DB 42 manual (aug2011).qxd

DB 42 manual (aug2011).qxd
Dream Beam 42
Assembly Manual
REVISION 2.0 (01/13/2012)
Craig Thompson K9CT DB42 Stack
2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415
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2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415
NOTE: On some of the items in this pick list, we have given you more quantities than you need in case for
some reason you lose or damage some of the fasteners, and to protect against us shorting you accidentally.
There are two quantities listed - “included”, and “required”. As long as you have the amount that is required,
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2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415
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NOTE: On some of the items in this pick list, we have given you more quantities than you need in case for
some reason you lose or damage some of the fasteners, and to protect against us shorting you accidentally.
There are two quantities listed - “included”, and “required”. As long as you have the amount that is required,
you are in good shape, but do not be alarmed if on some items you have more than you need.
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2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415
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NOTE: On some of the items in this pick list, we have given you more quantities than you need in case for
some reason you lose or damage some of the fasteners, and to protect against us shorting you accidentally.
There are two quantities listed - “included”, and “required”. As long as you have the amount that is required,
you are in good shape, but do not be alarmed if on some items you have more than you need.
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2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415
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NOTE: On some of the items in this pick list, we have given you more quantities than you need in case for
some reason you lose or damage some of the fasteners, and to protect against us shorting you accidentally.
There are two quantities listed - “included”, and “required”. As long as you have the amount that is required,
you are in good shape, but do not be alarmed if on some items you have more than you need.
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4
TOP LEVEL BUILD NOTES
BOOM ASSEMBLY - CHAPTER ONE
1. Refer to chapter 1 and follow the instructions for assembling the boom. In the next
few sections everything mounted to the boom will be installed in preparation for
running the control cables and coax jumpers. This ensures no saddle clamps or
brackets will be inadvertently placed over a control cable causing a short circuit.
MOUNTING ELEMENT PLATES - CHAPTER TWO
1. Refer to Chapter 2 and follow the instructions for mounting each element plate.
The Element Housing Unit (EHU) mounting details are also shown but they are not
mounted at this time.
MOUNTING AND WIRING EHU'S - CHAPTER TWO
1. Mount each EHU to element mounting plates and attach the control cable. Refer to
figure 2.02 and 2.03 for details on wiring the EHU connectors. Director 1 does NOT
have a connector, it has the cable hardwired inside of the EHU, you only need to route
the cable and attach the connector on the Connector Box end.
Refer to the following Chapter 2 figures for mounting details on each of the EHU's:
REFLECTOR - Figure 2.01, 2.40
DRIVEN – Figure 2.01, 2.20
DIRECTOR 1 – Figure 2.01, 2.15, 2.16
DIRECTOR 2 – Figure 2.01, 2.30
DIRECTOR 3 – Figure 2.01, 2.40
2. Route and tape control cable all the way to the connector box and cut the cable to a
length that leaves enough wire to allow routing the cable into the connector box neatly.
Refer to chapter 5 for details on attaching the connectors on each EHU control cable.
After installing the proper connector on each control cable plug the connector into
appropriate position as shown in Figure 5.03. If desired the cable can be cut and left
for now and all of the connector attachment done later. Just be sure not to cut it too
short.
MAST PLATE AND TRUSS ASSEMBLY - CHAPTER THREE
1. Refer to Chapter 3 and follow the instructions for assembling the mast plate and
boom truss support. Mount the boom truss end attachment brackets on the boom.
The marks made earlier on the boom are used when mounting this and all of the
following hardware. The boom truss cables are assembled on the completed boom
this is why all of the boom truss supports and attachments are installed at this time.
Refer to Chapter
2. Assemble Phillystran boom truss cables and attach them to the truss support and
boom attachment points as described in Section 3.2, the Double Boom Truss
Assembly Procedure.
3. If you have either the 39' Loop Element truss option and/or the 80m Dipole mount
the vertical supports onto boom. The actual trusses will be installed later. Refer to the
chapter 12 for instructions.
Attach antenna to the mast - CHAPTER THREE
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5
TOP LEVEL BUILD NOTES (CONTINUED)
MOUNTING COAX SWITCH, CONNECTOR BOX AND 6M ELEMENT - CHAPTERS
FOUR , FIVE AND SIX
1. Mount optional 6m elements if applicable. Refer to Chapter 4 for details.
2. Mount the Connector Box to the boom truss support. Refer to Chapter 5.0, Figure
5.01, 5.02 and 5.03 for mounting details.
3. Mount and Wire the Coax Switch. Refer to Chapter 6 for details. Route the Coax
Switch control wire to the Connector Box then cut and terminate the cable with the
supplied connector. Plug into connector J6 on the Connector Box PCB. Install all of
the coax jumpers from antenna switch to each EHU and tape them neatly to the boom.
PREPARING THE CONTROL CABLE AND TESTING WIRING - CHAPTER FIVE
AND CHAPTER SEVEN
1. Refer to Chapter 5 to prepare the 24 conductor control cable by installing the
connectors at both ends. If you have the optional DB25 Control Cable Splice refer to
chapter 5, section 5.1 and 5.2 for installation details. Otherwise use the supplied
solder type DB25 male connector. It is highly recommended that you test the antenna
as described in the next section BEFORE mounting it on the tower. You will need a
control cable to do this. If you have already ran the control cable to the radio room the
following test can be done if you have two people and a pair of two way radios. If
possible use the final cable you intend to use coiled up near the antenna, you then
know the entire system is good after the test. You can also just make a short test
cable to do the testing with.
2. Perform the diagnostic test as described in the Chapter 7, Section 7.0,
Pre-Installation Tests. If you have the 80m Dipole option perform the test described in
section 7.0 as well
PREPARING TELESCOPING POLES AND SWEEP ASSEMBLIES - CHAPTER
EIGHT
1. Refer to Chapter 8, Section 8.0 and 8.1 for details on preparing the telescoping
fiberglass poles.
Be aware the non-loop poles require no cutting, simply apply the heat shrink and end
cap as directed.
CPVC GUIDE TUBES AND DIVERTER CONE ASSEMBLY - CHAPTER NINE
1. Refer to Chapter 9 for details on assembling the guide tubes.
ATTACHING THE TELESCOPING POLES TO THE EHU'S - CHAPTER TEN
Attach telescoping poles to EHU's.
INSTALL 80M DIPOLE OPTION (If applicable) - CHAPTER ELEVEN
1. Refer to the manual for the 80m Dipole and install as shown. Refer to the chapter
5, figure 5.05 and chapter 11, figure 11.09, 11.09A and 11.09B for wiring details.
