EME Station 2.0 Part 10 – Antennas On The Tower

Completed 2m EME Antenna System

After a year’s worth of planning and 10 months of construction, we have our new 2m EME Antenna System installed on our EME Tower and working! This stage of our project took about a week and included a lot of help from Matt and Andrew at XX Towers.

Final Preparations

Antenna Ground Test

The first step was to arrange the four 2MXP28 Yagis that we built on saw horses near our EME Tower and check each antenna’s vertical and horizontal SWR. Performing SWR measurements with the antennas close to the ground like this does not produce very accurate measurements. Doing this does allow one to spot potential problems if some of the measured SWR fail to show a resonance or are wildly different than the other antennas in the group. All of our antennas checked out as expected.

50 Ft Boom Lift, H-Frame Cross Boom Assembly On The Ground

We also rented a 50-ft Boom Lift and set it up near our EME Tower. A tool like this is almost essential to safely assemble and adjust a large, complex antenna system involving an H-Frame. It also speeds up the assembly and adjustment process considerably.

Elevation Rotator and H-Frame

Elevation Rotator Installation on Mast

Elevation Rotator Installation on Mast

The first step was to install the MT-3000A Elevation Rotator on the mast. We pre-installed the control cable for the elevation rotator before installing it on the tower. This enabled us to get it temporarily hooked up to the Rotator Controller in our shack so that we could adjust the elevation of the H-Frame and Antennas as we installed them.

H-Frame Assembly on Tower

H-Frame Assembly on Tower

Next, Matt and Andrew installed the H-Frame Crossboom and Truss assembly on the Elevation Rotator. The assembled Vertical Risers went on next to complete the H-frame. The time spent pre-assembling these components and marking centers to enable accurate final assembly saved a great deal of time.

Antenna Installation

Upper Antenna Installation

Upper Antenna Installation

With the H-Frame in place, we installed the upper 2MXP28 Yagi Antennas next. The image above shows the rigging of the boom trusses which was done on the Tower.

Lower Antenna Installation and Adjustments

Lower Antenna Installation and Adjustments

Next came the lower 2MXP28 Yagis. We spent considerable time leveling and aligning all of the Antennas and H-Frame components at this stage.

Feedlines, Electronics, and Balancing

T-Braces and Feedlines

T-Braces and Feedlines

The T-Brace assemblies and Antenna Phasing Lines were installed next. Each Antenna requires two LMR-400 Phasing Lines and these coax cables add considerable weight to the backs of the Antennas. The T-Braces support these cables and help to align the Antennas on the H-Frame.

We replaced the Vertical H-Frame Boom Truss Pipe with a heavy section of Mast Pipe to act as a counter-weight and balance the final H-Frame and Antenna assembly. This step is critical to ensuring a long life for the Elevation Rotator’s drive system and chain.

Phasing Lines, Power Dividers, and Feedline Connections on Crossboom

Phasing Lines, Power Dividers, and Feedline Connections on Crossboom

The photo above shows the final installation of the Power Dividers, Antenna Phasing Lines (there are 8 in total), the MAP65 Preamp Housing, and the Feed and Control Cables that run down the Tower. We took the time to carefully make SWR measurements on each Antenna and check all of the connections to the MAP65 Housing at this stage.

Antenna Integration Details

Rotator Loop

Rotator Loop

The Rotator Loop contains the following cables and Coax Feedline connections from the H-Frame/Antenna assembly:

  • Vertical and Horizontal Rx Feedlines
  • Tx Feedline
  • Elevation Rotator Control Cable
  • MAP65 Housing Control Cable

All of these cables are bundled and securely fastened to the H-Frame Cross Boom and to the Tower. Andrew is a master at this sort of rigging!

Control Cable Connections at Tower Base

Control Cable Connections at Tower Base

I took some time to finalize the Control Cable connections at the base of our tower. Time was spent with a voltmeter doing checks to ensure that everything was connected correctly and working. This effort resulted in the discovery and correction of some wiring errors and a faulty relay in the MAP65 housing. Had I not done these steps, we would have surely destroyed the Preamps in the MAP65 Housing when we transmitted for the first time.

Testing Our New Antenna System

Vertical Polarity Tx SWR at Shack

Vertical Polarity Tx SWR at Shack

A series of SWR measurements were taken before sealing the coax cable connections on the tower. SWR measurements were checked and recorded for future reference at the following points in the feedline system:

  • At the ends of the phasing lines associated with each antenna
  • At the output of the two Power Dividers on the tower
  • At the shack entry ground block

Measurements were taken separately for both the Vertical and Horizontal elements of the final Antenna System. The image above shows a typical SWR measurement for our final Antenna System.

I did many final checks and adjustments while the Boom Lift was still here. These steps included:

  • Checking the oil level in the elevation rotator
  • Re-lubing the elevation rotator chain
  • Adjusting the limit switch stops on the Elevation Rotator to allow enough over-travel for future adjustments and maintenance
  • Checking all hardware for tightness
  • Sealing all coax cable connectors with Coax Wrap and Electrical Tape
  • Making some final adjustments to align the four 2MXP28 Antennas with each other and the H-Frame

Next Steps

The next step in our project will be the integration of our new 2m EME Antenna System into our shack. This step will include the final setup, configuration, and testing of the Rotator Controller, Interim SDR Receiver, Transmitter, Amplifier, and the MAP65 and Moon Tracking Software.

You can read more about our EME station project via the links that follow:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Tech Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

EME Station 2.0 Part 9 – H-Frame Assembly

M2 Antennas 2X2 2MXP28-32 H-Frame

M2 Antennas 2X2 2MXP28-32 H-Frame

The final major component to be assembled is the 2MXP28-32-2X2-3K H-Frame which will support our four 2MXP28 Antennas. The H-Frame is one of the most mechanically complex components in our EME antenna system so we began by carefully studying M2’s manual for this component.

