DX Engineering Thunderbolt DXE-7580VA-1 User manual

75 and 80 Meter

DX Engineering

Thunderbolt™

Monoband

Vertical Antenna

DXE-7580VA-1

US Patent No. 8,130,168

DXE-7580VA-1-INS Revision 4b

P.O. Box 1491 ∙ Akron, OH 44309-1491 USA

Phone: (800) 777-0703 ∙ Tech Support and International: (330) 572-3200

Fax: (330) 572-3279 ∙ E-mail: [email protected]

- 1 -

Table of Contents

Introduction & Features

Warning

Tools Required

Manual Updates and Information

Installation Sequence

Site Selection

Mounting Pipe

Coaxial Cable to Mounting Pipe

Radial System

Assembly Notes

Radial Plate to Mounting Pipe

Attaching Ground Radial Wires to the Radial Plate

Overall Pivot and Antenna Base Assembly Drawing

Pivot Base and Lower Antenna Assembly

Mounting and using the Optional DXE-VRW-1 Manual Winch

General Information about Aluminum Tubing

Assembling the Vertical Sections

Mating the Vertical Elements to the Pivot Base Assembly

75/80 Coil Assembly and Installation

Base Matching Network Assembly and Installation

Optional DXE-7580-THK Capacity Hat Assembly and Installation

Tuning the Vertical

Operation of the DXE-7580VA-1 for CW portion of the band

Locking the Pivot Base

DXE-7580VA-1 Part Lists

Pivot Base Assembly

Optional DXE-VRW-1 Manual Winch Assembly

Feedpoint Hardware

Vertical Elements Assembly

75/80 Coil Assembly

Base Matching Network Assembly

Optional DXE-7580-THK Capacity Hat Assembly

Additional Material Needed but not Supplied

Suggested Parts Not Included

Optional Accessory Items

Technical Support and Warranty

- 2 -

Introduction

Congratulations on obtaining your DX Engineering DXE-7580VA-1 Vertical Antenna! Now you

can have a high-performance vertical antenna specifically for the 75/80 meter band! The DX

Engineering 53 to 55-foot Monoband Vertical Antenna supplies the highest possible performance

with simple, sleek appearance. Achieve the strongest possible presence at your power level and be

competitive!

The DX Engineering DXE-7580VA-1 80/75 meter band vertical antenna is tunable down to 3650

kHz center frequency with 300 kHz bandwidth. This means that operation on the CW DX

frequencies and DX Phone frequencies is within range of most radio internal tuners - no antenna

changes are necessary to switch frequencies!

The optional patented CW Optimizer DXE-7580-THK Capacity Hat Kit allows adjustment down to

3400 kHz center frequency for dedicated CW ops and military/MARS ops. The DXE-7580-THK

consists of hub and 48" adjustable rods. Easy to add to or remove from upper antenna mast with two

studded element clamps after lowering antenna.

The DX Engineering DXE-7580VA-1 is a slow taper 53 to 55-foot high Monoband Vertical

Antenna system. The vertical antenna is specifically designed to operate on 75/80 meters. Included

with this antenna system is a rugged stainless steel pivot fixture for ease of assembly and

adjustments. Engineered with 6063 corrosion-resistant aluminum tubing, stainless steel mounting

brackets and stainless steel hardware, this antenna is very durable and attractive.

Features

High Efficiency Design

High Efficiency center loaded design - strongest signal possible

5 kW SSB and CW rated - unparalleled reliability

DX Engineering Adjustable Matching Network configures the lowest SWR

Broad 2:1 SWR bandwidth - 300 kHz

Lowest possible take-off angle reduces domestic QRM signals

High Strength Pivoting Fixture - US Patent No. 8,130,168

Ultra-rugged construction starts with 3 inch OD Aircraft Grade heavy wall tubing

Self supporting - will withstand steady-state winds in excess of 50 mph without guying

(guying required under extreme wind speed conditions)

Extremely high strength heavy wall tubing made to DX Engineering specifications

Massive Extren® channel insulator

The optional DXE-VRW-1 Manual Winch for easy one-person raising and lowering of the antenna

is available from DX Engineering. You can move the DXE-VRW-1 winch between similar

antennas in a multi-antenna installation.

- 3 -

This antenna system requires a heavy duty mounting pipe. Recommended installation should

provide up to 3" OD heavy wall galvanized steel pipe set in concrete. Schedule 80 pipe that is called

2-1/2" has an outside diameter of 2.875" is recommended. 36" of the mounting pipe should extend

above ground level. Depth of the mounting hole and amount of concrete is dependent on local soil

type, condition and antenna guying.

WARNING!