Install all element truss ropes and tension as described - CHAPTER TWO AND
CHAPTER 12
Perform mechanical testing - CHAPTER SEVEN AND CHAPTER THIRTEEN
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6
BEGINNING ASSEMBLY OF THE DB42 MONSTIR PRO YAGI
Notes:
Before beginning assembly of this antenna, please read the manual in it’s entirety to familiarize yourself with the task at hand. Doing so will eliminate potential confusion.
Be sure to do an inventory of your parts as soon as possible after receipt of the antenna, and
well before your intended installation date - this way we can get you the parts required
before it’s too late.
Following this page are inventory break down lists for each portion of the installation. When
doing inventory on the parts, we recommend you divide the items needed for each of the
separate steps. It will make handling and organization of the parts a much easier task!
We recommend you follow the sequence that the inventory breakdown lists are in, regardless of layout of the DB42 instruction manual.
A large, cleared flat area is recommended for assembly of an antenna of this size and complexity.
Typically, an area 40 ft x 50 ft would be ideal. We recommend using sawhorses or sturdy tables
when installing the boom. By having the boom elevated, it is easier to ensure that the elements are
level. Rubber or nitrile gloves are recommended when applying the anti-seize to the stainless steel
fasteners or the aluminum boom sections.
If you do not have room near the tower to assemble the antenna, we suggest you find a place that
you can put the antenna together in it’s entirety and then disassamble as needed for transportation
to the tower area.
Use of a level for adjusting the Element Housing Units (EHU’s) is highly recommended. This is a
surprisingly accurate and consistent method. Simply place the level on the mast plate, and adjust
each element accordingly.
Be sure to use the anti-seize compound supplied to prevent the galling of the stainless steel fasteners. If you do not use the anti-seize, count on issues with the hardware galling. Heat is one of the
primary culprits with galling, so if you use a ratchet, steady speed as you tighten will help minimize
galling. We have found that when the anti-seize is applied to the bolt portion of the hardware, it will
eliminate any galling issues.
There is one exception to using the anti-seize - do NOT use the anti-seize compound when
connecting the plastic sweeps coupler to the pole ends. This will be covered in more detail
later in the manual.
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7
PARTS REQUIRED BREAKDOWN BY CHAPTER
CHAPTER ONE
SECTION 1.0
SECTION 1.1
CHAPTER TWO
SECTION 2.1
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CHAPTER TWO
SECTION 2.1
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CHAPTER TWO
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CHAPTER TWO
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CHAPTER TWO
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CHAPTER THREE
SECTION 3.0
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CHAPTER THREE
SECTION 3.4
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CHAPTER FIVE
SECTION 5.0
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15
CHAPTER ELEVEN
SECTION 11.0
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16
CHAPTER ONE
Section 1.0
Locate boom pieces
QTY 2
QTY 2
QTY 2
QTY 2
QTY 1
1 3/4” X 72”
2” X 72”
2 1/4” X 48”
2 1/2” X 44”
3” X 72”
BOOM ASSEMBLY
NOTES:
Our boom pieces are all drilled on a very precise drill press. This ensures that all the bolts are
snug when assembled. If your boom ever gets damaged or destroyed we can now send the specific
replacement boom required. Always apply lubricant to stainless steel bolts that are using
stainless steel nuts. This will prevent the two from galling together. Each bolt has a specific
length for the tubing it is holding together this is critical so that only the shank is engaged in the tubing. Use 5 washers per bolt to secure the bolt as shown in figure 1.02.
Apply a thin film of connector protector or a spray-on lubricant (i.e. Anti-seize, Noalox) to the
male engagement area of the boom sections.
The boom ends will have a color coding so that you know which pieces slide into each other.
Match the colors as shown in figure 1.01 below and slide the boom pieces together until the
pre-drilled holes align.
Secure the correct bolts and washers onto the boom as shown in figure 1.02
Repeat this for each section until the boom is completely assembled.
The final step is to secure the eyebolt as shown in figure 1.01 and figure 1.02
See washer placment in figure 1.2 for 1/4” and 5/16” boom bolts
Figure 1.01
1 3/4” Boom
Section
10-1202-01
1/4” X 3” Hex Bolt
60-0029 and five
1/4” flat washer
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2” Boom
Section
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Section
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Section
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Boom Assembly
2 1/4” Boom
2 1/2”
Section
Boom
10-1202-21
Section
10-1202-71
5/16” X 4” Hex Bolt 600066 plus two 5/16” flat
washers 60-0033
1/4” X 3 1/2” Hex Bolt 60-0100, five
1/4” flat washer 60-0041, Boom sleve
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Section
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washers 60-0041
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Section
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flat washer 60-0041
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17
CHAPTER ONE
SECTION 1.0
BOOM ASSEMBLY (continued)
BOOM / EZ EYEBOLT DETAIL
NOTES: When securing the eye-bolt and boom bolts to the boom, install the eye and the head of
the bolts on the same side of the boom, so that they will be facing upwards when the boom is
secured to the tower. The 1/4” boom bolts require 5 washers, as shown below in figure 1.02.
IMPORTANT: The 5/16” boom bolts only require 2 washers, placed above the Nylock nut.
Boom Bolt Assembly
Bolt heads
facing up
QTY 2: 60-0041
SS Flat washers
No washers
needed for eyebolt
See page 2 for specific bolt lengths
QTY 3: 60-0041
SS Flat washers
Figure 1.02
Eye-Bolt Assembly
Top of boom
QTY 1: 60-0151
3/8” x 4.5” SS Eye-bolt
QTY: 1 60-0050
3/8” SS Nylock
QTY:1: 60-0030
1/4” Nylock Nut
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18
CHAPTER ONE
SECTION 1.1
BOOM ASSEMBLY (continued)
NOTES: We recommend that you use an aluminum saddle half for drawing your marks on the boom. Determine your
mark using figure 1.10 below, the dimension shown is to the closest edge of the saddle, then draw a line on each side
of the saddle piece. This prevents any possible mistakes on where the saddle edge should be on the measurement.
The truss anchor point between the boom bolts shown below is the same on both ends of the boom. The EZ-Eye is
NOT at the center point of the boom. Because of this, you will have a short side and a long side (on the 3” boom section) in relation to the EZ-Eye. Position boom as shown below when measuring for your marks. Mount each aluminum
plate and truss saddle as shown in the table, be aware that the dimensions shown in the table below refers to the saddles closest to the reflector end of the boom for the mounting plates.
Figure 1.10
DB42 BOOM MARKING TABLE
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19
CHAPTER TWO
SECTION 2.0
MOUNTING THE EHU’s TO THE BOOM
NOTES: Figure 2.01 shows the measurements from centerpoint to centerpoint for each element.