Parts Identification, Inventory, and Preparation

H-Frame Parts Inventory

H-Frame Parts Inventory

We also spent some time identifying and inventorying all of the parts. M2 supplied upgraded aluminum saddle clamps for our H-Frame. These parts improve the clamping action between the components and also reduce stresses on the fiberglass and other tube parts.

Truss Cable Parts Prep

Truss Cable Parts Prep

We spent some time preparing the parts for the Phillystran Truss cables for the Main Cross Boom and Vertical Risers. Prep included a drop of oil on each of the clamp threads and some NOALOX Antioxidant Compound on the turnbuckle threads. We also added stainless steel jam nuts to the turnbuckles to lock them in place after installation.

Initial Assembly of H-Frame Sections

Assembled H-Frame Sections

Assembled H-Frame Sections

We next mock-ed up the center section of the 3″ Main Cross Boom in the Elevation Rotator assembly to ensure proper fit and operation of the Elevation Rotator.

With this done, we assembled the Main Cross Boom, Vertical Risers, and T-Brace sections. This helped us to get all of the parts and hardware in the correct locations and to become familiar with how all of the parts fit together. We used a generous coat of NOALOX on all of the metal to metal tubing joints to facilitate the assembly and to prevent corrosion from forming at the joints of the metal tube sections. This sort of corrosion can cause increased noise levels after the array is installed outdoors for some time.

Main Crossboom Assembly

Cross Boom Truss Assembly

Cross Boom Truss Assembly

Next, the 3″ Main Cross Boom and its support Trusses were assembled. We carefully measured the assembly and marked the center as well as the locations of the Vertical Risers on the Main Cross Boom using a sharpie pen. these measurements will make the final assembly of the H-Frame on our Tower much easier.

Cross Boom Truss Details

Cross Boom Truss Details

The Phillystran Truss Cables and associated hardware were assembled and adjusted next.

Vertical Riser Assembly

Vertical Riser Mock-up

Vertical Riser Mock-up

We decided to Mock-up a section of the Vertical Riser center tubes and the associated Vertical Riser Truss supports on the Main Cross Boom. This allowed us to confirm that the final horizontal spacing of the Risers was correct and to get the clamps associated with this part of the H-Frame assembly properly oriented and squared.

Fiberglass Tubing Reinforcements

Reinforcement Bushing Design

Reinforcement Bushing Design

The Vertical Risers use fiberglass tubes at each end to provide a non-conductive mast for mounting the Antennas and their Truss Supports. The Antennas we are using are large and will need to be tightly clamped to ensure that they stay aligned and in place. The Antenna and associated Truss U-clamps put a great deal of stress on the fiberglass tubes and they can become distorted or damaged over time.

To prevent this, we decided to make a custom set of reinforcement bushings from polycarbonate plastic. Bushings were designed to reinforce all of the points on the fiberglass tubes of both Vertical Risers where U-Clamps will be used. You can see the full set of specifications for the bushings here.

W2SW Custom Reinforcement Bushings

W2SW Custom Reinforcement Bushings

Spencer, W2SW, owner, and founder of AntennaSys, Inc. made a beautiful set of custom bushings for us. Spencer has an amazing machine shop at his home and the parts turned out great and fitted precisely.

Reinforcement Bushing Installation

Reinforcement Bushing Installation

The reinforcement bushings were installed at the correct depth in each of the Fiberglass Tubes and are pinned in place using small stainless steel machine screws.

One consequence of installing the reinforcement bushings is that water can accumulate in the fiberglass tubes if they are in a horizontal position for a period of time. If such accumulated water freezes, it could cause damage to the tubes. This problem is easily solved by drilling a series of small 1/8-inch drain holes in the tubes on the bottom side when they are horizontal.

Assembled Vertical Riser

Assembled Vertical Riser

The final step was to assemble all of the parts associated with both Vertical Risers. The risers were marked to indicate the location of each Antenna Boom and Truss Clamp and the clamps were installed. The Phillystran Truss Cables were installed in the Eye Bolts on the Vertical Risers.

As we did with the Antenna Truss Cables, we will wait to install the turnbuckles until the Vertical Risers are installed on the tower and balanced. This will likely change the length of the Phillystran Truss cables.

Next Steps

The next step in our project will be the installation of our Elevation Rotator, H-Frame, Antennas, Power Dividers, MAP65 Housing, and Phasing Lines on our EME Tower. You can read more about our EME station project via the links that follow:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

EME Station 2.0 Part 8 – Elevation Rotator Assembly and Sub-System Test

Elevation Rotator and MAP65 EME Preamp System Test

The next major component in our new EME station is the assembly of the Elevation Rotator. This step also involves pre-assembly and testing of the MAP65 Pre-amp Housing, Antenna Power Dividers, Transmit/Receive Sequencer, and the Rotator Controller. Here are the components involved in this part of our project:

We choose the MT-3000A Elevation Rotator for its heavy-duty construction. This will be important to handle the weight of our EME antenna array as well as the winter conditions that we encounter here in New England.

Elevation Rotator Assembly

MT-3000A Elevation Rotator Parts

MT-3000A Elevation Rotator Parts

The first step was to inventory all of the parts for the MT-3000A Elevation Rotator and carefully read the MT-3000A manual from M2 Antennas.

Assembled MT-3000A Elevation Rotator

Assembled MT-3000A Elevation Rotator

Assembly of the MT-3000A is pretty straight forward. It uses a chain-drive system to produce a very strong, high-torque elevation rotator system. It’s important to fill the gear-box with the supplied gear oil and to lube the chain with the proper lubricant prior to testing and installing the rotator. Spray style chain lubricants for motorcycle chains work well in this application.

