installation is an "Inside"

Tower Mount, as shown in Figure 4, with a top

bushing or bearing to provide lateral support and

resist hi

h wind loads.

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.

When the rotator is properly mounted this way, it

can be rotated to turn an antenna 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 "Unbalanced 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 sim

ler.

3. A telescoping or other type mast, as shown in

Figure 6, can also be used. The lower mast

ort is re

uired for this installation.

There are variations of mounting, generally into one

of the above categories. For example, the rotator 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.

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 o

eration

rior to installation.

WIRING AND CHECK-OUT 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. It is

important that Terminal #I on the Rotator is

connected to Terminal #1 on the Control Unit

and so on. Attach and solder the ends of the

cable to the 8 pin connector supplied in the

connector parts pack Plug this connector into

the control unit when done.

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.

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.

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).

CAUTION

Shorts between terminals or grounded leads may

damage the rotator.

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".

Figure 3 Rotator Wiring

(Base)

Figure 2 Rotator Wiring

(control)

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

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

ou 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 if it is mounted horizontally, at any

angle, or upside down.

The rotator is mounted inside a tower (see Figure 3)

to the flat tower plate by means of four bolts

furnished in the hardware kit. Use the following

rocedure:

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-W-

S: 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 manner 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 concentrically

to the top bushing.

I. Return the rotator to full CW

osition.

FOR CUSTOMER'S USE ,

Enter the number/color of each lead connected to the

terminals, and pins of the plug.

1234

5678

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 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 tolerances are

required. It is important that the rotator does

not try to turn the mast eccentrically with the

bushin

or bearin

7. Tighten the four bolts carefully-to approximately

100 inch-

ounds of tor

ue.

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

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 3600

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.

Item

No.

Description

Screw, Pan head, 6-32 x 3/8"

52 Bolt, 1/4 - 20 x 1 1/4" 4

53 Clamp 4

54 U-bolt 4

55 Flat washer 4

56 Grommet 1

57 Terminal cover 1

58 Nut, 1/4" - 20 8

59 Lockwasher, s

lit, l/4" 1

Figure 4

Rotator Mounted Inside Tower

MAST MOUNTING

1. Mount the rotator to the lower mast support and to

the mast.

(

See Fi

ures 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 Fi

ure 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

Figure 6 Mast

Mounted Rotator

Figure 7

Rotator Mounted on Tower Top Plate

6. Raise the mast into position. Rotate the mast by

hand until the antenna director is headed North.

Tighten the base clamp. Line up the mast in the

vertical

osition and ti

hten the

wires.

TOP OF TOWER INSTALLATION

1. Mounting the rotator on top of a tower is similar

to the mast mounting except the lower mast

support is not used. (See Figure 8.)

2. The rotator is attached to the tower plate by means

of four bolts and lockwashers (see Figure 7).

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 to cut to clear the control cable.

3. Connect the control cable to the rotator after pass-

ing it through the tower plate. Tighten the

mountin

bolts securel

4. Assemble the mast and antenna to the top of the

rotator using the U-bolts, nuts and lockwashers

through the rotator and clamps as shown in

Figure 7. The maximum mast diameter that may

be used is 2 1/16" O.D.. Turn the antenna by

hand until the director is pointed North, then

hten the U-bolts securel

5. Tape the rotator control cable to the tower at

oints 18" to 24" a

art.

6. Connect the antenna cable to the antenna

(

manufacturer's recommendation). Make sure you

have enough slack for the 360° rotation. (the an-

tenna rotates "S" to "E" [counterclockwise] on

the first turn, therefore, slack should wrap

counterclockwise around the mast.) See Figure 7.

Figure 8

Rotator Mountin

on a Tower To

Plate

OPTIONAL ACCESSORIES

Product 121B is a thrust bearing that utilizes a

bronze/oil bearing. It will clear up to a 2 3/16"

diameter mast. It can be bolted to all Hy-Gain crank-

up towers when the rotator is mounted inside the

tower.

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 directl

under the meter to exactl

South.

The Tower Mounting/Spacing Kit is a flat plate

equipped with four 0.5 inch standard bushings

drilled to match the hold-down screw holes in the

bottom of a Hy-Gain bell type rotator.

The plate is designed to allow enough clearance

under the bottom of the rotator to clear the rotator

housing bolt heads and control cable.

PRELIMINARY

CHECK AND CALIBRATION

4. Meter Calibration Procedure: Operate the rotator

to its full clockwise position. Adjust the calibra-

tion potentiometer until the meter indicates full

scale to the right. The meter is now calibrated.