While we have had you use the marking table measurements in figure 1.10 for placement of each
item on the boom, this next step of measuring centerpoint-to-centerpoint is extremely important to
insure you have proper center-to-center spacing between each element. When in doubt, always
default to these dimensions as It is critical to have accurate center-to-center spacing for the
antenna to work properly.
CENTER-TO-CENTER ELEMENT SPACING GUIDE
Figure 2.01
ALL DIMENSIONS INDICATE ELEMENT-CENTER TO ELEMENT-CENTER SPACING
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20
CHAPTER TWO
SECTION 2.0
EHU MOUNTING (continued)
WIRING THE ELEMENT HOUSING UNIT (EHU)
NOTES:
Follow the directions below for wiring each of your element housing units (EHU’s) from the respective EHU to the DB42 connector junction box. You must wire the EHU’s before placing on the mounting plates but it is recommended that you refrain from routing the wires from each EHU to the connector junction box until all items on the boom are assembled. Be sure to avoid any sharp edges
when routing the cables and TAKE GREAT CARE to not place any aluminum saddles over control
cables or a short could occur.
Follow figure 2.02 for wiring and routing cable in the wire tray on the lip of the EHU.
Depending on EHU type there will be 4 conductor or 6 conductor wire. Follow the wiring code that is printed on the
circuit board inside the EHU as shown in figure 2.03.
Be sure to unplug the top portion of the connector when wiring, as you cannot see the correct wiring code until the
upper plug is removed. The correct wiring code is printed closest to the terminal block and reads left to right:
Bk, R ,G, W, Blu, Br. For 4 wires use Bk, R, G, W and ignore Blu & Br. For 6 wires use: Bk, R, G, W, Blu, Br.
Trim the shield wire so that it is not exposed inside the EHU.
Dip each wire into the
included connector
protector before
securing.
NOTE:
Wire the cable to the correct terminal on the wiring connector board. Follow the color code on the circuit board
as shown in figure 2.03. Route the wire into the wire
tray. Place a .25” piece of the provided coax-seal over
the cable and form it so that its flush with the wire tray.
Do this in the 3 locations shown below. (This will keep
the cable in place and prevent water from leaking into
the EHU.)
Figure 2.02
Wire tray
Reel
Figure 2.03
Use this line for wiring. For 4 wire connections the wiring order is: BK, R, G, W. For
6 wire connections the wiring order is: BK,
R, G, W, Blu, Br.
Location for
COAX seal
SteppIR Use only, do not use this line for wiring!
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21
CHAPTER TWO
SECTION 2.1
Notes:
EHU MOUNTING (continued)
ASSEMBLING DIRECTOR 1 (49 FT LOOP ELEMENT)
It is best to first install the EHU mounting plates, and then go back and mount each EHU to the
respective mounting plate. This way the EHU is not in the way as you are trying to level the
mounting plates to the boom.
To get all the elements level use a level to set each element plate. Then tighten the saddle
clamps, make sure to alternately tightening the bolts on the saddle clamps to avoid moving the
plate and changing the level.
After all the element plates are level, you can increase the saddles grip by putting the provided
Refer to the marks on the boom from figure 1.10 for correct placement of the driven element. Figure
2.10 shows the 49 foot Element Housing and Return EST assembly.
Mount the Element Support Plate and Return Plate to the boom, leave the bolts loose enough to allow
for leveling adjustments.
Level the plates to the boom, so that the eye portion of the EZ eye is on the top side of the boom.
Attach the EST extension tubes as shown in figure 2.13 and figure 2.14 once the plates are secured.
Place the stress relief tubes over the applicable EST extensions as shown in figure 2.13 and figure
2.14.
Tighten boom saddle bolts to 20ft/lbs (27.09Nm)
Tighten the EST extension saddle bolts to 15 ft/lbs (20.34Nm)
Follow figure 2.13 and figure 2.14 for correct assembly of EST extensions. Place the Stress Relief
Tubes over the applicable EST extensions as shown in figure 2.14.
Figure 2.10
MAST PLATE
Director 1 EST Extension Assembly
10-1608-01 Return Tube Mounting Plate
70-2028-01 Return EST Extension 66 3/8”
70-2028-01 Return EST
3” Boom Section
.4” ring for attaching rubber
boot and telescoping pole.
Shown later in manual
.4” ring for attaching rubber
boot and telescoping pole.
Shown later in manual
Driven Element Support Plate
10-1605
70-2029-01 Driven EST Extension 60 3/4”
70-2029-01 Driven EST Extension 60 3/4”
The tips of EST extensions should be the
same distance from the boom to allow for
the telescoping poles to be mounted correctly. This will affect the straightness of the
element.
The tips of EST extensions should be the
same distance from the boom to allow for
the telescoping poles to be mounted correctly. This will affect the straightness of the
element.
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22
CHAPTER TWO
SECTION 2.1
EHU MOUNTING (continued)
Figure 2.13
Director 1
Assembly
"
""
!
#
!
5
0
"
-!,
$
%!+66
61
!!!
"
$
%!+66
61
!!!)
"
-
!
#
-!
5
0
!
#
0
!
!
"
-!,
"#!!
$%!!&'(
#!)
*'#!! $
!+$,+
+
!
-
!
#
3
2
0
#!!
$%!!&'( #
!)
*'./+, +!,
!,+!%0
)+/1++
!!2
23 ,
*4,/
"-!
*'#
7!+,/!!,++
+!!2+!6++
!$ +2
,+#!$!!+4!+
!!$4
2+!!!++876 $6+6!! +#!$!2
9$! +6!+!1
6662!2,6+(9&! +
!,!2
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23
CHAPTER TWO
SECTION 2.1
EHU MOUNTING (continued)
ASSEMBLING THE STRESS RELIEF SPLICES FOR THE DB42 EST EXTENSIONS
Figure 2.14
QTY 1: 2” x 12”
Stress relief splice
10-1630-21
QTY 2: 2” x 3”
Stress relief splice
10-1630-11
QTY 2: 2” x 3”
Stress relief splice
10-1630-11
Note:
÷
÷
÷
!" #"
$ !" ###
$%&
'
( # #) *&+
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24
CHAPTER TWO
SECTION 2.1
EHU MOUNTING Figure 2.15
(continued)
NOTES:
With the 1/4” aluminum spacers (10-1613-11, fig 2.16)
under the EHU, the plastic extension tubes roughly
align with the center of the
1-3/4” fiberglass tube. Once the element has been
mounted, check to ensure that both the element plate
and return plate are level. All elements can be adjusted by loosening the aluminum saddles and rotating
each element accordingly. We highly recommend
using a level for this.
