ASSEMBLY INSTRUCTIONS

SWITCHABLE POLARITY
16 ELEMENT BEAM

LASER 500

Mace Manufacturing Co. - Division of Majestic Communications, Inc.

4091 I&count - Memphis, Tennessee 38118 (901) 794-9494
 MAC0 LASER 500
PARTS LIST

O
PART . OTYD . SIZE LENGTH DESCRIPTION CHECKLIST
T39 2 3” .065” 20’ Alum. Tubing
T36P 1 2 . 8 3 2 ” .125” 4 8 ” Alum. Tubing
TllP 16 518” .047” 72” Alum. Tubing slotted both ends
TO1 28 l/2” .035” 72” Alum. Tubing
VO2P 1 1~2”~ 1~2” 3 6 ” Vertical Guy Support
PO4P 1 6” x l/4” 18” Plate
WD3P 1 6118 50’ Steel Guy Cable
WO4P 1 14 GA. 40’ Bare Copper Wire
FAlP 4 48” Fiberglass Rods
GOlP 2 11 Meter Gamma Matches
HARDWARE BAG #l
W58P 32 518” Extruded Alum. Clamps
EGl 6 Egg Insulators
S28 1 l/2” 3 l/2” Hex Bolts
s21 42 1 O-24 l/2” Machine Screws
Nil 44 1 O-24 Square Nuts
N15 1 l/2” Hex Nuts
N16 1 l/2” Lockwasher
N17 3 l/2” Flatwashers / Cut
N18P 2 5/16” 4” Eyebolts / Welded
PL2 28 .437” Plastic Caps - Black
NO1 14 5/l 6” Hex Nuts
NO2 10 5/l 6” Lockwashers
N12 12 #lO Lockwashers
N26 4 #lO Flatwashers
ZO2P 4 l/2” 4” Gamma Straps
ZO8P 4 Female Coax. Connectors w/Mounting Nuts
S42 2 Plastic Cap - Black
PL6 1 3” Plastic Cap - Red
PL6R 1 3” Hex Nuts
N19 42 318” Lockwasher
N20 42 318” HARDWARE BAG #2
Plated U-Bolts
uo3 21 3” Plated U-Bolts
UOl 5 2” HARDWARE BAG #3
Plated Saddles
so3 21 3” Plated Saddle
so1 5 2” HARDWARE BAG #4
BE3P 16 3” Boom-to-Element Mounts
WHEN ORDERING REPLACEMENT PARTS, ALWAYS GIVE PART NUMBER AND DESCRIPTION.
PLEASE NOTE: In an effort to keep the price on Mace Antennas down, we have decided not to clean up all the burrs and rough
edges on the parts. We recommend that you deburr and clean up each part with files, sandpaper, etc. so that they go together
easily. We are aware this needs to be done, but have elected not to do it to save you the money we would have to add to the
price of the kit for this service.
1 LASER 500
 MACOLASER500
ASSEMBLY INSTRUCTIONS

FIGURE 1 GENERAL INSTRUCTIONS

This drawing depicts an overall view of what the antenna should look like upon completion of assembly.
Refer to Figures 2 thru 4 for specific assembly details. All hardware should be coated with a silicon rubber sealant
or similar compound to insure that wind vibration does not cause it to work loose.
Upon completion of assembly, install the red plastic cap (PL6R) on the director end ofthe antenna, and the
black plastic cap (PL6) on the reflector end. This will allow you to determine at a glance the direction of transmit
and receive.