Do not adjust the calibration potentiometer 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 uit

is turned "ON' again. It will not damage the unit to

leave it turned "ON' for extended

eriods.

IMPORTANT

THERMAL PROTECTION: If the rotator fails

to turn after 4 or 5 minutes of continuous

operation, the thermal switch comes 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. Tom the Control Unit Power "ON' with the upper

right "ON-OFF" switch. The meter should be

illuminated and the needle should be to the ri

ht.

2. Depress the brake lever (center) and hold.

Depress the CCW lever (left) and operate the

rotator to its full CCW position. Observe the

antenna cable on the first rotation to insure it

does not get fouled.

To operate this rotator, depress the brake lever, then

depress either the CCW lever or CW lever. Hold both

levers down until the antenna reaches the desired

heading. Release the direction lever, then the brake

lever.

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 clad 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

accomplished 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 CENTERED METER

SCALE COVERSION

The stock CD-45-II Control Unit is shipped with the

meter scale installed for "North" center operation;

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 CD-45-I1 with an interchangeable

meter scale. See the note following Step #11.

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.

We recommend the following

1. Disconnect the

ower

9. Reinstall the meter (remove the temporary

jumper), the P.C. Board and lamp hardware.

Check for pinched, shorted end, or over-stressed

wires.

2. Remove the control cable, carefully label' g each

wire with its corresponding terminal number.

This operation may be omitted if the control

box can be worked on easily without removing

the leads.

10. Reinstall the to

and bottom

l 1. Reconnect the control cable in the exact

uence as the

were removed.

3. Remove the to

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.

If your beam was installed originally using the CD-

45II 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.

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.

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.

NOTE: In the past, the South Centered meter scale

was on the reverse side of the factory installed North

Center 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.

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.

ROTATOR CONSTRUCTION

(

Refer to Fi

ures 12

)

TROUBLESHOOTING

1. Outer Housing: The upper mast support (Bell)

and the brake housing are cast aluminum. The

upper mast support is secured to the brake

housing by four #12-24 x 3/4" self-tapping hex

head screws.

2. Position Sensor: The position sensing potentiome-

ter is located in the to

of the bell castin

3. Drive: A low voltage AC motor and its associated

gears drive the output ring gear at about 1 RPM.

The ring gear in turn is mechanically

interlocked in the u

er mast su

ort

(

Bell

)

4. Brake: The brake is a disc type which is an

integral part of the motor armature. When power

is applied to the motor, the armature lifts pulling

the two disc pads apart which allows the gear

train to operate freely. With no power applied,

the weight of the motor armature forces the two

brake pads together which in turn brakes the

rotator.

5. Rotation Limits: Activated by the stop arm are

two electrical end of rotation switches which dis-

connect the motor power just before the rotating

bell housing reaches its full CW (0°) or CCW

(

360°

)

ositions.

6. Bearings: Two rows of ball bearings are provided.

Lubricate sparingly with factory approved

special low temperature grease. This grease

allow normal o

eration to -30°F

(

-34°C

)

CAUTION

This unit has been thoroughly tested and cycled

before shipment. Follow the terminal board

wiring carefully between Rotator and Control

Box. Incorrect wiring will burn out the rotator

potentiometer and void the warranty.

Be sure Rotator and Control Units are compat-

ible. Do not intermix models with different oper-

ating voltages. This results in sluggish or non-

operating performance, burned out motors,

overheated transformers and burned out rotator

potentiometers, etc.

Most operational difficulties with rotators are

traceable to broken, shorted or grounded wires

usually at the terminal strips. Time spent in cutting

the leads to exact lengths, tinning, forming and

wrapping around terminals, cutting insulation to

exact len

ths

and clam

revent strain on an

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 it is due to actual play in

the rotator mechanism. A slight amount of "play" is

built into the rotator to avoid binding due to

environmental chan

es.

ANTENNA ROTATES IN HEAVY WIND

This is usually a matter of the mast slipping in the

support. 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. Check the nuts on the U-

bolts to insure that the

are ti

ht.

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 140 MFD motor start capacitor could be

at fault. It is recommended that a new capacitor be

tried before any other action is taken. If the electrical

circuit is okay, then check for. mechanical binding.

Pay particular attention to bearings and alignment of

the shaft on an inside tower mount. On any inside

tower installation, care must be exercised to get the

top mast shimmed to the exact rotational center of

the rotator upper mast support. If temperatures are at

-30°F (34°C) or lower, operation will be slow or

sluggish. This is normal!