Remove foam/cardboard pad from inside
driven housing. This is critical!
Refer to Figure 2.15 for assembly of the director 1 element housing, gasket and cover.
For wiring of EHU, refer to Chapter 7.
When the six screws are secured to the driven
element housing it can now be installed to the
driven element plate.
Refer to Figure 2.16 for attaching director 1 to
the element plate.
Director 1 EHU Preparation
QTY 6: 10-32 Nylock nut
60-0019
QTY 1: Director 1
housing 70-3409-01
QTY 1: Director 1
gasket
QTY 2 :60-0017-10
10-32x3/4” SS
FLATHEAD
SCREWS
QTY 1: Director 1
housing cover 40m
10-1022-21
QTY 4: 10-32 X 3/4” SS screw
60-0017
Mounting Director 1 Housing
QTY 4: 10-32 X 3/4” SS screw
with nylon locking strip
60-0101
QTY 4: #10 SS washers
60-0018
DIR1 EHU has a plastic
(CPVC) stub protruding
QTY 4: 1/4” aluminum spacer
10-1613-11
2.5
The best location to place the
level when leveling the Driven
Element Support Plate is along
the lip of the element plate
”O
D
3”
Figure 2.16
OD
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25
CHAPTER TWO
SECTION 2.2
EHU MOUNTING (continued)
20M DRIVEN ELEMENT ASSEMBLY
NOTES:
Make sure to align the element to
the boom correctly, which direction it is facing affects the polarity
of the antenna.
QTY 10: 60-0017
#10 x 3/4” SS screw
QTY 10: 60-0018
#10 SS washer
Use a level to ensure that the
mounting plates are level in retrospect with each other, before
attaching the EHU’s.
This bolt should be
directly over center
of boom.
QTY 1: 70-3412-01
Driven element EHU
QTY 4: 60-0065
5/16” x 3-1/2” SS Hex Bolt
Re
QTY 1: 10-1502-01
Element housing gasket
flec
tor
QTY 1: 70-2030-11
Element Mounting plate
QTY 4: 60-0046
5/16 SS Nylock nut
2”
QTY 10: 60-0019
10-32 SS Nylock nut
QTY 4: 10-1601-22
2” Aluminum saddles
OD
Bo
o
m
Se
ctio
n
10
-1 2
02
-11
NOTE: The driven element and director 2
look identical in appearance, but have a
different relay board inside. Check the
part number sticker inside the EHU and be
certain that it matches the part number
above.
FIGURE 2.20
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26
CHAPTER TWO
SECTION 2.3
QTY 10: 60-0017
#10 x 3/4” SS screw
DIRECTOR 2 ASSEMBLY
NOTES:
Make sure to align the element to
the boom correctly, which direction it is facing effects the polarity
of the antenna.
QTY 10: 60-0018
#10 SS washer
Use a level to ensure that the
mounting plates are level in retrospect with each other, before
attaching the EHU’s.
This bolt should be
directly over center
of boom.
QTY 1: 70-3408-01
Director 2 EHU
QTY 4: 60-0014
5/16” x 3-3/4” Hex Bolt
Ma
EHU MOUNTING (continued)
QTY 1: 10-1502-01
Element housing gasket
st P
late
QTY 1: 70-2030-01
Element Mounting plate
QTY 4: 60-0046
5/16 SS NYLOCK NUT
2 -1
QTY 10: 10-32
Nylock NUT 60-0019
/4”
QTY 4: 10-1601-32
2-1/4” Aluminum saddles
OD
Bo
o
m
Se
ctio
n
10
-1 2
02
-2 1
NOTE: The driven element and director 2
look identical in appearance, but have a
different relay board inside. Check the
part number sticker inside the EHU and be
certain that it matches the EHU part number shown above.
FIGURE 2.30
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27
CHAPTER TWO
SECTION 2.4
REFLECTOR & DIRECTOR 3 ASSEMBLY
EHU MOUNTING (continued)
First attach the EHU to the element mounting plate and return EST to its mounting plate, then attach the plates
to the boom. See figure 2.30.
Use a level to check the EHU and Return EST before tightening the aluminum saddles to the boom. When the
plate is level, tighten the saddle bolts to 20 ft/lbs (27.09Nm)
Don’t forget to mount the truss attachment plate (10-1607-01)
Figure 2.40
!!! WARNING !!! Tighten the 4 bolts for the saddles that hold the fiberglass return tube to 7 ft/lb
MAXIMUM; Over-tightening can result in product
failure. Do not use the aluminum saddle set screws
on the fiberglass tubes.
QTY 8: 60-0075
5/16” x 3-1/4” Hex bolt
Reflector & Director 3 Assembly
QTY 10: 60-0017
10-32 x 3/4” SS Screw
QTY 1: 70-3421-01
40/30 Passive Element
MA
ST
PL
AT
E
QTY 10: 60-0060
#10 SS Washer
Return EST
10-1015-11
QTY 1: 30m/40m Element
Housing gasket
10-1502-01
Element Return Plate
10-1608-01
DIR 3 ONLY
QTY 2: 60-0114
5/16” x 3-3/4” Hex bolt
REF ONLY
QTY 2: 60-0075
5/16” x 3-1/4” Hex bolt
Electrical center of element
QTY 12: 60-0046
5/16” Nylock nut
13
/4”
Return EST Assembly
QTY 2: 60-0075
5/16” x 3-1/4” Hex bolt
bo
om
se
ctio
n1
0 -1
20
2 -0
1
QTY 1: Element
Mounting Plate with
30m/40m aligning gasket
70-2030-01
NOTES:
Attach the EHU to the the element plate before attaching the plate
to the boom. This will help during the assembly process.
QTY 1: 10-1050-11
Steel Counterweight
(used on DIR3 end
only)
Be certain the mounting orientation of the housing in relation to the
mast plate and other elements is correct.
The elements electrical center must be directly over the boom. the
electrical center is the 1/4” bolt mounted through the EHU.
QTY 12: 10-1601--02
1-3/4” Aluminum saddle
Director 3 and the Reflector are the same configuration with the
exception that they mount in the opposite direction on the boom.
The return tube is located closest to the mast plate for both elements.
QTY 10: 60-0019
10-32 Nylock nut
QTY 12: 60-0046
5/16” Nylock nut
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28
CHAPTER THREE
SECTION 3.0
MAST PLATE & TRUSS ASSEMBLY
Mount the mast plate to the boom,ensuring that the fully threaded bolt is centered on the EZ eye-bolt that is
mounted on the 3” x .25” wall aluminum tubing as shown in figure 3.01. When finished, mount the tower mast to
the mast plate as shown in figure 3.02.