FIGURE 2. BOOM AND GUY ASSEMBLY

Mark the center of the boom coupler (T36P) and slide both boom sections over each end so that they meet
in the center. Next mount the boom-to-mast plate PO4P and the guy support (VO2P) at the center ofthe boom using
3” U-bolts, saddles and hardware as shown in detail 2A.
The first step is assembling the guy cable is to cut 8 pieces of the following lengths
off the roll of cable.
2 PCS. . . . . . . . . . . . . . 2’ 0” long
2 PCS. . . . . . . . . . . . . . 2’ 10” long
2 PCS. . . . . . . . . . . . . . 6” l-1/2” long
2 PCS. . . . . . . . . . . . . . 6” 10” long
Take both 2’ 0” lengths and attach one end of each to an egg insulator (EGl) and the other end to an eyebolt
(Nl8P) so that the distance between the eyebolt and insulator is 1 foot. Make all your wraps as shown in details 2C
& 2D. Attach both eyebolts to the vertical guy support with 5/16” hex nuts as shown in detail 2C. Run the outside
hex nuts only a couple ofturns onto ends ofthe eyebolts and leave the inside nuts loose so that you can take the slack
out of the cable later.
Now take one 6’ i-1/2” length and attach it to the cable and insulator on the vertical guy support that goes
toward the driven element end of the boom. Fasten the other 6’ l-1/2” length to the end of the cable assembly with
an egg insulator. Next attach the 2’ 10” length to the end with another egg insulator in the same manner.
You should have two 6’ 10” lengths and one 2’-10” length remaining. Assemble andattach them to the vertical
guy support on the other side in the same manner. (At this point it will be necessary to go on to element assembly
and mounting before attaching the guy cables to the boom.)
After you have mounted your elements wrap the ends of both guy cable assemblies around the boom at the
5th. director on one end and the driven element on the other end. Pull out as “much slackas possible” and make your
wrap as shown in detail 2D.
Take the rest of the slack out of the cables by tightening the outside hex nuts on the
eyebolts. Lock them in place by tightening the inside hex nuts.
This antenna is designed for mounting on a 2” O.D. heavy duty mast. Mount using 2” U-bolts, saddles and
hardware as shown in detail 2B.

CAUTION: TARE CARE TO AVOID ANY CONTACT WITH OVERHEAR POWERLINES

WHEN RALSING YOUR ANTENNA. SERIOUS OR FATAL INJURY COULD RESULT.

MAC0 MANUFACTURING, 4091 VISCOUNT AVE., MEMPHIS, TN 38118

For parts or information call (901) 794-9494.
LASER 500 2
FIGURE 3 ELEMENT ASSEMBLY
Prior to assembling elements slide a boom-to-element mount (BE3P) onto each of the (16) element center
sections (TIIP). Assemble each element as shown using the clamps and hardware specified. Refer to the element table
to determine dimensions for each element. Install a black plastic cap (PL2) onto both ends of each element. Assemble
the reflector elements in the same manner. sliding the fiberglass arms approximately 6 inches into the ends ofthe center
sections (TllP). Snug the clamps but don’t tighten at this time because the arms will have to be adjusted after installing
the reflector wire.

FIGURE 3B ELEMENT MOUNTING

Mark each element at the center and be sure that the boom-to-element mounts (BE3P) are centered on the
elements before tightening hardware. Starting 1” from the director end of the boom, mount each element using 3” U-
bolts, saddles, boom-to-element mounts and hardware as shown. Refer to Figures 1 & 3B for element spacing
dimensions. (At this point go back and complete the guy cable assembly.)

FIGURE 3C REFLECTOR ASSEMBLY

The length of the reflector wire is very critical. It must be the correct length to operate correctly. Take the wire
(WO4P) and uncoil it making sure that there are no kinks; secure it to a nail. Pull the wire until it stretches an inch or
so. The easy way to get the correct length for the reflector loop is as follows:
I. Drive 2 nails in a board or fence l/2 the length of the loop apart --which is 228” (5.790m) between
them.
2. Stretch the wire around the nails by hand as tightly as possible and splice ends together. Solder the splice. Remove
one nail and remove the loop. Cut any excess wire off.
3. Loosely assemble the machine screws (S2 l), flatwashers (N26), lockwashers (N12), and hex nuts
(NO6) onto the lugs of the fiberglass arms, adjusting the length as shown.
4. Tighten 3 of the 4 clamps that hold the fiberglass rods.
5. Install the wire as shown.
6. Tighten the wire by pulling the fourth fiberglass rod until the wire is the same tightness as it was
around the nails. The wire loop is now the correct length. Note the total length of the loop is critical, and also is the
length of each side. REMEMBER: Reflector dimensions are only preliminary. Change to get equal sides of 9’6”
Fiberglass length is not critical, however the equal wire length of 9’ 6” is very critical.

FIGURE 4 GAMMA MATCH MOUNTING

Mount the (2) gamma matches (GO 1P) to the horizontal and vertical driven elements, using the gamma straps
(ZO2P, ZOSP) and attaching hardware as shown. Attach your 52 ohm coaxial cables to the connectors (S42) and dress
along boom and down the mast.

