CUSHCRAFT AV80 Instruction manual

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AVSO
your Cushcraft AVg0 is a loaded 1/g wave antenna that can be either switched between the 75 meter SSB band and the 80 meter CW band remotely or set up
for iixed operation on either end of the band. lt is designed to operate at full power for long periods of time. lt is a convenient size and is easily assembled.
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 HIGH VOLTAGE OR 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 FALL. FOLLOW THE GUIDELINES
FOR ANTENNA INSTALLATIONS RECOMMENDED BY THE U.S. CONSUMER PRODUCT SAFEW COMMISSION AND LISTED IN THE ENCLOSED
PAMPHLET.
The Cushcraft AVg0 is designed and manufactured to give trouble lree service. This antenna will perform as specified if the instructions and suggestions in
this manual are followed and care is used in the assembly and installation. When checking the components received in your antenna package use the parts
listed beside each diagram. There is a master parts list on page 2. lf you are unable to locate any tube or component, check the inside ol all tubing.
IMPORTANT: Save thJweight label from the outside of the canon. Each antenna is weighed at the lactory to verify the pans count. lf you claim a missing
part, you will be asked lor the welght verification label. PLANNING
plan your installation carefully. lf you use volunteer helpers be sure that they are qualilied to assist you. Make certain that everyone involved understands
that you are the boss and that they must follow your instructions. lf you have any doubts at all, employ a prolessional antenna installation company to install
your antenna. LOCATION
Location ol the antenna is very important. Sunounding objects such as trees, power lines, other antennas, etc. will seriously reduce etficiency. To minimize
the effects of sunounding objäcts, mount the antenna as much in the clear as possible. EXTREME CARE MUST BE USED FOR YOUR SAFETY' YoU
MUST INSURE THAT WHILE THE AVBO IS IN OPERATION NEITHER PEOPLE OR PETS CAN COME IN CONTACT WITH ANY PORTION OF YOUR
ANTENNA. DEADLY VOLTAGES AND CURRENTS MAY EXIST. ALSO, SINCE THE EFFECTS OF EXPOSURE TO RF FIELDS 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 ANTENNAAS SHOWN IN FIGURE G,
MOUNTING
your mast should be rigid and vertical. Always use a mast at least 1-3/4" (4.4 cm) in diameter. Be sure your mast is very rugged. The wind load of the AV80
wiihiceonitrequiresthatyouprovideastrongmount. Forelevatedmounting,Cushcraftrecommendsal-3l4lo2'(4.4-5.1cm) schedule40metal pipe
be used as the supporting member.
cushcraft recommends suyins the AV80 with u non.onor.#.TI.TlT#,El'J' iiL9rd exposure to weather can be attached to the AVBo ar the
point shown in Figure D. RADIAL SYSTEM
The AVg0 is a low lrequency HF loaded monopole antenna. Pan of the antenna is the ground system. Thele have been volumes written on the merits of
several types of radial systems. We describe two alternatives from among the many. Please choose the approach you prefer. Radial wire should be at least
AWG#16 and strong enough to withstand exposure to weather. Wire can be insulated or bare.
Elevated System - An elevated radial system should be at least B feet (2.5 meters) above the ground. At least lour radial wires, each approximately 1/4
wavelengthiong(68feetor20.7meters) shouldbeplacedsymmetricallyaspossiblearoundtheantenna. Keepwiresagtoaminimum. lfspaceislimited'
the radials can be formed to fit in the space available. Objects between the radials will affect the eleclrical wavelength. The ends ol thre radials should be
insulated lrom their supports.
Ground Mounted System - Mount the antenna base 3 inches (7.6 cm) above the ground. Place 12 or more radial wires 1/4 wavelength (68 feet or 20'7
meters) symmetrically around the antenna.
SYSTEM GROUNDING
Direct grounding of the antenna and mast is very important. This serves as protection from lightning strikes and static buildup, and from high voltage which
is presänt in thJ radio equipment connected to the antenna. A good electrical connection should be made to one or more ground rods (or other.extensive
groundsystem) directlyatthebaseoftheAVS0,usingatleast#l0AWGgroundwireandnoncorrosivehardware. Fordetailsandsafetystandards,consult
the National Electrical Code. You should also use a coaxial lightning arrester. Cushcraft offers several differenl models, such as LAC-1 , LAC-2 and the LAC'
4 series.
ASSEMBLY
Assemble your antenna by following the directions and illustrations in steps 1 through 5. After the antenna is completely assembled, verify dimensions for
accuracy. Then, return to the section below for final tuning.
. . TUNING PROCEDURE
DO NOT MAKE ADJUSTMENTS IN THE MATCHING NETWORK BOX WHILE TRANSMITTING. DOING SO COULD LEAD TO ELECTNOCUTION. AII
tuningisdoneinsidethematchingnetwork. Donotadjustthelengthof theradiator. BycompressingtheturnsonL1,L2andL3(FigureA) theAV80will be
resonant at ihe bottom of the CW and SSB bands. To raise the resonant f requency begin by spreading the turns on L3. To raise the CW resonant frequency
higher, spread the turns on L2. For SSB, spread the turns on L1 .