See figure 3.01 for attaching the DB42 to the tower mast. While we show you how to do this here, we recommend you wait until the antenna is fully assembled to actually mount the DB42 to the mast. First, secure one half
of the 2” saddle to the mast, using the 10-32 x 5/8” machine screws. This will help to align the tower mast to the
mast plate. Once the antenna is in place, secure the other half of the saddles around the tower mast using the
5/16 x 5” hex head bolts and Nylock nuts.
0&.
91
8
!"#$ 10 4
71
%&
10
71
91
8
4
''5
-.#.&#
,+&./
' -.#.&
&/
:
13
8
93 '
() '(
* +# +&
,-.#.&#,
+&./
Figure 3.01
3644 0*4
(
'5
(
' Figure 3.02
123 0*4
'(
0#&%
(
* +# +&
,
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29
CHAPTER THREE
SECTION 3.1
MAST PLATE & TRUSS ASSEMBLY (continued)
MOUNTING THE TRUSS SUPPORT TO THE MAST PLATE
With the Mast plate loosely attached to the boom and secured through the EZ Eye, follow
figure 3.10 for assembling the mast to the mast plate.
Make sure the truss support mast is resting on the center of the boom before you tighten the
saddles around it.
Figure 3.10
QTY 1: 48” Boom Truss Support Mast
10-1018-01
r3
Di
QTY 4: 60-0046
5/16” Nylock nut
(2 per saddle pair)
2
2”
-1 /
bo
om
c
Se
n
tio
1
2
0 -1
02
-2 1
QTY 4: 10-1601-02
1 3/4” Aluminum Saddles
3”
cto
re
Di
bo
om
c
Se
n
tio
1
2
0 -1
02
-3 1
QTY 4: 60-0100
5/16” X 3-1/2” SS bolt
r1
Figure 3.11
We suggest using this saddle for installation of the Connector
Junction Box. Using the supplied connector junction box
NOTES:
At this time mount the connector box onto the truss
support mast saddles as suggested in figure 3.11.
For correct height of the boom truss support mastmast simply rest the bottom of the boom truss support
mast on top of the boom.
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30
EHU MOUNTING (continued)
CHAPTER THREE
SECTION 3.2
PREPARING THE DOUBLE TRUSS SUPPORT ASSEMBLY
With the truss attachment plates already secured to the boom, secure the turnbuckle side of each truss to the
mast pole as shown in figure 3.20.
Assemble each truss to the appropriate side of the trust boom.
This process is much easier with two people - one to lift the end of the boom, while the other person attaches
the turnbuckle to the mast pole.
* % !%
Figure 3.20
10-1618-11 Boom
truss support
!!"#
1.75”
x 36”
QTY 1: 600152
3/8” x 1.75”
Bolt
!"#
#
$%&%'()
60-0035-24
#+
2100I Phillystran
',-' %
QTY 1: 60-0050
Nylock nut
(cut as required)
"#
.' %))
-%+ %&'
10-1018-11
Boom
truss
mast
%
1.75”
x 48”
"#
COLOR
CODE
Suggestion:
You can use some of the trimmed
phillystran to tie secure the turnbuckles in place. Weave the
phillystan though the housing of
the turnbuckle and through the
eyes of the eye bolts. Tape ends
and secure truss to boom truss
support mast.
!"#$
DESCRIPTION
PART # QTY
GRAY
3/8”x1.75” Hex
head bolt
60-0152
2
YELLOW
3/8 “ Nylock Nut
60-0050
2
RED
7/16” Galvanized
flat washer
60-0144
4
6” Galvanized
turnbuckle
60-0070
2
3/8” x 3” Eyebolt
w/ Nylock nut
60-0037
60-0050
2
2
BLUE
GREEN
NOTES:
The boom should be close to level with the turnbuckles 3/4
fully extemded. This will allow you to make minor changes
upward or downward to level the boom if needed.
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31
CHAPTER THREE
SECTION 3.3
MAST PLATE & TRUSS ASSEMBLY (continued)
ASSEMBLING THE DOUBLE TRUSS
Locate the Phillystran truss cable. This will be used to assemble the boom truss.
Assemble the truss supports as per Figure 3.30
The truss supports are different lengths by design. The Director 2 side of the boom truss will
be longer at 182” once assembled. The Reflector side of the boom truss will be 157” once
assembled.
!"#
Figure 3.30
Two complete truss sets as
shown in this drawing.
QTY 2: 4” SS
turnbuckle
60-0083
QTY 4: 10-1601-22 2”
Aluminum saddle
4
Note: The double truss will
have have holes added as
shown in red below, one for
each truss. The middle hole is
not used for the DB42. See
Order
of Ass
embly
4
3
bottom middle of figure 3.20
2
1
for a photo detail
QTY 4: 60-0065
3-1/2” SS Hex bolt
1
2
Orde
ro
QTY 4: 3/16” Thimble
60-0048
3
f Asse
mbly
4
Order
of Ass
embly
3
2
1
Philystran from
tip to end,10”
long minimum.
QTY 16: 3/16” Wire Clip
60-0045
NOTES:
The double truss utilizes two sets of the items shown in figure 3.30.
QTY 4: Phillystran
cap black
60-0044
1
2
Orde
r of A 3
ssem 4
bly
QTY 2: 10-1607-01
Truss Attachment Plate (Use
two on each end of the boom
truss).
QTY 4: 60-0066
5/16” SS Nylock nut
Be sure to install the thimble in the eye of the turnbuckle and or truss attachment
plate before securing the wire clips to the Phillystran. The thimbles may need to
be spread apart in order to fit in the turnbuckle eye and or truss attachment plate.
Once you have crimped the Phillystran with the wire clips it will permanently
crush the outer vinyl covering of the Phillystran. Use CAUTION when measuring
and securing wire clips.
The number one wire clip should be installed as close as possible to the thimble.
Wire clips 2-4 should have a 1” spacing. You will need a minimum of 10” from
the tip of the loop to the cut point. Cut extra Phillystran leaving a 2” end past wire
clip number four. Install the Phillystran black end caps and secure with electrical
tape after cutting.
IMPORTANT: install wire clips so that the U bolt is on the loose end side of the
Phillystran. The saddle of the wire clip will be on the long side of the Phillystran.
Re-tighten the wire clips after waiting at least 20 minutes. The vinyl jacket
“flows”, causing the wire clips to potentially loosen up.
The trusses should level the boom with the turnbuckles having half of the threads
still available to adjust up or down. This will allow you to do minor adjustments.
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32
CHAPTER THREE
SECTION 3.4
MAST PLATE & TRUSS ASSEMBLY (continued)
ASSEMBLING THE TRUSS FOR THE 40/30 LOOP ELEMENT (49 FT)
THIS STEP IS PRESENTED AT THIS TIME SO YOU CAN FULLY UNDERSTAND THE CHAPTER.