ADJUSTING STANDING WAVE RATIO

Refer to Figure 4. The dimensions given are approximate and should be used as a starting point. The following
instructions cover the adjustment of one gamma match. To adjust the second gamma match, simply repeat this
procedure.
The gamma match has 2 adjustments. First is the capacitor adjust and the second is the slider adjust. Connect
a S. W. R bridge to the coax between your transmitter and the antenna and check the S.W.R. If adjustment is required
loosen the clamp on the gamma match and the screws holding the slider (Gamma Straps ZO2P). Next move the capacitor
adjustment first in one direction then the other until a minimum S.W.R. reading is obtained. If S.W.R. is not yet
satisfactory, move the slider out 2” away from the boom. Ifthe reading has gone up, move the slider back to the original
position and then 2” toward the boom. Now readjust the capacitor for minimum S.W.R. you should now be able to
determine which direction to move the slider. Repeat the above procedure moving the slider in smaller increments until
a satisfactory S.W.R. reading is obtained. Tighten all hardware. Disconnect the S.W.R. bridge and reconnect your
coaxial cable.

3 LASER500
 REFLECTOR
I- ( S E E F I G . 38)

DRIVEN ELEMENTS

P
(17’~5”)
PLG-BLACK A
PLASTIC CAP
\

G A M M A MAT
(SEE FIG. 4)
/
1st DIRECTORS k
(16’ - 9”)
A

2nd DIRECTORS-
(16’ - 9”)

3rd DIRECTORS’
(16’ - 8”)
A

4th DIRECTOR5
(16’ - 8”)
A
‘PLGR - R E D
5th DIRECTORS PLASTIC CAP
(16’ - 8”) \
A

6th DIRECTOtis \
-
(16’ - 8”) PLi’-PLASTIC C A P
A (TYP. 28 PLACES)
NOTES:
* 1. For details of boom assembly and mast mounting see figure 2.
*2. For details of element assembly and mounting see figure 3.
*3 Horizontal and vertical element spacing dimensions are
identical with l/4” gap between boom-to-element mounts.
(see figure 3C)

LASER500
 m - w - - - - - - - . c ___------- - - - - - - - - - - v - - -
- - - - - - - e - e----s
S28. N15, N16, N17P,
c
I v
I 3 l/2” x 112’ HEX. HD. BOLT,
<E%-~“,~~TlON
I (3) l/2” FLAT WASHERS,
I l/2” LK. WSHR. & HEX NUT
I
* (SEE NOTE BELOW)
T39 - 20” I
-3OM SECTION 1 BOOM WITH BOOM-TO- \ *
. UT-,- BO,-,-, SECTlONsl MAST PLATE ATTACHED
/ x;KETHER A T CENTER: _ /,,-- a!=
BOOM , I
I
I
I
I
I
VO7P I
I
_--. - VFRTICAI
_-. ..-. .- -4
I
G SUPPORT PO4P- BOOM- .TO-
_ ,MAST PLATE I
I
I
I
I
I
/ UOI, SOI. NOI, N02,h !
2” 0. D. MAST/ .- 2” U-BOLTS 8. S A D D L E S
( C U S T O M E F> 5116” NUTS 8, WASHERS
FURNISHED) (TYP. 4 PLACEis) _I

‘NOTE: TO USE THE BOOM TILT FEATURE. FIRST

MOUNT BOOM ON THE MAST WITH THE (4) U-BOLTS I
8. SADDLES AS SHOWN. DRILL A l/2” HOLE IN THE
I”” I, MAST TO LINE UP WITH THE l/2” HOLE IN THE PLATE:
3” U-BOL TP Iau cl\nnt cc AND INSTALL THE BOLT, WASHERS & NUT. TO TILT :
57 \~C\VYLLU
5116” N U T S a WASHER~S THE BOOM, SIMPLY REMOVE THE U-BOLTS. WHEN ;
I
\
\----------------
DETAIL 2A ’
,-r\,rY
__--
e? -I n-r-c.\
I T t-. 3 r-LHLC3,