AVSO
MASTER PARTS LIST
#' - IMPEDANCE MATCHING ASSEMBLY SET.UP
Before using your AVBo it is necessary to set up lhe matching network
(MNB0) for proper operation. The matching network is equipped with a
relay that switches inductance in and out o{ the circuit to allow remote
selection of CW or SSB operation. To use this relay you must supply +12
Volts DC to either the phono plug SOI (Option 3) or inject +12 Volts DC
through the coax (Option 4). Select one of the following options.
Option 1 - To operate on 80m (CW) only. Cut the jumpers J1 and J2
(Figure A).
Option 2 - To operate on 75m (SSB) only. Cut the jumpers J1 and J3
(Figure A).
Option 3 - To switch between CW and SSB using built-in relay and
separate +12V DC line to phono lack SO1 (Figure A), determine
whether you want the antenna tuned to CW or SSB when no
power is applied to the relay (use chart in Figure B). Cut the
corresponding jumper wire (Figure A). Also cut jumper wire
J1. A phono plug is supplied in the parts bag for this option.
9 010009 8-32 (1.7 cm) stainless steel machine screw 4
32 902832 49" (124.5 cm) tapered stainless steel rod Mtip 4
49 014149 #8 nuVwasher 24
51 014151 5/16" (.79 cm) nuVwasher I
62 014162 #10 nuVwasher 1
63 170063 112" x112" x3-112"(1.3 x 1.3 x 8.9 cm) aluminum V-block 4
79 010079 8-32 x 1/2 stainless steel machine screw 12
96 202296 Aluminum radial clamp 4
99 050099 2" (5.1 cm) black plastic cap 1
109 351 109 Switchcraft plug 1
115 050115 Vinylboot 1
116 240116 Silicone pack 1
140 194140 MN support bracket 1
232 010232 B-32x2-112" (6.35 cm) stainless steel machine screw 6
326 290326 Danger label 1
404 010404 5116" x3-114" x2-7l1 6" (.8 x 8.2 x 6.2 cm) stainless 2
steel U-bolt
405 010405 5116" x4-112" x2-7h6" (.8x 11,4x6.2cm)stainless 2
steel U-bolt
414 030414 1-5/16" to 2-114'(3,3 to 5.7 cm) stainless steel worm clamp 6
748 190748 Angle bracket lor lower radials 4
899 102899 Solder lug 4
941 360941 Aluminum flat washer 8
4079 194079 4" x 10" (10.2 x 25.4 cm) aluminum mounting plate 1
BA AV8OBA Base assembly 1
BB AV8OBB 6.27' x 2" (1 91 x 5.1 cm) swaged aluminum tube 4
BC AV8oBC 6.0'x 2" (183 x 5.1 cm) swaged aluminum tube 1
MN AV8OMN MN-80 box assembly lor AV80 1
FIGURE A
Phono
Jack
(so1)