Rotator Controller Integration and Testing

Green Heron RT-21 Az-El Rotator Controller

Green Heron RT-21 Az-El Rotator Controller

The next step was to make up a rotator and connect the MT-3000A to our Green Heron RT-21 Az/El Rotator Controller for a test. The RT-21 Az/El is a very flexible controller that is capable of controlling almost any popular antenna rotator. We’ve already tested this unit with the M2 Antennas OR2800G2 Azimuth Rotator that is installed on our EME tower.

RT-21 Configuration of the MT-3000A Elevation Rotator

RT-21 Configuration of the MT-3000A Elevation Rotator

The MT-3000A is a pulse-counter style rotator with 0.1-degree positioning resolution. It required a custom setup in the Green Heron RT-21 Az/El which was easily accomplished with Green Heron Engineering’s setup utility. One must determine the correct Divide Ratio setting by experimentation. When the correct value is found, a rotation of 90 degrees on the controller will result in exactly 90 degrees of actual movement by the MT-3000A. This calibration was much easier to do with the MT-3000A in our shop than it would have been once the unit was installed on our tower. We also set up the RT-21 Az/El Controller to allow for 5 degrees of rotation beyond the 0 and 90-degree points.

After some testing, I decided to use the 42Vdc tap setting in the RT-21 Elevation Controller with our MT-3000A. The specifications for the MT-3000A allow for up to 42 Vdc to be used to run its motor. To be safe, we set the Max Speed setting in the RT-21 Az/El to “8” which resulted in a maximum of 40 Vdc measured with a voltmeter at the output of the controller.

Assembly and Integration of MAP65 Housing and Cross Boom

Elevation Rotator and MAP65 Preamp Housing Assembly

Elevation Rotator and MAP65 Preamp Housing Assembly

The next step was to install the H-frame Main Boom center section and Truss Support Tubes in the MT-3000A. The MAP65 EME Preamp Housing is mounted on the horizontal Truss Support Tube as shown above.

MAP65 EME Preamp System Housing

MAP65 EME Preamp System Housing

A control cable for the MAP65 EME Preamp Housing was made up and connected to the terminal strip on the housing.

EME Sequencer Testing

S2 Sequencer

S2 Sequencer

The S2 EME Sequencer from M2 Antennas is designed to control the MAP65 Housing but its internal jumpers must be properly set to do this. We spent some time with the manual for the S2 Sequencer and for the MAP65 Housing carefully setting the S2 Sequencer’s jumpers and verifying proper voltages at both the output of the S2 Sequencer and the terminal strip in the MAP65 housing with a voltmeter. The manuals for the S2 EME Sequencer and the MAP65 EME Preamp Housing were clear on these steps.

Mounting Power Dividers

Power Divider Mounting Bracket

Power Divider Mounting Bracket

The next step in this part of our project was to mount the M2 Antennas 4-Port Power Dividers that are used to connect the MAP65 Pre-Amp housing to the four 2MXP28 Antennas. Two power dividers are required as each antenna has a separate feed point connection for their horizontal and vertical polarities. We made up some custom mounting brackets for the power dividers from 1-1/4″ aluminum angle material.

MAP65 EME Preamp Housing Connections

MAP65 EME Preamp Housing Connections

The MAP65 Preamp Housing connects to the outputs of the two Power Dividers that feed the H-polarity and V-polarity of the antenna array. The outputs from the MAP65 EME Housing connect to the H-polarity and V-polarity receive coax cables and the Transmit Hardline Coax Cable that runs from the tower to our shack.

Coax Interconnect Cables

Power Divider and Feedline Jumper Coax Cables

Power Divider and Feedline Jumper Coax Cables

The final step was to make up LMR-400 coax cables to connect the MAP65 Preamp Housing to the Power Dividers. We used right-angle male N connectors to make the connections to the 4-Port power drivers to avoid sharp bends in the cables.

We also made up three additional LMR-400uF coax cables to connect the MAP65 Preamp Housing to the coax Tx and Rx feedlines that are installed on our tower. It’s important to keep the H-Pol and V-Pol cables as close to identical in length as possible to minimize and phase differences between the associated receive feedline systems.

Next Steps

The next step in our project will be the final assembly and preparation of the H-frame which will be used to mount our four 2MXP28 Antennas. You can read more about our EME station project via the links that follow:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred – AB1OC

EME Station 2.0 Part 6 – Tower Grounding System

Tower Ground System

Tower Ground System

Now that spring is here, we’ve continued work on our EME station project. The most recent project was to build complete the ground system for our new EME tower. The proper way to ground a tower is shown above. Each leg of the tower is connected to an 8′ ground rod via a heavy-gauge ground cable. The cable is attached to the tower leg using stainless steel clamps meant for this purpose. The three ground rods associated with the tower legs are then bonded together using a heavy copper ground cable ring.

Ground Cable CAD Weld

Ground Cable CAD Weld

The ground cables are welded to the top of the ground rods using CAD weld on-shots. This creates a strong connection that will not corrode or fail. It is important that the ground rods be free of dirt, corrosion, oxidation, and burrs before performing the CAD welding. We used a combination of 3-wire and 4-wire one-shot CAD welds to build our ground system and connect it to the bonding system running from out tower to the entry to our shack.

Main Grounding System Bonding

Main Grounding System Bonding

The final step was to connect the bonding run from the tower to the perimeter grounding system around our house. This completed the tower grounding system and enabled us to complete our final permit inspection courtesy of our local building inspector.