HOWEVER, IT IS PRUDENT TO WAIT UNTIL AFTER CHAPTER 7 “PRE-INSTALLATION
TESTING” IS COMPLETED TO INSTALL THE TRUSS FOR DIRECTOR 1.
Prepare the telescoping poles and the Secure the truss support, saddles and turnbuckles as
shown in figure 3.40.
The truss support must be mounted on on the opposite side of the boom from the mast plate.
Position the truss support so it is perpendicular to the EHU mounting plates. This is not critical as
long as you get it reasonably close.
Unscrew the SS nut from 3/16” eye bolt and discard. You will use the small SS washers so be
sure to keep them for this assembly. Secure the eye bolt to the coupler on the 30m/40m sweep
as per figure 3.42.
Lengthen the turnbuckles until the threads are approximately half way out. To attach the loose
end of the long Dacron rope you will need to run the rope through the open eye of the turnbuckle. Attach a separate Dacron line to each of the 3/16” stainless steel eyebolts mounted on the
sweep. The amount of tension on the truss rope will vary, depending on your own personal preference. Therefore, we recommend you do not cut the Dacron rope until you are certain you have
the truss tension at a point you are comfortable with.
Pull the rope tight enough so that the telescoping poles are close to level.
Once the 30m/40m loop is close to level secure the rope to the turnbuckle by looping the rope
twice through the eye and tying 3 half hitches. Finish the knot by covering the half hitches with
the provided electrical tape.
Use the turnbuckles to do any fine tune adjusting to your element. DO NOT pull up too high on
the 30m/40m element. This will cause the element to collect water and damage the antenna.
The tip of the sweep should never be higher then any other part of the telescoping pole.
Do not attempt to try to get the element perfectly straight, if you pull it up just enough so that it
is close to the droop of the 20m element it will look great. Lock down the turnbuckle by tightening the small nuts on the turnbuckle. Be sure to safety wire each turnbuckle, so that they cannot
turn and come loose.
Repeat steps 6-12 to complete the other half of the truss support. Figure 3.41 for complete lay-
Figure 3.40
Truss Layout
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33
CHAPTER THREE
SECTION 3.4
DIRECTOR 1 TRUSS ASSEMBLY (continued)
QTY 2: 4“ SS turnbuckle
60-0083
QTY 1: 1/4”-20 X 1 1/4”
SS bolt 60-0110
QTY 2: 5/16 SS washer
60-0033
QTY 1: 1/4-20 nylock nut
60-0046
QTY 2: 5/16 Nylock Nut
60-0046
Dacron truss rope
21-7002-01
2 -1
QTY 1: Truss support
10-1054-01
/2”
QTY 2: 60-066
5/16 x 4” Hex head bolt
3”
15”
QTY 2: ” Aluminum
Saddle 10-1601-01
Figure 3.41
30m/40m Truss Support Assembly
Figure 3.42
QTY 2: #10 Washer
60-0018
30
40
m/
m
e
sw
ep
Fib
e
le
Te
op
sc
in
ol e
gP
rg l
as
QTY 1: 3/16” x 2”
SS eye bolt 60-0107
sR
od
10-1503-01 Fiberglass
support rod
QTY 1: 10-24 Nylock Nut
60-0111
Truss Eyebolt Assembly
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34
CHAPTER FOUR
SECTION 4.0
OPTIONAL 6M PASSIVE ELEMENT ASSEMBLY
Follow figure 4.01 for assembling the 6m passive elements. Figure 4.01 is showing the 6m long element. Use
the same procedure for mounting the other two passive elements. Be certain to mount all three 6m elements in
the exact same orientation as shown in figure 4.02 below.
In the table below, you will see two measurement lengths. The first one is the measurement from the reflector
EHU center point to the center point of the aluminum tubing for each 6m passive element kit. The first measurement is for D1A, which is the closest to the Reflector. D2A, and D3A follow. The second length shown in the table
is the actual length that each respective 6m passive needs to be.
The 6m passive elements have slit ends. Telescope the 3/8” OD aluminum tubing inside of the 1/2” OD tubing
until you reache the respective length in the table below. Tighten hose clamp over the slit in the 1/2” tubing.
Repeat for each 6m passive element.
It is critical that the spacing between the 6m elements and the lengths of each respective 6m passive is accurate,
or it could greatly diminish performance. Refer to figure 2.01 for the center-to-center spacing for all of the elements, including the 6m passives.
6m Element
6m option Dir 1
6m option Dir 2
6m option Dir 3
Measurement between reflector centerpoint to 6m passive centerpoint
117.5 Inches
275.0 Inches
Total element ength of
6m passive
110.5 Inches
108.25 Inches
432.0 Inches
106.125 Inches
Part Number
70-1001-11
70-1001-61
70-1001-11
6m Passive Assembly
Figure 4.01
Qty 1: 60-6000-05
3/4” SS hose clamp
QTY 2: 60-0115
5/16 x 4-1/2” Hex head bolt
To DIR 1
Qty 1: 60-6000-05
3/4” SS hose clamp
Figure 4.02
QTY 2: 10-1601-61
3” Aluminum saddle
QTY 2: 5/16” Nylock Nut
60-0046
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35
CHAPTER FIVE
SECTION 5.0
CONNECTOR JUNCTION BOX / CONTROL CABLE
Connector Junction Box Installation
QTY
Part #
1
4
1
1
1
10-1615-01
60-0022
10-1053-02
10-1260-3
10-1029-01
Description
Connector box assembly with lid and connector board
4 X 4-4 SS nylock nut
Connector box aluminum mounting plate
Connector board with connector and 4-40 screws with standoffs
Connector protector
Figure 5.01 shows a photo of an installed DB42 connector
junction box.
Refer to the wiring diagram in figure 5.02 and the photo
shown in figure 5.03. Place the wires for each individual connector plug and tighten. Dip each bare wire in the included connector protector before inserting.
Figure 5.01
To assemble the connector box, make sure that the board is
seated completely inside the connector box housing. There
should be 4 X 4-40 screws sticking out of the bottom of the
connector housing. It is important that the board be mounted in
the correct direction inside the housing, as shown in figure
5.01 and figure 5.04.
Place the connector box housing onto the mounting plate so
that the tear away holes are facing down. Tighten the 4 X 4-40
nuts to the screws so that the Connector Box is mounted in the
correct orientation (this may have been done at the factory in
some cases).
Plug the correct connector into their respective sockets and tear away one of the three holes in the connector
box as shown in figure 5.01. Do not seal up the Connector box, it is designed to let air pass through and
evaporate any condensation that forms in the box.