Option 4 - To switch between CW and SSB using built-in relay and
injecting +12V DC through coax, determine whether you
want the antenna tuned to CW or SSB when no power is
applied to the relay (use chart in Figure B). Cut the
corresponding jumper wire (Figure A). The AV80 matching
network will automatically decouple the +'l2V DC from
your RF signal. You will have to construct a +12V DC
injection circuit (Figure B) to be plac€d at the opposite end
of your coax. Do not connect any equipment between
your injection circuit and the AV80. Cushcraft does not
supply a +12V DC injection circuit. Failure to use a proper
injection circuit will lead to damage of transmitting
equipment. Cushcraft is not responsible for damages
associated with the use of a DC voltage injected through
coax cable attached to the AVBo.
FIGU RE
B
Typical +12 Volt DC
lnjection Circuit
(Suggested not supplied)
300V for 300W or
lF-r
.o1ut th
KEY P/N DISPLAY DESC stzE QW
49 0 1 4149 &NUTiIiVASHEB ö-öz 4
62 014162 NUT/IiVASHER 10-24
140 194140 v44 MN SUPORT
BRACKET
232 010232 " SS I,4ACHINE
u scREW 8-32x2-112"
(6.35 cm)
BA AVSOBA BASE
ASSEMBLY
MN AVSOMN @BOX
ASSEMBLY
#2. ATTACH MATCHING
ASSEMBLY
Attach the black box assembly (MN) to the base assembly using
the hardware shown in Figure C.
FIGURE

AVSO
#3 . ASSEMBLE RADIATOR
Locate the 4 sections of aluminum tubing with swaged ends
(BB). Slide one worm clamp (414) over the top of the base
section. Next, slide the large end of one of the BB tubes over
the top of the base section. Align the through holes and place
a 2-112" (6.3 cm) machine screw (232) through the tubes and
secure rvith (49) nuVwashers (see Figure F). Tighten clamps.
Repeat this procedure for the remaining 3 BB tubes. The last
radiator section is the non-swaged tube (BC). Slide plastic end
cap (99) onto the non-slotted end of BC. Attach radial clamps
(96) and top radials (32) (Figure E) just below the black end
cap. Secure BC to antenna in the same fashion as the previous 12,
sections. (30.5 cm)
t(
Suggested attachment
pont for guys.
FIGURE
DFIGU RE
F
FIGURE E
KEY P/N DISPLAY DESC slzE QTY
32 902832 +!: SS ROD
(124.5 cm) 49" 4
49 014149 e
il# NUTMASHER 8-32 17
ao 01 0079 @SS MACHINE
SCREW 1t2.
(1.3 cm) 12
vb 202296 ffi ALUMINUM
RADIAL CLAMP 4
99 050099 ffi BLACK
CAP 2',
(5.1 cm) I
232 010232 SS MACHINE
SCREW 2-112',
(6.35 cm) 5
414 030414 191
(i SS WOHM
CLAMP 2-1t4',
(5.7 cm)
Ä
BA AVSOBA 1 BASE
ASSEMBLY 1
l5.e.J \\
BB AVSOBB {€2 SWAGED
ALUM TUBE 6.27'x2'
(191 x 5.1 cm) 4
BC AV8OBC {tta ALUM
TUBE 6.0'x 2"
(183 x 5.1 cm) 1

