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X740
Instructions manual
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Cushcraft X740 Instructions manual

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ASSEMBLY &
INSTALLATION
X740
40 Meter ADD-ON KIT FOR X7
COMMUNICATIONS ANTENNAS
951473 (5/98)
X740
Thank you for your purchase of the Cushcraft X740 40 meter add-on kit. This kit is designed and manufactured to give the best performance and trouble free service. The antenna will perform as specified if the instructions are followed during assembly and installation. Cushcraft operates a full service Technical Support staff to answer questions regarding assembly, tuning, parts and just about everything else. Please contact us by phone (603) 627-7877 (8 AM - 5PM Eastern time or voice mail after hours), FAX (603) 627-1764, or email techsup@cushcraft.com.
WARNING
THIS ANTENNA IS AN ELECTRICAL CONDUCTOR. CONTACT WITH POWER LINES CAN RESULT IN DEATH OR SERIOUS INJURY. DO NOT INSTALL THIS ANTENNA WHERE THERE IS ANY POSSIBILITY OF CONTACT WITH OR HIGH VOLTAGE ARC-OVER FROM POWER CABLES OR SERVICE DROPS TO BUILDINGS. THE ANTENNA, SUPPORTING MAST AND/OR TOWER MUST NOT BE CLOSE TO ANY POWER LINES DURING INSTALLATION, REMOVAL OR IN THE EVENT PART OF THE SYSTEM SHOULD ACCIDENTALLY F ALL. FOLLOW THE GUIDELINES FOR ANTENNA INSTALLA TION RECOMMENDED BY THE U.S. CONSUMER PRODUCT SAFETY COMMISSION AND LISTED IN THE ENCLOSED PAMPHLETS.
Antenna System Planning
Before assembly, take time to review your installation plans for the antenna. Location of the antenna is very important. Surrounding objects such as trees, power lines, buildings, and other antennas will interact with an HF Yagi. To minimize the effects of surrounding objects, mount the antenna as high and in the clear as possible. Metallic guy wire within 30 feet of this antenna, if broken with strain insulators, will improve performance.
OPERATION. DEADLY VOLTAGES AND CURRENTS MAY EXIST. ALSO, SINCE THE EFFECTS OF EXPOSURE TO RF ARE NOT FULLY UNDERSTOOD, LONG TERM EXPOSURE TO INTENSE RF FIELDS IS NOT RECOMMENDED. THERE IS A WARNING STICKER WHICH MUST BE ATTACHED TO THE BOOM AS SHOWN IN FIGURE A
they are qualified to assist you. Make certain that everyone involved understands that you are in charge and that they must follow your instructions. If you have any doubts at all, employ a professional antenna installation company to install your antenna.
System Grounding
Direct grounding of the antenna, mast and tower is very important. This serves as protection from lightning strikes and static buildup. A good electrical connection should be made to one or more ground rods directly at the base of the tower or mast using at least #10 AWG ground wire and non-corrosive hardware. For details and safety standards, consult the National Electrical Code. A coaxial lightning arrester should be used. Cushcraft offers several different models such as the LAC series.
Assembly
The assembly procedure for the X740 consists of assembling the following subassemblies. 1) Verification of Parts. 2) Element Assembly
3) Element to Boom Assembly. 4 )Feed System Assembly. 5) Element Truss Assembly. 6) X-hat Assembly Assembly of the X740 will
be easiest if the preceding steps are performed in the given order.
YOU MUST INSURE THAT NEITHER PEOPLE OR PETS CAN COME IN CONTACT WITH YOUR ANTENNA WHILE IT IS IN
. Plan your installation carefully. If you use volunteer helpers be sure that
Please read through the entire assembly procedure before beginning.
1-Verification of Parts
Verify all parts are present by using the X740 Master Parts List. Check off each part when it is counted. There are extra parts intentionally shipped with this antenna. Place common hardware in temporary containers for ease of assembly. Note all hardware is Stainless Steel.