INSTALLATION OF ANY ANTENNA NEAR POWER LINES IS DANGEROUS

Warning:Do not locate the antenna near overhead power lines or other electric light or power

circuits, or where it can come into contact with such circuits. When installing the antenna, take

extreme care not to come into contact with such circuits, because they may cause serious injury or

death.

Overhead Power Line Safety

Before you begin working, check carefully for overhead power lines in the area you will be

working. Don't assume that wires are telephone or cable lines: check with your electric utility for

advice. Although overhead power lines may appear to be insulated, often these coverings are

intended only to protect metal wires from weather conditions and may not protect you from electric

shock

Keep your distance! Remember the 10-foot rule: When carrying and using ladders and other long

tools, keep them at least 10 feet away from all overhead lines - including any lines from the power

pole to your home.

Tools Required

Two 9/16" wrenches, (one of them should be open-end)

One 7/16" open end wrench

Two 3/4" wrenches

Medium size flat blade screwdriver or 5/16" nut driver for the element clamps

Tape measure

Felt-tip marker

Small Phillips Head Screwdriver

- 4 -

Manual Updates and Information

Every effort is made to supply the latest manual revision with each product. Occasionally a manual

will be updated between the time your DX Engineering product is shipped and when you receive it.

Please check the DX Engineering web site (www.dxengineering.com) for the latest revision manual.

Please - Take the time to read the entire manual before you start assembly. There are plenty of

pictures and drawings to see, and if you read the entire manual first, you'll get a better feel for the

overall construction methods described. Assembly is not difficult, but there are a number of parts

that must go together in a certain sequence to make assembly easier.

Installation Sequence

1. Site Selection

2. Mounting Pipe

3. Coaxial Cable to Mounting Pipe

4. Radial System

5. Pivot Base Assembly (US Patent No. 8,130,168)

6. Mounting Pivot Base to Mounting Pipe

7. Antenna Assembly

8. Tuning

Site Selection

Select a mounting location clear from power lines, structures and other antennas by a minimum of

65 feet (55 + 10 ft safety rule). Consider overhead power lines, utility cables and wires. The

further away the vertical is mounted from local noise sources or other metallic objects, which can

re-radiate noise and affect the tuning, radiation pattern and SWR, the better. Determine the direction

you want the antenna to pivot and make sure there is adequate clearance (at least 65 feet).

Mounting Pipe

Use a customer supplied 2-1/2" schedule 80 galvanized steel thick-walled mounting pipe at least

7-1/2 feet long. The 2-1/2" schedule 80 galvanized steel pipe will have an outside diameter of

2.895". This will allow 4-1/2 feet below ground and 3 feet above ground.

Some manufacturers use the term DOM (drawn over mandrel) which will give you a true OD

dimension. Other types of mounting pipe may be used but due to lateral strength needed ensure the

mounting pipe is strong enough. The material most available is ASTM A513 Type 5 which is a

1020 material. Some pipe suppliers list the material as either 1020 or 1026. Type 1020 has the

following properties:

ASTM A513 (1020): Up to 2-3/4" OD with maximum wall thickness of 0.125"

Tensile: 80,000 PSI. Yield: 70,000 PSI. Elongation in 2": 15%. Rockwell Hardness: B80

- 5 -

ASTM A513 (1020): Over 2-3/4" OD with wall thickness heavier than 0.125"

Tensile: 70,000 PSI. Yield: 60,000 PSI. Elongation in 2": 20%. Rockwell Hardness: B80

The following sizes of 65,000 PSI yield tubing are also suggested:

2.50" OD x 0.375" wall thickness

2.50" OD solid bar

3.00" OD x 0.25" wall thickness

Depending on your geographic location, various dealers should be able to supply the mounting post

you specify. The following dealers can supply DOM tubing: (Other dealers in your area may be a

better choice.) On Line Metal Store: www.onlinemetals.com

Speedy Metals: www.speedymetals.com

Metals Depot: www.metalsdepot.com

Note: DX Engineering does not recommend or endorse any specific vendor.

This mounting pipe must be permanently mounted in the ground, preferably in a concrete base 2

feet by 2 feet by 4 feet deep (with gravel below for drainage). The antenna system requires this type

of mounting to help withstand the lateral forces present on

the antenna during wind conditions and when operating the

pivot function. Make the hole deep enough to

accommodate at least 4 feet of pipe and 4 to 6 inches of

gravel at the bottom for drainage. Set the mounting pipe on

the gravel, use the concrete to fill around the pipe per the

concrete instructions. Fill the hole until the concrete is level

with the ground around it. Use a level on the mounting pipe

as you fill the hole to be sure the mounting pipe is

vertically straight.

Your location, landscape and ground conditions may

require different mounting solutions in order to have the

steel mounting pipe and the vertical antenna in a secure

position.