Finished Tower Base

Finished Tower Base

With all of this work done and the inspection complete, we added a mulch bed around our new tower to make this area of our lawn easy to maintain.

The next step in our project is to begin building the antennas that will go on our EME tower. You can read more about our EME station project via the links that follow:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

EME Station 2.0 Part 5 – Control Cables and Rotator Controller

Control Cable Junction Box on EME Tower

Control Cable Junction Box on EME Tower

Snow is coming to New England this weekend so we wanted to get the control cables run to our new EME Tower before the ground is covered with snow. The project involved installing a Utility Enclosure on our tower and running three control cables to our shack for the following devices:

Az-El Rotor and Preamp Switching Control Connections

Az-El Rotator and Preamp Switching Control Connections

We began by install some barrier strips and a copper ground strap in the Utility Enclosure. The copper strap provides a good ground connection to the tower and associated grounding system. The enclosure is clamped to the tower using two stainless steel clamps.

We ran three new control cables through the conduits that we installed between the tower and our shack and terminated them in the utility enclosure. We only needed 6 leads for control of the planned MAP65 Switching and Preamp System which will go on our tower later so we doubled up some of the higher current connections using two wires in the 8-conductor cable.

Green Heron RT-21 Az-El Rotator Controller

Green Heron RT-21 Az-El Rotator Controller

The final step was to hook up our rotator cables to a Green Heron RT-21 Az/El Rotator Controller in our shack.  We do not yet have our elevation rotator so we tested the M2 Orion 2800 Azimuth Rotator that is installed in our tower. The azimuth rotator is configured so that the rotator’s dead spot faces north. This is a good configuration of our planned EME operation.

With all of our control cabling in place, we are ready to begin preparing our Antennas, Elevation Rotator, H-Frame, and MAP65 components to go on our EME Tower. We’re hoping that the weather will cooperate and enable us to get these steps completed during this winter.

Here are some links to other articles in our series about our EME Station 2.0 project:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

EME Station 2.0 Part 4 – New EME Tower Is Up!

Three Tower Antenna Farm

New EME Tower in Our Antenna Farm

Our goal for this phase of our EME Station Project is to get our new tower up, install the Azimuth Rotator and Mast, and run the hardline and coax cables for our antennas from the shack to our new tower. Our EME tower is constructed using Rohn 55G tower sections. It will be 26 ft tall and will have approximately 18″ of our 3″ mast protruding above the tower. The tower is a free-standing/guyed hybrid design with the first section being cemented into the ground.

EME Tower

FInished Tower Base

The base section and the three guy anchor blocks were completed a little while back. The holes were backfilled and we’ve given the cement a couple of weeks to cure.

First Tower Section Installed Using a Gin Pole

First Tower Section Installed Using a Gin Pole

Matt, KC1XX, and Andrew of XX Towers began by installing a winch and a gin pole on the base section of the tower. They used the Gin Pole to hoist the second tower section into place and secure it. They also attached the top plate to the third tower section in preparation for installing it along with our mast.

Mast and Top Tower Section Going Up

Mast and Top Tower Section Going Up

It is always a challenge to install a mast inside a new tower. The mast we are using is a heavy, 22 ft 4130 chrome molly steel mast that weighs over 250 lbs. Getting the mast inside the tower was quite a feat! Matt and Andrew rigged the top tower section and the mast together and pulled both up together on the Gin Pole. Next, one leg of the top tower section was attached and a second pully was used to pull the mast up through the top tower section until it could be placed inside the tower. The last step was to raise the top tower section a second time using the Gin Pole to seat it on top of the rest of the tower. Finally, the mast was lowered inside the tower to the base and the top tower section was bolted on to complete the tower.

Upper Guy Anchor Bracket on Tower

Upper Guy Anchor Bracket on Tower

The next step involved attaching the upper guy anchor bracket to the top section of the tower and rigging the guy anchor cables. We decided to use Phillystran Guy Cable to avoid interactions with our antennas.

Guy Anchor Cable

Guy Anchor Cable

The completed cables are tensioned using turnbuckles. We adjusted the cables to plumb the tower and then safety-wired the turnbuckles so they will not come loose.

Azimuth Rototor in Tower

Azimuth Rotator in Tower

The next step was to install an M2 Antenna Systems Orion 2800G2 Azimuth Rotator in our tower. The use of the 22 ft mast allowed us to place the rotator about 5 ft above the ground where we can easily service it in the future. The long mast also acts as a torque shock absorber when the rotator starts or stops moving suddenly. With the rotator in place, we attached the mast and clamped it at the rotator and thrust bearing at the top of the tower.

Tower Base, Coax Feedlines, and Guy Anchors

Tower Base, Coax Feedlines, and Guy Anchors

The last step in our project was to install our coax cables and hardlines on the tower and run them through a 4″ underground conduit to our shack. We pre-made the two LMR-600 coax cables for the receive side of our EME Antenna System previously. We cut a section of LDF5-50A 7/8″ Hardline to approximately the same length as the LMR-600 coax cables.

Pushing Coax Cables and Hardline Through the Condui

Pushing Coax Cables and Hardline Through the Conduit

We used a cutoff plastic bottle to protect the ends of the coax cables and hardline as we pushed them through approximately 50 ft of buried 4″ conduit. The conduits were constructed to create a gradual turn into and out of the ground and the cables went into the conduit smoothly.

Coax Cables Exiting the Conduit Near Our Shack

Coax Cables Exiting the Conduit Near Our Shack

With the cables in place, we installed N-female connectors on each end of the 7/8″ hardline. We used rubber reducers to make it easier to deter water from entering the conduits where the cables exit.