IMPROPER METER INDICATION CHECKING THE CONTROL UNIT

The brake and motor operate independently of the

indicating system. If the pilot light bums at proper

brilliancy, the instrument transformer is okay and the

output is not shorted. Check the 1/8 amp meter circuit

fuse with an ohmmeter. Check for about 13 VDC

across Terminal No. 3 and No. 7 with the switch

'operated. If the proper voltage is not obtained, 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 Terminal

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 Control

Unit" and "Checkin

the Rotator from Ground".

GROUND WIRES

Grounds on cable leads can bum 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. For full explanations, refer to Figure 8

HELPFUL SUGGESTIONS

Be sure to check your rotator cable for shorting,

open circuits, incorrect wiring, intermittent

connections, shorted terminals, poor lead dress at

terminals, rodent damage, and mast support or thrust

b i bi di

1. Voltages with Unit Plugged In.

To check the control unit, plug the line cord into

AC power. With no connections to the connector,

turn the on-off switch to the "ON' position, the

meter light will illuminate. The meter needle will

remain on the left hand "S".

Connector pins 1 and 2 should show 30 volts AC

(approximately) when the brake lever is

depressed.

Connector pins 1 and 5 should show 30 volts AC

with brake release lever depressed and CW lever

ressed.

Connector pins 1 and 6 should show 30 volts AC

with brake release lever depressed and CCW

lever de

ressed.

Connector pins 3 and 7 should show

approximately 13 VDC.

2. Resistances with Unit Not Plugged In.

Disconnect the AC power source and remove

the control cable.

The control box can be checked without

removing the cover by using a volt-ohmmeter to

check values across connector pins. Resistances

across Connector pins 1 thru 5 with clockwise

switch lever (right hand) depressed and across

Connector pins 1 thru 6 with counterclockwise

switch lever (left hand) depressed. Resistance

across input line cord with on-off switch in the

"ON'

osition and the brake lever de

ressed

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 cable

connector from the control unit. From the schematic

diagram, it is apparent that the resistance of the lead

wires will be added to the resistance of the motor

windings and potentiometer strip in making the

resistance checks as shown in Table 2.

To Read Between

Check Resistance Terminals

1/2 Motor Winding

1/2 Motor + Switch

1.5 ohms

1-8

1-4

1-6

10. Sandpaper or wire brush the terminal strip. Rust

causes high resistance causing control/rotator not

to work properly.

Entire Motor 3.0 ohms 4-8 Service Information

ht Limit Switch 0 ohms + leads 8-5

Left Limit Switch 0 ohms + leads 4-6 If you are encounter technical problems and need

Entire Pot Strip 500 ohms 3-7 assistance, you should contact Hy-Gain Customer

Service Department.

Pot Arm to + End 0 to 500 ohms 1-3

Pot Arm to - End 0 to 500 ohms 1-7 All requests, inquires, warranty claims, or for

plus leads ordering replacement parts, contact:

ADDITIONAL CHECK LIST

Table 2 Hy-Gain

308 Industrial Park Road Starkville,

Mississippi 39759 USA Phone:

662

323

9538

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.)

5. Check both control and rotator terminal strips 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.

8. Substitute a 3 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.

PARTS LIST

CD-45-II Control Unit Replacement Parts

Item Part

1 5156502 Control Unit, 220VAC, com

lete .......................................................1

2 5156500 Control Unit, 120VAC, complete .......................................................1

3 5139000 Printed Circuit Board .......................................................................1

4 55135200 Capacitor, 470 mfd, 50V, C-1.................................................... ..... 1

5 5051314 Resistor, 390 ohms, 5% 2W, R-1..................................................... 1

6 5015300 Diode, Zener, VR-1..........................................................................1

7 85759002 Diode, CR-1.....................................................................................1

8 52154257 Resistor, IOK olun, 1/4 W, R-2.................... ................................... 1

9 5056300 Fuse, 1/8 Amp, F-1 ..........................................................................1

10 52874001 Holder Fuse......................................................................................2

11 1034403 Fuse, 3 Amp, F-2 (110V version) ............................................ ........ 1

12 5089501 Bulb, Meter, #1819 ..........................................................................1

13 710053 Fuse, 1 Amp, S16-Blo, F-2 (220V version) ...................................... 1

14 5138600 Switch, Snap, S03, S-4, S-5 ............................................................ 1

15 5141100 Cover, Top .......................................................................................1

16 5141200 Cover, Bottom..................................................................................4

17 5152700 Pads, Skid.........................................................................................9

18 520057 Screw, #6-32 x 3/8", Pan Head ....................................................... 1

19 567105 Washer.............................................................................................1

20 640076 Socket, 8-pin....................................................................................1