A
#4 - BASE TO MAST ASSEMBLY
Attach the antenna base to your mast as shown in Figure G. First attach
the.mounting plate (4079) with U-botts (aOS), aluminum V-btocks (63),
and nuvwashers (51). The bottom of the plate should should be even
with the bottom of the antenna to leave room for the radial clamping
system, Affix danger label (326) to the antenna so that is easy to see:
When attaching antenna to the mast use the 404 U-bolts, aluminum V_
blocks (63), and nuVwashers (51).
FIG U RE
KEY P/N DISPLAY DESC SIZE Qry
51 014151 a:\
{* NUT /VASHER 5/16"
(.8 cm) I
63 1 70063 tr4 V.BLOCK z',
(5.1 cm) 4
404 010404 )U-BOLT 2-7116x3-114'
(6.2 x 8.2 cm) 2
405 010405 )U-BOLT 2-7h6" x 4-12"
(6.2x11.4cm) 2
4079 194079 MOUNTING
I PLATE
326 290326 DANGER
LABEL
#5 ATTACH BASE RADIALS
Attach radials to the antenna refering to Figure H. Use the worm clamp
(414), angle brackets (748) and hardware provided. Space the radials
evenly around the base.
KEY P/N DISPLAY DESC srzE OTY
901 0009 @SS MACHINE
SCREW 8-32 x 5/8"
(1.7 cm) 4
49 014 1 49 &NUTMASHER 8-32 4
414 030414 FE
(( sSS WORM
CLAMP 2-1t4
(5,7 cm) 1
748 1 90748 qANGTE
BRACKET 4
899 102899 %SOLDEF
LUG 4
941 360941 @ALUM
FLAT WASHER I

AVSO
#6 . FEEDLINE
The AVB0 is designed for use with 50 Ohm coaxial cable terminated
with a PL-259 connector. Any length of cable can be used with your
AVBO. The shortest length of cable will have the least loss. A connector
boot is included for use with your new antenna (figure l). Slide the boot
over the cable before attaching your PL-259' Coat only the outside
connector threads and shell with silicone grease' Do not coat the center
pin or receptacle. After the PL-259 is firmly screwed onto the antenna
connector, slide the vinyl boot over the connector and against the
connector bracket for a good weather-tight connection. Afier the antenna
is on the mast, tape the feedline to the mast. ll you plan to install the
antenna in a salty or corrosive environment, you may want to consider
coating it with a Clear marine varnish or equivalent after it is assembled'
For final tuning see Page 1.
KEY PART# )ESCRIPTION slzE OTY
0501 1 5115 @CONNECTOR
BOOT
1
2401 1 6116 SILICONE
PACKAGE
1
re
q
---> SILICONE
'' (116)
115
FIGU RE
I
SPECIFICATIONS
Frequency, MHz
Electrical Wavelength
SWR 1.2:1 Typical
2:1 Bandwidth (KHz)
Power Rating, Watts PEP
Radiation Angle, degrees
Horizontal Radiation Pattern, degrees
Height, ft (m)
Mast Size Ralge,jn (cm)
Wind Load, ftz (m1)
Weisht,lb (kg)
3.5-4.0
'118 wavelength to top hat
225
1500
18
JOU
36 (10.97)
1.5-1.75 (3.8-4.4)
4.2 (.42)
20 (e.1)

LIMITED WARRANTY
Cushcraft Corporation, P.O. Box 4680, Manchester, New Hampshire 03108, wanants to the original purchaser for one year
from date of purchase that each Cushcraft antenna is free of defects in material or workmanship. lf, in the judgement of
Cushcraft, any such antenna is defective, then Cushcraft Corporation will, at its option, repair or replace the antenna at
its expense within thirty days of the date the antenna is returned (at purchasers expense) to Cushcraft or one of its
authorized representatives. This wananty 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 limitations 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 e).tend
to any products which have been subject the misuse, neglect, accident or improper installation. Any repairs or alterations
outside of the Cushcraft factory will nullify this warranty.
,@Gcrcilr
48 PERIMETER ROAD, MANCHESTER, NH O31OB USA
TELEPHON E: 603-627 -7 877 . FAX: [phone] . E-mail: techsup @ cushcraft.com
SPECIFICATIONS SU&JECTTO CHANGE WITHOUT NOTICE