Coax Cable Ground Block Connections

Coax Cable Ground Block Connections

We expanded out main shack entry ground block using an 18 position tinned cover ground bar from Storm Copper to make room for additional static arrestors for our EME Antenna System. The LMR-600 receive-side coax cables and the 7/8″ hardline connection for the transmit-side of our EME antennas terminate on N-connector Static Arrestors from Alpha Delta.

Completed EME Tower

Completed EME Tower

Our new EME tower is up and ready to accept the Elevation Rotator, H-Frame, and Antennas from M2 Antenna Systems when they arrive. We plan to complete the grounding system and get the Azimuth Rotator hooked up and tested with our Green Heron Engineering RT-21 Az/El Rotator Controller in the near future.

Here are some links to other articles in our series about our EME Station 2.0 project:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

EME Station 2.0 Part 2 – Excavation, Footings, and Conduits for New Tower

EME Tower

FInished Tower Base and Cable Conduits

The first part of our EME project is to put up a new tower to support our antennas. Our plans call for a 26′ tower built using three Rohn 55G tower sections. Four feet of the first section of the tower is cemented in a concrete footing to anchor the tower’s base. The tower is also going to be guyed to ensure that it is very stable.

EME Tower

Digging Footings for our New Tower

We are working with Matt Strelow, KC1XX, and Andrew Toth of XX Towers to put up our new tower. Matt brought out his tractor and dug the footings for our tower and for the associated conduits that will carry coax and control cables to our shack. The photo above shows the completed hole and form for the main tower base. Matt is working on the footings for one of the three guy anchors.

EME Tower

First Tower Section and Rebar Cage

Here’s a closer look at the tower base. The footing includes a rebar cage to reinforce the concrete footing. There is also 6″ of crushed stone in the bottom of the hole that the tower legs sit it. It is very important that the bottoms of the tower legs remain open and do not become plugged with cement so that water in the legs can drain. If the legs cannot drain properly, water will accumulate and freeze. This can split open the tower legs and ruin the tower.

EME Tower

Cable Conduits with Drains

We also installed two conduits (a 4″ and a 2″ run of schedule 80 conduits) from the base of our tower to our shack. These conduits will carry coax feed lines and control cables to our new tower. We used a pair of 22° elbows to create a smooth transition to bring the conduits out of the ground. This will ensure that our hardline and other coax cables can be placed in the conduits without creating excessive bends.

Conduits will fill with water even if they are sealed. This happens as a result of the condensation of water in the air. To prevent our conduits from filling with water, we created two drain pits at the bottom of the trench at the two lowest spots in the conduit runs and filled them with stone. We drilled a few holes in the bottom of the conduits above the drain pits to allow the water to drain so our cables will remain dry.

EME Tower

Cadweld’ed Ground Cable Bonded to a Ground Rod

We also created a bonding ground cable run from our new tower to the ground system at our shack entry. The bonding system was created by driving an 8′ ground rod every 10′ in the trench between our new tower and the perimeter ground around our house.

#2 stranded copper ground cable was Cadweld’ed to each ground rod to create a ground path to bond the tower to the perimeter grounding system around our house. Using a Cadweld system is simple and produces strong connections that will not deteriorate.

Here’s a video that shows our a Cadweld is made. We’ll cover completing the ground connections to the tower and the perimeter grounding system in a future article.

EME Tower

Completed Footings – Ready to Pour Cement

Finally, we used some sections of rebar to firmly support the guy anchor rods prior to pouring the cement. If you look closely, you can see a portion of the rebar material in one of the guy anchor footings in the photo above.

EME Tower

Cement Mixer

The next step in this part of our project was to pour the cement. A large cement mixer brought the proper cement mix to our QTH and Matt used his tractor to transport the cement from the mixer to the forms. We did a bit of finishing work on the cement base for our tower and let the cement dry for a few days.

EME Tower

FInished Tower Base and Cable Conduits

The last step was to remove the forms and backfill the footings. A little work with a cement finishing block was done on the cement base to round off the rough edges left by the forms. The cable conduits emerge from the ground next to the tower base. You can also see one end of the copper bonding cable next to the conduits as well.

EME Tower

Completed Guy Anchor

Here’s one of the completed guy anchor rods after backfilling. We are going to let the cement harden for a couple of weeks and then we’ll complete the construction of our new tower.

Here are some links to other articles in our series about our EME Station 2.0 project:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

EME Station 2.0 Part 1 – Goals and Station Design

The Moon

The Moon

EME or Earth-Moon-Earth contacts involve bouncing signals off the moon to make contacts. EME provides a means to make DX contacts using the VHF and higher bands. There are also some EME Contests including the ARRL EME Contest that provides opportunities to make EME contacts.

We made some 2m EME contacts a while ago using the 2m antenna on our tower at about 112′. This experience created interest on my part in building a more capable EME station at some point in time. Well, the time has finally arrived.

EME Propagation

Understanding EME Propagation is a project in of itself. The following is a brief overview of some of the (mostly negative) effects involved.

The path loss for EME contacts varies by Band and is in excess of 250 dB on the 2m band. There are some significant “propagation” effects that further impair our ability to make EME contacts. These include:

  • Faraday Rotation – an effect which results in the polarity of signals being rotated by differing amounts as they pass through the ionosphere on their way to the moon and back
  • Libration Fading – fading caused by the adding of the multiple wave-fronts that are reflected by the uneven surface of the moon
  • Path loss variations as the earth to moon distance varies – the moon’s orbit around the earth is somewhat elliptical in shape resulting in a distance variation of approximately 50,000 km during the moon’s monthly orbital cycle. This equates to about a 2 dB variation in total path loss. An average figure for the path loss for 2m EME might be in the range of 252 dB.
  • Transit Delays – at the speed of light, it takes between 2.4 and 2.7 seconds for our signals to travel from earth to the moon and back.
  • Noise – the signals returning from the moon are extremely weak and must compete with natural (and man-made) noise sources. The sun and the noise from other stars in our galaxy are significant factors for EME communications on the 2m band.
  • Doppler shifts – as the earth rotates, the total length of the path to the moon and back is constantly changing and this results in some frequency shift due to doppler effects. Doppler shift changes fairly slowly compared to the time it takes to complete a 2m EME QSO so it is not a major factor for the 2m band.
  • Moon’s size vs. Antenna Aperture – the moon is a small target (about 0.5 degrees) compared to the radiation pattern of most 2m antenna systems. This means that most of our transmitted power passes by the moon and continues into space.