21 5088400 Lever, Switch, for S-3, S-4 & S-5.................................................... 1

22 450403 Relief, Strain, Heyco 3772 (220 V version) ..................................... 2

23 506665 Screw, #6-32 x 1/4", round head ...................................................... 2

24 560068 Washer, Back-up (220V version)........ ............................................1

25 1073501 Transformer, Power (220V version) . ..............................................1

26 1073301 Transformer, Power (120V version) ................................................1

27 5020200 Transformer, Meter (220V version) ................................................. 1

28 5017700 Transformer, Meter (120V version) ................................................. 1

29 5151501 Capacitor, Motor Start..................................................................... 1

30 5086100 Cord, Line, 3-wire (120V version) ................................................... 1

31 450431 Relief, Strain, Heyco 1217 (120V version) ...................................... 1

32 5079800 Cord, Line, 3-wire (220 VAC; European Plug) ............................... 1

33 5147702 Meter................................................................................................1

34 5175200 Switch, On/Off S-1 ..........................................................................1

35 723406 Potentiometer...................................................................................1

36 1056300 Holder, Fuse, for F-2; (120V version) ....... :......... ........................... 1

37 710054 Holder, Fuse, for F-2; (220V version) ............................................ 1

38 5156100 Plate, Face........................................................................................1

39 5089103 Chassis.............................................................................................1

HAM IV/CD-45-II Control Unit Re

lacement Parts

(

Continued

)

Item Part

No. No. Description Qty

40 506325 Bolt, Hex Head, 1/4"-20 x 3/4" .......................................................1

41 567110 Lockwasher, Int. 1/4" ..................................................................... 2

42 567120 Flatwasher, 1/4" ..............................................................................2

43 556960 Nut, Hex, 1/4"-20.............................................................................1

44 550029 Nut, Wing, 1/4"-20...........................................................................1

45 710083 Holder, Bulb.....................................................................................1

46 .567125 Lockwasher, #10 Internal................................................................ 4

Figure 9

Wiring Schematic

Figure 11

Control Unit-Back View

Figure 10

Control Unit-Top View

Figure 12

Control Unit - Front Panel

CD-45-II Rotator

Item

No. Part No. Description Qty

7 5011300 Retainer, ball bearing ...................................................................... 2

11 5023100 Potentiometer Assy. ......................................................................... l

12 -5030400 Support, upper mast (bell casting) ...................................................1

13 5030600 Ring, retaining..................................................................................1

15 5031300 Gear, driving ....................................................................................1

16 5033501 Bearings, ball .................................................................................50

24 5037406 Motor Assy....................................................................................... l

25 5039800 Board, Terminal ...............................................................................1

30 5105700 Screw, #12-24 x 3/4"....................................................................... 4

5042510 Accessory Kit......................................................................................1

51 107632061 Screw, round head............................................................................2

52 110820035 Bolt, 1/4-20 x 1 1/4" ....................................................................... 4

53 -5035100 Clamp, mast.....................................................................................4

54 5035200 U-bolt...............................................................................................4

55 5050200 Flat washer.......................................................................................4

56 5091400 Grommet..........................................................................................1

57 5033900 Terminal cover.................................................................................1

58 556960 1/4"-20, Nut .....................................................................................8

59 567115 1/4", split lockwasher.................................................................... 12

870598 Parts Pack, Connectors....................................................................... 1

60 640077 Plug, cinch, 8 pin .............................................................................1

61 650082 Amp socket......................................................................................8

62 650180 Shell amp .........................................................................................1

63 650181 Plug, amp .........................................................................................1

64 650293 Amp socket......................................................................................8

Figure 13

Overall View of CD-45II Rotator

Figure 14

Wiring Diagram

Tower Drilling Template

This information is believed correct, but no warranty is given or implied and no liability is

assumed by Hy-Gain as to its accuracy or completeness. Changes maybe made from time to

time so the user should verify all factors that may be critical. This information is not to be

construed as to authorizing or advising use of any patented invention.

HOLES TO BE 17/64” CLEARANCE DRILL

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 warrant

are satisfied.

1. 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

mone

order for $8.00 coverin

osta

e and handlin

3. Under no circumstances is Hy-Gain

liable for consequential damages to

erson or

ert

the use of an

-Gain

roducts.

4. 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

arran

ements are made.

5. 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.

7. All H

-Gain

roducts to be serviced in-warrant

or out-of-warrant

should be

addressed to hy-gain, 308 Industrial Park Road,

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.

8. This warranty gives you specific rights, and you may also have other rights which

vary from state to state.

LIMITED WARRANTY

HY GAIN CD 45IIX ROTATOR

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