Part No. Description Metric Equiv Quantity 124567 1" x 8" Drilled Fiberglass Insulator 2.5 x 20.3 cm 1 190026 Formed Aluminum Bracket 5 190028 Formed Aluminum Half Washer 4 194707 4" x 24" Drilled U-Channel Bracket 10.2 x 61 cm 1 200088 1" Diameter Formed Aluminum Clamp 2.5 cm 2 290326 Warning sticker 1 321045 3/8" Aluminum Spacer 1.0 cm 2 323718 Extruded Al V-Block 1 324071 Black Plastic Insulator 1 324509 4 x 5 1/4" x 3/16" Drilled Al Bracket 10.2 x 13.3 x 0.5 cm 2 EA 1-1/4" x 72" Drilled&slotted Al Tube w/insert 3.2 x 183 cm 2 EB 1-1/8" x 48" Al Tube slotted 1 end 2.8 cm x 183 cm 2 EC 1" x 48" Aluminum Tube slotted 1 end 2.5 x 183 cm 2 ED 1/2" x 48" Aluminum Tube slotted 1 end 1.3 x 183 cm 2 EE 3/8" x 36" Aluminum Tube 1.0 x 91 cm 2 EF 1-1/8" x 18" Aluminum Tube drilled 1 end 2.8 cm x 45.7 cm 1 LCA 40 Meter Loading Coil 2 MNX740 X740 Matching Network 1 XHR 3/8" x 34 1/2" Aluminum Rod drilled in center 1.0 x 87.6 cm 4 X79FS 1/2" Tinned Copper Braid 6" Long with Lugs 1.2 cm x 15 cm 2
1
41 11
941 11
231
231
567
X740
2 - Element Assembly
Figure A and B show the steps required for element assembly. Identify the parts required using the Element Subassembly Parts List. Slide EA sections over fiberglass insulator (567) until #8 screw holes line up. Insert screws (231) through holes and secure with lock washer (941) and nut (11). Insert EB tubes 4” (10.2 cm) into EA slotted ends until they stop against the EA insert tube and secure with worm clamp (412). Insert EC tubes 4" (10.2 cm) into slotted ends of EB and secure with worm clamp (411). Insert LCA coils 4" (10.2 cm) into slotted ends of EC and secure with worm clamp (411). Insert ED tubes 4" (10.2 cm) into slotted ends of LCA coils and secure with worm clamp (409). Insert EE tubes into ED tubes and adjust the element half lengths per Chart A. Secure EE tube with worm clamp (407). Place plastic caps (77) on ends of EE
Center Element
Frequency Half Length
(MHz) Inches Meters
7.000 250 6.35
7.075 248 6.30
7.150 246 6.25
7.225 244 6.20
7.300 242 6.15
ID Part # Description Dimensions Qty
11 010011 SS Nut #8-32 2
26 290326 Warning 1
41 011941 SS Lock #8 2
77 050077 Black 3/8’ 2
231 010231 SS Machine #8-32 x 1-3/4” 2
407 030407 Worm 5/8” 2
409 030409 Worm 11/16” 2
411 030411 Worm 1-1/8” 4
412 030412 Worm 1-1/2” 2
567 124567 Fiberglass 1” x 8” 1
EA Aluminum 1-1/4” x 72” 2
EB Aluminum 1-1/8” x 48” 2
EC Aluminum 1” x 48” 2
ED Aluminum 1/2” x 48” 2
EE Aluminum 3/8” x 36” 2
LCA LCA Loading 2
Sticker
Washer
Plastic Cap (0.9 cm)
Screw (4.4 cm)
Clamp (1.6 cm)
Clamp (1.7 cm)
Clamp (2.9 cm)
Clamp (3.8 cm)
Insulator (2.5 x 20.3)
Tube (3.2 x 183 cm)
Tube (2.8 x 183 cm)
Tube 2.5 x 183 cm)
Tube (1.3 x 183 cm)
Tube (1.0 x 91 cm)
Coil
EA
EA
26
412
EB
Element Half Length
411
EC
Figure B
2
411
LCA
409
ED
Figure A
407
EE
77
X740
#1
#2
#3
3 - Element to Boom Assembly
Figure C, D and E show the steps for element mounting on the X7 Boom. Identify the parts required using the Element to Boom Subassembly Parts List. Attach the two 4" x 5 1/4" Extruded AL Brackets (509) to the X7BA boom section in the unused hole between X7 elements #2 and #3. Use the hardware shown. Tighten the bolts in the order shown. Attach the U-Channel Plate (707) to the Element EA sections using 6 Cush-a-Clamps (97) and the 1/4" Lock Washers (84) and 1/4-20 Nylon Lock Nuts (99). Center the fiberglass insulator (567) in the center of the U-Channel bracket (707). Insure the #8 hardware in the fiberglass insulator (567) is parallel to the boom with the #8 nuts (11) towards the rear of the boom (reflector end), see Figure F. Attach the Element to the Boom by bolting the U-Channel bracket (707) to the element brackets (509) using the 1/4" hardware shown in Figure E. Place 1/4-20 bolt (82) thru holes in V-Block (18) and attach hardware as shown. Leave bolt loose until Step 6.