Refer to figure 5.05 for connecting the wiring to the antenna switch and for the optional 80m dipole.
Perform a test motor function on your antenna to ensure that wiring has been performed correctly. Refer to
your antenna manual and operations manual for test motor fuction procedures.
Secure the lid of the connector box onto the the housing of your new connector box. If everything has been
installed correctly then the lid should shut in a downward motion. Click the lid shut and your assembly is complete. Figure 5.04 shows how the connector junction box should be mounted on the mast plate.
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36
CHAPTER FIVE
SECTION 5.0
CONNECTOR JUNCTION BOX / CONTROL CABLE (continued)
WIRING THE CONTROL CABLE TO THE CONNECTOR JUNCTION BOX
Figure 5.02
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37
CHAPTER FIVE
SECTION 5.0
CONNECTOR JUNCTION BOX / CONTROL CABLE (continued)
CONNECTOR JUNCTION BOX LAYOUT / MOUNTING
Figure 5.03
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4 wire control cable key
6 wire control cable key
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Figure 5.04
FIGURE 5.2: CONNECTOR BOX MOUNTING
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38
CONNECTOR JUNCTION BOX / CONTROL CABLE (continued)
CHAPTER FIVE
SECTION 5.0
WIRING THE JUNCTION BOX TO THE ANTENNA SWITCH
(ALSO) WIRING THE JUNCTION BOX TO THE 80M DIPOLE HOUSING
Figure 5.05
Notes:
If the 80m dipole option was purchased,
terminal lug “S” and “C” on J6 (inside
connector junction box) will have 2 wires
being inserted in each lug. Be sure to twist
these into a “pair” before inserting into the
respective terminal lug (these lugs are
highlighted in yellow).
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To avoid confusion in wiring, it is recommended that the wires of the 4 conductor
control cable that are not used are trimmed
back from the connections. Wires used
going to J5 plug are: shield, black, white
and red. Green is not used. For optional
80m dipole wires used are: shield, black
and green. Red and white are not used.
The factory installed jumper should be left
untouched!
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Start your wiring at J6 plug inside the connector box; route the wiring from there to
the antenna switch box and/or 80m dipole
box. 5 ft of control wire is provided,
which can either be coiled up or trimmed
to size. Be sure to route the cable BEFORE cutting it to be sure you have
enough.
Do not tin the ends of the wires.
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FACTORY
INSTALLED
JUMPER
()
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39
CHAPTER FIVE
SECTION 5.1
CONNECTOR JUNCTION BOX / CONTROL CABLE (continued)
CONNECTING THE CONTROL CABLE TO THE DB25 SPLICE
Figure 5.10
"
#
Figure 5.11
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NOTE: Be careful when wiring the
control cable to the 25 pin dsub
splice - as you can see in the above
picture, the pin numbers sequential
numbering changes directions on
each row of pins.
N
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40
CHAPTER FIVE
SECTION 5.1
CONNECTOR JUNCTION BOX / CONTROL CABLE (continued)
CONNECTING THE CONTROL CABLE TO THE DB25 SPLICE
The DB25 control cable splice allows for much more convenient connection of control cable to the SteppIR controller. By
utilizing this connector splice, there is no need to cut the DB25 connector off and re-solder when running cable through conduit. In addition, now you can purchase custom cable lengths to within 1 foot of your desired length, eliminating potential for
excess cable. To install the DB25 control cable splice, follow these instructions:
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" 2 & ! 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415
41
CHAPTER SIX
SECTION 6.0
INSTALLING THE ANTENNA SWITCH
Figure 6.01
Figure 6.02
FROM RADIO OR 80M DIPOLE OPTION
TO DRIVEN ELEMENT
OUT 1
SteppIR
TO DIRECTOR 1
TO DIRECTOR 2
COAX ROUTING DIAGRAM FOR ANTENNA SWITCH
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42
CHAPTER SIX
SECTION 6.0
ANTENNA SWITCH / COAX ROUTING (continued)
MOUNTING THE ANTENNA SWITCH TO THE BOOM
Figure 6.03
Antenna switch housing (do not
mount until all testing is complete)
Antenna switch housing gasket
(cut to length)
QTY 2: 60-0019
#10 Nylock nut
Antenna switch PCB board
(mounted to housing lid)
QTY 2: 60-0115
5/16 x 4-1/2” Hex head bolt
QTY 1: 10-1619-01
Coax switch bracket
RE
FL
EC
TO
R
QTY 4: Flat head screw
(located in small ziplock bag)
QTY 2: 60-0113
#10 x 5/8” Pan head screw
DIR
Notes:
Attach the coax switch bracket to the antenna
switch housing lid.
Leave the antenna switch housing and gasket off
so testing can be completed before the lid and
gasket are permanently secured to the antenna
Attach the assembly to the boom, without the lid
and gasket (as shown in figure 6.3).
When testing is completed, mount the housing
and housing gasket and secure in place.
EC
TO
R
QTY 2: 10-1601-61
3” Aluminum saddle half
QTY 2: 60-0046
5/16” Nylock nut
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43
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44
Coax IN (if no 80m dipole )
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80m Dipole coax
switch box (optional)
Figure 6.04
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Coax IN
(80m dipole option only)
CHAPTER SIX
SECTION 6.0
ANTENNA SWITCH / COAX ROUTING (continued)
COAX JUMPER ROUTING GUIDE
CHAPTER SEVEN
SECTION 7.0
TESTING THE WIRING / COAX CONNECTIONS
(BEFORE INSTALLING THE FIBERGLASS POLES)
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45
CHAPTER SEVEN
SECTION 7.0
TESTING THE WIRING / COAX CONNECTIONS (continued)
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46
CHAPTER EIGHT
SECTION 8.0
PREPARING THE TELESCOPING POLES / LOOPS
NOTES:
Extend the telescoping poles to full length by firmly “locking” each section of the pole in place. A good methodology
is to position each half of the joint so that they are several inches apart (while still within each other), and then pull
quickly and firmly. Do this for each pole. A picture of a telescoping pole is shown in figure 8.12.
Prepare each of the 40/30 telescoping poles as shown in figure 8.01, for insertion into the plastic loops. Figures
8.05, 8.06 and 8.07 provide a visual on preparing the pole tips.
The telescoping poles for the non-loop elements do not require this preparation. DO NOT CUT the non-loop telescoping poles! The non-loop poles utilize a plastic rain cap, shown in figure 8.11.
On all the elements we now include double wall polyolefin heat shrink. Each telescoping pole uses 3 of the polyolefin
heat shrink pieces, so on a 20m-6m element half, 3 pieces are used and on a 40/30 element half, six pieces are
used.