Taking the moon’s size, an average orbital distance, and an average Libration Fading level into account, one can expect only about 6.5 % of the power that is directed towards the moon to be reflected back towards earth.

EME “Good Guys”

One might look at the challenges associated with making EME contacts and say “why bother”? EME contacts present one of the most challenging and technical forms of Amateur Radio communications. It is this challenge the fascinates most EME’ers including this one. Fortunately, there are some “good-guy” effects that help to put EME communications within reach of most Amateur Radio stations. These include:

  • WSJT-X and the JT65 Digital Protocol – In the early days of EME communications, one had to rely on CW mode to make contacts. All of the impairments outlined above made these contacts very challenging and the antennas and power levels required put EME communications out of the reach of most Amateurs. Along came Joe Taylor’s digital JT65 protocol which changed all of this. It is now possible to make 2m EME contacts with a single (albeit large) 2m yagi and 200W or so of input power. As a result of these innovations, many more Amateurs have built EME stations and are active on the 2m (and other) bands. Many DXpeditions are now also including EME communications in their operations.
  • Ground Gain Effects – a horizontally polarized antenna system will experience approximately 6 dB of additional gain when the antenna(s) are pointed approximately parallel to the ground. Ground gain effects made it possible for us to use our single 2m antenna to make our first 2m EME contacts.
  • MAP65 Adaptive Polarization – Fading resulting from polarity changes due to Faraday Rotation can cause a received signal to fade to nothing over the period of time needed to complete a 2m EME contact. These polarity “lock-out” effects can make contacts take a significant amount of time to complete. Fortunately, a version of the software which implements the JT65 protocol called MAP65 has been created that will automatically detect and adapt to the actual polarity of signals returning from the moon. More on how this is achieved follows below. MAP65 is most useful for making “random” EME contacts during contests. In these situations, a variety of signals will be present in a given band with different polarities, and the MAP65 software can adapt to each one’s polarity and decode as many simultaneous signals as possible.
  • Commercially Available Amplifiers for the VHF+ Bands – Modern, solid-state amplifiers have become much for available for the 2m band (and other VHF and higher bands). This has made single-antenna EME on 2m and above much more practical for smaller stations with a single antenna or a small antenna array.

Our 2m EME Goals and Station Design

We began this project by making a list of goals for our 2m EME Station 2.0. Here is that list:

  • Operation using JT65 and QRA64 digital protocols and possibly CW on the 2m EME band
  • 80th percentile or better station (i.e. we want to be able to work 80% of the JT65 capable 2m EME stations out there)
  • Operation in EME contests and EME DX’ing; earn a 2m EME DXCC

We have come up with the following station design parameters to meet these goals:

  • An array of four cross-polarized antennas with an aggregate gain of approximately 23 dBi
  • A new 26′ Rohn 55G tower to support the antennas
  • A computer-controlled Azimuth/Elevation rotator system to allow us to track the moon
  • A legal limit input power of 1500W
  • A MAP65 capable SDR-based receive system which can support adaptive polarity
  • Low-noise, high gain preamplifiers located at the antennas
  • A low-loss feedline system for both the transmit and receive sides of the system
  • Use of both the MAP65 and standard versions for WSJT-X for digital operations
  • Use of Linrad as a front-end to the receive side of our system
  • An Icom IC-9700 Transceiver and an OM Power OM2002+ 2m Power Amplifier for transmitting

Antennas

WA1NZP Antenna System (4 M2 XP32 X-Polarity Antenna Array)

WA1NPZ Antenna System (4 M2 Antennas XP32 X-Polarity Antenna Array)

It takes some fairly large antennas to create an 80th percentile EME station. We are planning a setup similar to Bob, WA1NPZ’s system shown above. We are going to put up a 26′ Rohn 55G tower for our EME antenna system. We will be using four M2 Antenna System XP28 Antennas mounted on an H-frame to create a 15′ x 15′ square array.

The combined gain of the system will be approximately 23 dBi with a 3 dB beamwidth of 12.5°. The XP28 antennas are designed for stacking and have good Gain/Temperature (G/T) characteristics. G/T is a measure of the gain and noise performance of an antenna system. See VE7BQH’s tables for some interesting data on G/T for many commercially available EME and VHF+ antennas.

The antenna system will have separate feeds for the antenna array’s Horizontal (H) and Vertical (V) planes. The Horizontal elements will be oriented parallel to the ground to maximize ground gain when the H plane is used for transmitting (and receive). A pair of 4-port power combiners will be used to combine the H and V polarities of the four antennas into a pair of H and V feedline connections.

Plans call for a combination of the M2 Orion 2800G2 and MT3000A rotators to be used along with a Green Heron RT-21 Az/El Rotator Controller to provide computer-controlled tracking of the moon. A 22′ section of 3″ Chrome Molly mast material will allow the azimuth rotator to be located near the base of the tower where it can be easily serviced.