-,,--.w-~
j
\
NOT USING THE BOOM TILT FEATURE YOU SHOULD .
INSTALL THE 5th U-BOLT AND HARDWARE.
T\CTAII
“L I r\lL ?c)
L”
I

I
I
‘NOTE: HORIZONTAL ELEMENTS ARE ONLY \ - - - - a - _ - - - - - - - - - - - - - - - - -
S H O W N F O R R E F E R E N C E . S E E F I G . 38 FOR
ELEMENT MOUNTING DETAILS

T39 - 20 FT.
BOOM SECTION 2” 0.D. MAST BOOM SECTION
(DET. 28)

EGI -INSULATOR \
l VO2P - VERTICAL1
1 GUY SUPPORT
I
N18, NO1
I
4” EYEBOLTS
I GUY CABLE
5/16” HEXNUTS
I
I
I

HORIZONTAL / U
BOOM-TO-ELEMENT
MOUNT

DETAIL 2C INSULATOR DETAIL 2A )

i- - __________-___-- --,,,----m---d
:
h----------------e. -m-,---l. -

5 LASER500
 I 1ST DIRECTOR 1 16’ 9” 1 5’ 4-l/2”
2ND DIRECTOR 16’ 9” 5’ 4-l/2”
W58. 521. Nl 1 W58. S21. Nil
C L A M P WI1 H #llJ-24 x1/2’ C L A M P WITH X10-24 x112” 3ND DIRECTOR 16’ 8” 5’ 4”
S&REW 8 SO. N U T S C R E W 8. SQ. NUT
1‘h’H DIRECTOR1 16’ 8” 1 5’ 4”
~TH DI R EC T O R 16’ 8” 5’ 4”
FIBERGLASS
6TH DIRECTOR 16’ 8” 5’ 4”
112” 0 D.
TUSING

REFLECTORDIMENSIONS AREONLY PRELIMI-

NARY. CHANGETOGETEQUALSIDESOF9’6’.
\ FIBERGLASS LENGTH IS NOT CRITICAL, HOW-
IllP’
518” 0 D
TUBING TUBING

ELtMEN I ASSEMBLY (FIGURE 3A)

ORIZONTAL
TUBING ELEMENT
ELEMENT
BE2P - MOUNT
HOOM - IO
ELEMENT
MOUNT

S/8” 0. D
TUBING

“01 SO1 NU,, NO2--/

UUI. SO2 NUI. NO2. 1 2” U-BOLT 8. S A D D L E
2” U-BOLT 8 SADDLE 5/16” N U T S & W A S H E R S
5116” N U T S 8 W A S H E R S
HORIZONTAL ELEMENT SPACING ELEMENT SPACING

VEH I ICAL FL FMtNl M O U N T I N G

F I G U R E 38
------------------------------------__

( F I G U R E 3C)

S 2 1 Nil. N12. N 2 6 . FIBERGLASS

R O D (FAlP)

( T W I S T ENOS TOGETHE
&SOLDER)

LASERS00 - 6
* NOTE. THESE DIMENSONS ARE APPROXI-
MATE.iEFER TO THE INSTRUCTIONS ON
ADJUSTINNG THE S.W.R. TO DETERMINE EX-
ACT SETTINGS. THERE ARE 2 SEPARATE
GAMMA ADJUSTMENTS, I. CAPACITOR AD-
JUSTMENT, 2. SLIDER POSI’I‘ION.
DO NOT MOVE BOTH AT THE SAME TIME.
MOVE THE CAPACITOR FIRST, THEN, IF NEC-
ESSARY MOVE THE SLIDER, AND GO BACK TO
THE CAPACITOR. Z08P-GAMMA S T R A P S
(INSTALL FLUSH AGAINST
BOOM-TO-ELEMENT MOUNT)

USTOMER FURNISHED
OAXIAL C A B L E S

HORIZONTAL
DRIVEN
ELEMENT

7@ \
3/E” 24 NUT \ s42

\
\ \
\

318”
PLASTIC
FLATWASHER SHOULDER
WASHER

(SLIDER) 1

V E R T I C A L /
DRIVEN ELEMENT

GOIP
HORIZONTAL
GAMMA MATCH VERTICAL
GAMMA MATCH

LASER 500
GAMMA MATCH MOUNTING <?GEizrJ

LASER 500