Figure C
84
592
509
85
85
212
99
82
84
82
84
99
99
Figure D
99
18
45
92
84
588
99
82
84
99
82
Tighten Last
Tighten First
99
84
Tighten Second
3
Figure E
707
X740
81
Drip Loop
ID Part # Description Dimensions Qty
18 323718 V-Block 1
41 011941 SS Lock #8 4
45 321045 Aluminum 3/8” 2
81 032881 Worm 2-3/4” 2
82 010082 SS Hex 1/4-20 x 1” 7
84 010084 SS Lock 1/4” 22
85 010085 SS Nut 1/4-20 2
87 014387 SS Lock #8-32 4
97 014497 Cush-a 1-1/4” 6
99 014399 SS Lock 1/4” 22
212 010212 SS Hex 1/4-20 x 2” 2
509 324509 Aluminum 4” x 5-1/4 x 3/16” 2
588 014588 SS Hex 1/4” x 3-1/2” 1
592 014592 SS Flat 1/4” (1/8” thick) 2
707 194707 U-Channel 4” x 24” 1
MNX MNX740 Matching 1
X79FS Copper 1/2” x 6” 2
Washer
Spacer (1.0 cm)
Clamp (7 cm)
Bolt (.6 x 2.5 cm)
Washer (.6 cm)
(.6 cm)
Nut
Clamp (3.2 cm)
Nut (.6 cm)
Bolt (5.1 cm)
Bracket (10.2 x 13.3 x .5 cm)
Bolt (.6 x 10.2 cm)
Washer (.6 x .3 cm)
Bracket (10.2 x 61 cm)
Network
Braid (1.2 x 15 cm)
MNX
Figure F
81
41
87
1”
(2.5 cm)
87
41
X79FS
41
87
41
87
99
84
4 - Feed System Assembly
Figure F shows the steps for feed system assembly. Identify the parts required using the Feed System Subassembly Parts List. Position the Matching Network (MNX) on the bottom of the X7 boom on the reflector side of the 40 meter driven element. Space the MNX feed screws 1"(2.5 cm) from the U-Channel bracket (707). Secure the MNX to the boom using two worm clamps (81). Attach the Feed Straps (FS) to the two screws on the MNX and the two driven element screws with the hardware shown. Position the Feed Straps away from the U-Channel bracket (707).
99
84
97
4
X740
5 - X-Hat Assembly
Figure G shows the steps for assembly of the two X-Hats. Identify the parts required using the X-Hat Subassembly Parts List. Two XHR rods attach to each 40 meter coil (LCA). Use the hardware shown in Figure G. The rods may be mounted in any position relative to the element or boom.
ID Part # Description Dimensions Qty
41
28
31
XHR
26
31 010231 SS Machine #8-32 x 1-3/4” 4
41 011941 SS Lock #8 4
87 014387 SS Lock #8-32 4
26 190026 Aluminum 4
28 190028 Aluminum 4
XHR Aluminum 3/8” x 34-1/2” 4
87
Screw (4.4 cm)
Washer
Nut
Bracket
Half Washer
Rod (1.0 x 87.6 cm)
XHR
41
31
Figure G
26
87
28
5
X740
6 - Element Truss Assembly
Figures H, I, J and K show the steps for assembly of the element truss. The truss is not required for mechanical strength, it is provided so the 40 meter element will have the same form as the other X7 elements. The 40 meter element is mechanically designed for 90+ mph wind survival without the truss. Identify the parts required using the Element Truss Subassembly Parts List. Place 1" (2.5 cm) clamps (88) on EC sections of element 2" (5.1 cm) from the slotted end of EC. Use the hardware called out in Figure J. Compress the clamp completely. Refer to Figure I and insert the EF tube into the hole in the V-Block (18). Slide EF as far down as possible. Attach Insulator (71) to drilled end of EF using hardware shown in Figure H. Connect one end of Phillystran cable (22) to one of the element clamps (88) using three cable clamps (24). Loop the Phillystran cable through the insulator and attach the loose end to the other element clamp (88) while keeping the cable tight. Secure the cable with 3 cable clamps (24).