Tower Mounted Preamps and Polarity Switching

MAP65 Switching and Preamp Housing

MAP65 Switching and Preamp Housing

M2 Antenna Systems will be supplying a MAP65 Switching and Preamp System that will mount on the tower near the antennas. The MAP65 Housing provides switching and separate receive preamplifiers and feedlines for the H and V polarities of the antennas. Separate H and V receive coax connections bring the Horizontal and Vertical elements of the antennas back to the shack. A third coax connection is provided for Transmit. The transmit feedline can be routed to either the H or the V antenna polarity to help minimize Faraday Rotation related fading at the other end of the contact.

S2 Sequencer

S2 Sequencer

An M2 Antennas S2 Sequencer will provide Tx/Rx sequencing and H/V transmit polarity selection via the MAP65 Switching and Preamp System on the tower. The sequencer is essential to provide safe changeovers between receive and transmit and to protect the preamplifiers and the power amplifier during high power operation.

Feedline plans call for a run of 7/8″ Hardline Coax for transmit and a pair of LMR-400uF Coax cables for the H and V receive polarities.

MAP65 Capable Receive Chain

LinRF IQ+ Block Diagram

LinRF IQ+ Block Diagram

The signals returning from the moon in an EME system are very, very weak. Because of this, Noise and Dynamic Range performance are critical factors in an EME receive system. In addition, we will need a pair of high-performance, phase-coherent receivers to enable Adaptive Polarization via MAP65.

LinkRF IQ+ Dual Polarity Receive System

LinkRF IQ+ Dual Polarity Receive System

We are planning to use a LinkRF IQ+ Dual Channel Receive Converter in our EME system. The Link RF IQ+ features excellent noise and dynamic range performance and its phase-coherent design will support adaptive polarity via MAP65. The IQ+ separately converts both the H and V polarities of the antennas into two separate pairs of I/Q streams.

UADC4 High-Performance A/D Converter

UADC4 High-Performance 4-Channel A/D Converter

The four channels (two I/Q streams) from the LinkRF IQ+ must be digitized and fed to a Windows PC for decoding. The conventional way to do this is with a 4-channel, 24-bit soundcard. The available computer soundcards add a good bit of noise and therefore limit the overall dynamic range of an EME system. Alex, HB9DRI at LinkRF has come up with the UADC4 – a high-performance 4-channel ADC that is specially designed for software-defined radio. The UADC4 design is based on CERO- IF conversion and is optimized for EME use. The UADC4 should add about 10 – 15 dB of dynamic range improvement over a typical 24-bit PC Soundcard. Alex is currently taking pre-orders for the next run for UADC4 devices. You can contact him at info@linkrf.ch for more information.

Software

JT65 Software Block Diagram

JT65B Software Block Diagram

Our plans for JT65 software and related components for our EME station are shown above. We are planning on running a combination of Linrad and WSJT software on the same Windows PC to handle JT65B QSOs. There are two configurations that are applicable to our plans:

We are also planning to develop a simple windows application that will read the Moon Tracking data that is generated by WSJT MAP65 and WSJT-X and use it to control the rotator system associated with our EME antennas. More on this to come in a future article.

Transmit System

OM power OM2002+ 2m Amplifier

OM power OM2002+ 2m Amplifier

A combination of an Icom IC-9700 Transceiver and an OM Power OM2002+ 2m Amplifier will be used for the Transmit side of our system. The OM2002+ can generate 1500W when transmitting in JT65B mode.

Well, that about covers it as far as our 2m EME goals and station design go. The plan is to break ground for the new EME tower later this week. We’ll continue to post more articles in this series as our project proceeds.

Here are some links to other articles in our series about our EME Station 2.0 project:

If you’d like to learn more about How To Get Started in EME, check out the Nashua Area Radio Society Teach Night on this topic. You can find the EME Tech Night here.

Fred, AB1OC

New 70cm Yagi

M2 Antenna Systems 432-9WLA Specifications

M2 Antenna Systems 432-9WLA Specifications

We decided to replace our current 70cm yagi with a newer, higher performance one from M2 Antenna Systems. We choose the M2 432-9WLA. The new antenna has a higher gain and a cleaner pattern than our current 70cm yagi. It also has a longer boom.

New Yagi Ready For Installation

New Yagi Ready For Installation

The first step in the project was to assemble the antenna and check its SWR on the ground. The elements on an antenna like this typically vary by small amounts and are usually not arranged from shortest to longest. It is important to carefully measure each element during installation to confirm that each element is installed at the correct location on the boom.

The folks at M2 Antenna Systems made up a custom boom support truss for us. This is important given the potential for ice and snow accumulation that we face here in New England. We also made up a section of LMR-600uF coax to connect the antenna to the feedline and preamp system on our tower.

Driven Element Details

Driven Element Details

The new antenna uses a Folded Dipole style feed point. This system is essentially a T-matching arrangement where the two sides of the driven element are fed 180 degrees out of phase. It is important to set the locations of the shorting blocks carefully to ensure proper operation of the driven element and a resulting low SWR.

Yagi Going Up The Tower

Yagi Going Up The Tower

Matt, KC1XX, and Andrew from XXTowers handled the installation of the new Yagi on our tower. The installation involved climbing our 100 ft tower and the 25 ft mast at the top to remove the old yagi and install the new one. Note the careful rigging of the new antenna and associated feedline. This allows the new antenna to be pulled up the tower without damaging it.

Climbing a mast is not for the faint at heart! An installation like this one is clearly a job for experienced professionals. Andrew makes this task look easy. Our tower camera captured some video (click on the image above to play) of Andrew’s handy work.