Note: Galvanized steel, rather than aluminum, is much

more suitable for mounting in concrete.

Aluminum will quickly corrode due to

incompatibility with the materials used to make

concrete.

Coaxial Cable to Mounting Pipe

The coaxial cable should be routed to the base of the antenna system and be buried below the radial

system. PVC Conduit pipe may be used to house the coaxial cable. Bury the cable 6" to 12" below

ground level.

- 6 -

Radial System

The use of a radial system is a key requirement for a high performance quarter wave vertical

antenna system. With a vertical antenna system, the radials are the

second half of the antenna. The radials contribute to the radiation

efficiency of the entire vertical antenna system.

At a minimum, 32 radials, each 65 feet long, should be used with

this antenna. DXE-RADW Radial Wire, a 14 gauge stranded copper

with a black relaxed PVC insulation wire is suggested for the best

results.

The wire radials should placed as symmetrically as possible straight

from the feedpoint around the vertical antenna and spaced evenly,

regardless of how many radials are used. Do not cross or bunch any

radial wires as this nullifies their effectiveness. If you have limited space, put in as many straight

radials as you can. The radials must be connected to the shield of your feedline. The DXE-RADP-3

Stainless Steel Radial Plate is an ideal optional item which provides an excellent system for

attaching radial wires to your vertical antenna system feedpoint.

Radial wires can be laid on the roots of the grass using DXE-STPL Radial Wire Anchor Pins to

hold them down. Using enough staples will ensure the wires will not be snagged by mowers,

people, or animals. Grass will quickly overgrow the radials and it will be virtually impossible to see

them. An article describing this process is available on the DX Engineering website in the Tech

Info section. Radials can also be buried just under the surface by using a power edger to make a slit

in the soil.

Assembly Notes

Note: DXE-P8A Penetrox™A Anti-Oxidant should be used between all antenna element

sections. Penetrox™ A is an electrical joint compound to affect a substantial

electrical connection between metal parts such as telescoping aluminum tubing or

other antenna pieces. It ensures high conductivity at all voltage levels by displacing

moisture and preventing corrosion or oxidation.

Note: UMI-81343 Never-Seez® or DXE-NSBT8 Anti-Seize should be used on all clamps,

bolts and stainless steel threaded hardware to prevent galling and to ensure proper

tightening.

- 7 -

Note: The following assembly instructions are based on using a customer supplied

2.895" OD Mounting Pipe, with the optional DXE-VR-1 Manual Winch,

optional DXE-RADP-3 Radial Plate, optional DXE-363-SST Bulkhead

Connector and the optional DXE-7580-THK Capacity Hat Assembly.

Radial Plate to Mounting Pipe

Place the optional DXE-RADP-3 Radial Plate over the 2.895" OD mounting pipe. Connections to

the antenna will be made via the optional DXE-363-SST bulkhead fitting SO-239 socket connector.

The DXE-RADP-3 Radial Plate comes with 20 sets of stainless steel hardware for mounting the

radial wires. It is suggested that 32 radial each 65 feet long be used, therefore additional DXE-

RADP-1HWK Radial Plate Wire Attachment Hardware Kits will be required.

Optional DXE-RADP-3 Radial Plate Mounted to a 3" OD Mounting Pipe

- 8 -

Attaching Ground Radial Wires to the Radial Plate

Using the 20 sets of supplied 1/4" stainless steel hardware (Bolt, Star Washer, Flat Washer, Split

Washer, Nut) connect the optional ground radial wires to the DXE-RADP-3 Radial Plate as shown

below. Additional hardware kits are available (DXE-RADP-1HWK) that contain 20 sets of Radial

Plate Hardware.

There are optional DX Engineering Radial Wire Kits available. DXE-RADW-500K/BD contains a

500 foot spool of 14 gauge copper stranded wire with black PVC insulation, 20 Terminal Lugs and

100 Steel or Biodegradable Lawn Staples. The DXE-RADW-1000K/BD Radial Wire Kit contains

a 1,000 foot spool of 14 gauge copper stranded wire with black PVC insulation, 40 Terminal Lugs

and 200 Steel or Biodegradable Lawn Staples. RADW-20RT, -32RT or -65RT contain 20 each

radial wires with 1/4" terminal attached. These kits come in 20 Ft, 32 Ft or 65 Ft lengths.

Depending on the number of radial wires used, space them out evenly around the Radial Plate. The

Radial Plate will accommodate up to 60 radial wires (60 laser drilled holes), or up to 120 radials if

doubled up.

Radial Wire Pattern

Radial Wire Hardware Installation

- 9 -

Overall Pivot Base (US Patent No. 8,130,168) Assembly Drawing

The exploded view drawing is for reference and shows the overall Pivot Base Assembly.

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