Place plastic cap (31) on drilled end of EF tube. Adjust the 40 meter element to match the other elements by raising the EF tube. Tighten V­Block (18) bolt to secure EF tube.
ID Part # Description Dimensions Qty
22 094622 Phillystran 1/8” x 30’ 1
24 024624 Cable 1/8” 6
26 190026 Aluminum 1
31 050131 Plastic 1-1/8” 1
32 010232 SS Machine #8-32 x 2-1/2 1
41 011941 SS Lock #8 1
59 024259 Thimble 1/8” 2
71 324071 Black Plastic 1
82 010082 SS Hex 1/4-20 x 1” 2
84 010084 SS Lock 1/4” 2
87 014387 SS Lock #8-32 1
88 200088 Aluminum 1” 2
99 014399 SS Lock 1/4-20 2
104 010104 SS Flat 1/4” 2
207 010207 SS Flat 3/8” 2
EF Aluminum 1-1/8” x 18” 1
Cable (.3 x 9.1m)
Clamp (.3 cm)
Bracket
Cap (2.9 cm)
Screw (6.4 cm)
Washer
(.3 cm)
Insulator
Bolt (2.5 cm)
Washer (.6 cm)
Nut
Clamp (2.5 cm)
Nut (.6 cm)
Washer (.6 cm)
Washer (.95 cm)
Tube (2.8 x 45.7)
87
207
Figure J
31
259
71
104
26
41
EF
24
32
22
Figure J
18
99
22
24
24
82
Figure J
88
Load bearing
cable lays in
bottom of saddle.
Bottom of saddle
Figure K
6
X740
SPECIFICATIONS For X7 wtih X740 Kit Installed
Frequency Coverage (Meters) 10, 15, 20, 40 Total number of Elements 8 Free Space Gain (dBi) 40M 2.0
@ One Wavelength 15M 7.3
above ground 10M 7.0 Maximum Front to Back Ratio (dB) 30 Number of Elements per Band 3 (1 on 40M) VSWR Minimum 1.1:1 VSWR 1.5:1 Bandwidth (KHz) 40M 100
Longest Element, ft (m) 41 (12.5) Turning Radius, ft (m) 20.0 (6.09) Boom Length, ft (m) 18 (5.49) Boom Diameter, in (cm) 2-1/2 (6.35) Maximum Mast Diameter OD, in (cm) 2-1/2 (6.35) Maximum Wind Survival, mph (kph) >100 (>161) Maximum Wind Surface Area, ft
2
(m2) 9.9 (.92) Windload @ 80 mph, lb (kg) 253 (114.8) Maximum Power Handling (KW) 2 Weight, lb. (kg) 80 (36.3) Design Safety Factor 1.25
20M 7.3
20M 600 15M 750 10M 1700
Cushcraft Corporation, 48 Perimeter Road, Manchester, New Hampshire 03103, warrants to the original consumer purchaser for one year from date of purchase that each Cushcraft antenna is free of defects in material or workmanship. If, in the judgement of Cushcraft, any such antenna is defective, then Cushcraft will, at its option, repair or replace the antenna at its expense within thirty days of the date the antenna is returned (at purchaser's expense) to Cushcraft or one of its authorized representatives. This warranty is in lieu of all other expressed warranties. Any implied warranty is limited in duration to one year. Cushcraft Corporation shall not be liable for any incidental or consequential damages which may result from a defect. Some states do not allow a limitation on how long an implied warranty lasts or exclusions or limitations of incidental or consequential damages, so the above limitation and exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This warranty does not extend to any products which have been subject to misuse, neglect, accident or improper installation. Any repairs or alterations outside of the Cushcraft factory will nullify this warranty.
48 Perimeter Road, Manchester NH 03103 USA • Telephone: 603-627-7877 • Fax: 603-627-1764 • E-mail: sales@cushcraft.com
Web Site: http://www.cushcraft.com • International - Tel: +1-603-627-7877 • Fax:+1-603-627-1764
Limited Warranty
COMMUNICATIONS ANTENNAS
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