Completed Installation

Completed Installation

The new yagi (top antenna in the picture above) is installed on a 5 ft fiberglass mast extension. The extension is used to ensure that the antenna does not “see” a metal mast which would disrupt the antenna’s pattern. The final installed height of our new yagi is a little over 125 ft. Note Andrew’s good work in attaching the feedline to the mast.

432-9WLA Installed SDR - Shack End

432-9WLA Installed SDR – Shack End

With the new yagi installed and hooked up, we made a final check of the end-to-end SWR from the shack. The antenna’s SWR is very good and the 2:1 SWR bandwidth extends from the bottom of the 70cm band to almost 450 Mhz. The new antenna is optimized for weak signal work up through the ATV sub-band and its SWR is below 1.2:1 in this range.

Fred, AB1OC

Amatuer Radio Video How-To – Putting Up A Tower

July 2019 Tech Night – Putting Up A Tower

We recently did a how-to presentation on Putting Up A Tower at a Nashua Area Radio Society Tech Night. The video from this presentation can be viewed above.

Putting Up A Tower Video – Topics Covered

We covered a variety of information related to planning, building and integrating Guyed and House-Bracketed towers. You can view the accompanying presentation materials here.

The Nashua Area Radio Society produces similar how-to training materials on almost a monthly basis and we make these materials available to our Members an Internet Subscribers (folks that live too far from our location to be regular members) for a small cost which supports our new Ham development programs and covers the production and storage costs associated with the video material. Here’s a list of the training topics that we’ve produced to date:

2019 Tech Nights

  • Fox Hunting: Radio Direction Finding for Beginners including a Tape Measure Yagi Build by Jamey Finchum, AC1DC
  • Surface Mount Technology by Hamilton Stewart, K1HMS
  • RF Design with Smith Charts, Building a First HF Station, and Begining with CW – Hamilton Stewart, K1HMS; Anthony Rizzolo, KC1DXL; and Jerry Doty, K1OKD
  • All About Field Day 2019 by our Field Day Planning Team
  • Putting up a Tower by Fred Kemmerer, AB1OC

2018 Tech Nights

  • Operating Your Station Remotely by Fred Kemmerer, AB1OC
  • Transceiver Frequency Measurement and Calibration by George Allison, K1IG.
  • DMR Radios and Programming by Bill Barber, NE1B
  • WSJT-X: FT8, WSPR, MSK144 and More by Fred Kemmerer, AB1OC
  • Getting Started with Raspberry Pi Computers by Anita Kemmerer, AB1QB, Jamey Finchum, AC1DC,  Brian McCaffrey, W1BP, Fred Kemmerer, AB1OC, and Craig Bailey, N1SFT
  • All About Field Day 2018 by our Field Day Planning Team
  • Portable Operating Gear – demonstrations by Nashua Area Radio Society Members
  • K1EL Kits by Steve Elliott, K1EL
  • Antenna Modeling I by Scott Andersen, NE1RD.
  • Building and Operating a Mobile HF Station by Fred Kemmerer, AB1OC

2017 Tech Nights

  • High-Altitude Balloons: Amateur Radio at the Edge of Space and was presented by our HAB Team.
  • Getting On The Air 2.0 by Fred Kemmerer, AB1OC, and B. Scott Andersen, NE1RD
  • All About n1fd.org – Getting the most from our Website by Fred Kemmerer, AB1OC.
  • Digital Modes: RTTY, PSK, and WSJT-X by Mike Struzik AB1YKAnita Kemmerer AB1QB, and Fred Kemmerer, AB1OC
  • Bonding and Grounding by Jeff Millar, WA1HCO and Fred Kemmerer, AB1OC.
  • All About Field Day 2017  by Dave Merchant, K1DLM, and our Field Day Planning Team.
  • Building and Operating a Satellite Ground Station by Burns Fisher, W2BFJ and Fred Kemmerer, AB1OC.
  • DXing and QSLing by Anita Kemmerer, AB1QB; Bill Barber, NE1B; Fred Kemmerer, AB1OC; and Dick Powell, WK1J.
  • Weak Signal VHF and UHF Stations by Jeff Millar, WA1HCO and Bill Barber, NE1B.
  • Getting the Most from your HF Transceiver and More by Fred Kemmerer, AB1OC and Dave Michaels, N1RF.

2016 Tech Nights

  • Popular Loggers – Ham Radio Deluxe and DXLab Suite by Dave Merchant, K1DLM and Fred Kemmerer, AB1OC.
  • Low-Band Antennas by Dennis Marandos, K1LGQ; Hamilton Stewart, K1HMS; Brian McCaffrey, W1BP; and Fred Kemmerer, AB1OC.
  • RF Simulation and Matching by Jeff Millar, WA1HCO
  • Directional Antennas by Fred Kemmerer, AB1OC; Dave Michaels, N1RF; Brian Smigielski, AB1ZO; and Greg Fuller, W1TEN
  • All About Field Day 2016  by our Field Day Planning Team.
  • Surface Mount Soldering and Desoldering, a Hands-On Presentation by Jeff Millar, WA1HCO
  • Building Your First Station and Getting On The Air by Fred Kemmerer, AB1OC, and Dave Michaels N1RF
  • Software Defined Radios by Fred Kemmerer, AB1OC and Skip Youngberg, K1NKR
  • Advanced Repeaters (DMR, EchoLink, DMR, and D-STAR) by Anita Kemmerer; AB1QB, Fred Kemmerer, AB1OC; and Bill Barber, NE1B
  • Antenna Modeling with EZNEC by Fred Kemmerer, AB1OC

You can gain on-going access to the full library of Amateur Radio Training and How-To materials by supporting our work to bring new people and young people into the Amateur Radio Service as a Nashua Area Radio Society Internet Subscriber. You can learn more about how to become an Internet Subscriber here.

Fred, AB1OC