Once finished, the seal is secure and waterproof. This product requires a heat gun for activation of the adhesive.
When positioning the heat shrink, place it so that the joint of the telescoping pole is centered in the middle of the heat
shrink. Figure 8.02 shows how this is done.
Apply heat around the entire area of heat shrink. Note: There are 4 blue colored lines imprinted on the tubing. The
joint is considered done being heated and waterproof when the lines change color to a yellowish green. Each line
needs to change in color to ensure even adhesion temperatures. With this change, there is no longer any need to
tape the joints on the loop elements.
Figure 8.01
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47
CHAPTER EIGHT
SECTION 8.0
PREPARING THE TELESCOPING POLES & LOOPS (continued)
HEAT SHRINKING / CHAMFERING TELESCOPING POLES
Figure 8.02
Cut the tip of each 40/30 pole to the required 213” length, using hacksaw or similar cutting blade suit
able for fiberglass. Refer to drawing 70-1013-51 for pole preparation details.
After cutting the telescoping pole to the proper length, use the supplied conical grinding stone (PN 09-1025) and a powered drill to chamfer the inside of each loop pole tip. This will form a transition ramp to guide the bullet into the pole.
Refer to figure 3.3 for the proper chamfering method. Accuracy is important when assembling the pole tip. The blue silicone wrap must be located underneath the portion of the plastic sweep material that the stainless steel guidance clamp
is tightened over. In addition, the tip of the pole must line up with the clamp edge as shown in figure 8.09.
Figure 8.03
Ensure the tip of the pole is clean by wiping with an unsoiled cloth. Apply the self adhesive grip tape as shown in figure
8.04 and apply pressure for a few seconds to ensure the adhesive bonds to the pole. Do not apply tape at temperatures less than 50 degrees F. The edge of this tape is used as a marker to indicate where to position the sweep fitting
and that determines the length of the loop. Make sure you position it reasonably close to what the drawing indicates so
the element is even in length on both sides, as it looks better this way.
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48
PREPARING THE TELESCOPING POLES & LOOPS (continued)
CHAPTER EIGHT
SECTION 8.0
PREPARING THE POLE TIPS FOR THE 40/30 LOOPS
Apply 2.5 inches of the blue silicon tape as shown in figure 8.05 and 8.06. Stretch the tape so it is about half of the normal 0.5 inch width as you apply it. The silicon tape is intended for a single use, that is why more than needed is supplied - if you ever take the coupler apart, redo the seal using the remaining NEW tape. Starting at 2 inches from the tip
of the pole, wrap two complete wraps while stretching the tape to one-half of it’s normal width. The wraps should start at
the 2 inch mark, go down to the 1.25” mark and finish back at the 2 inch mark. This ensures there are no loose “flaps”
of silicon on the leading edge of the seal that will roll up or catch when the tip is inserted into the coupler. The silicon
tape sticks to itself permanently, but needs some pressure applied for a few seconds in order to start bonding. This
method requires NO lubricant, so do NOT put anything on the pole tip. Using any petroleum based product on the
pole tip or the plastic coupler WILL lead to destruction of the plastic coupler!
Figure 8.04
Figure 8.05
Figure 8.06
Assemble as described in the manual using a screwdriver or two to spread the sweep fitting, as shown in figure 8.07,
and push the pole tip in while slowly rotating it until the grip tape has just fully slid entirely into the sweep fitting so the
edge of the grip tape lines up with the outside edge of the sweep fitting as shown in figure 8.08 .
Figure 8.07
Figure 8.08
The loop coupler allows the pole to extend about 1 inch into the polyethylene sweep tube, eliminating any possible water
build up that could freeze onto the copper tape and trap the element. Install the 6-32 screws and tighten them, starting
with the middle screw on each side and then the outside two. Go back and recheck tightness on each screw because
as each screw is tightened it may cause the others next to it to loosen up. The plastic loop sweeps each have three
drain holes located at what would be the end of the completed element. These holes MUST face downward, to allow
any water that could be trapped inside the poles drain out. A colored adhesive dot will be on the loop, this dot must face
upward. In addition, ALWAYS do a visual check to ensure that the drain holes are indeed facing downward.
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49
CHAPTER EIGHT
SECTION 8.0
PREPARING THE TELESCOPING POLES & LOOPS (CONTINUED)
ATTACHING THE POLE TIPS TO THE LOOPS
Place the 5/16” wide x #10 stainless hose clamp as shown in figure 8.09 (prior page) on the side of the sweep that
aligns with the element return tube ONLY. The hose clamp is not needed on the side of the sweep that aligns with the
EHU tube. As accurately as possible, position the clamp as shown in figure 8.09. this ensures that the edge of the
clamp and the end of the fiberglass pole are aligned with each other. Tighten the clamp snugly, wait at least ten minutes
and retighten.
Repeat for each loop element.
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Figure 8.09
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WARNING:
DO NOT USE ANY PETROLEUM BASED LUBRICANTS SUCH AS
ANTISEIZE WITH THESE COUPLERS AS IT WILL DESTROY THEM.
IT IS BEST TO NOT USE ANY TYPE OF LUBRICANT ON THE STAINLESS STEEL FASTENERS, TO BE CERTAIN THE POLYCARBONATE
PLASTIC IS NOT DAMAGED.
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50
CHAPTER EIGHT
SECTION 8.1
PREPARING THE TELESCOPING POLES & LOOPS (continued)
INSERTING FOAM PLUG ASSEMBLY ON NON-LOOP POLES
Each 20m-6m element tip requires a breathable foam plug to be inserted onto the tip end of it so that the element is
allowed to vent, but not let any non-liquid enter into the antenna. The foam plug assembly is NOT required for 40/30
elements.
The foam plug assembly consists of the foam plug, and a flexible plastic housing as shown in figure 8.10. The foam
is pushed into the plastic housing at the factory.
Push the black flexible plastic housing onto the tip of the pole. Approximately 1.25” of the housing should be covering the pole tip as shown in figure 8.11. The interference fit will be very tight. If you want to be doubly certain the
foam plug assembly is secure, you can secure the non-foam edge with a wrap of electrical tape.
Figure 8.11
Figure 8.10
Figure 8.12
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51
CHAPTER NINE
SECTION 9.0
CPVC INNER TUBING & DIVERTER CONE ASSEMBLY
Apply a thin layer of the provided glue to the outside of the bare ends of the 39-7/8” CPVC support
tube.
On one end, glue on the Diverter Cone 10-1509-02
On the other end glue the 49” CPVC inner support tube with the coupler. Follow figure 9.01 for gluing
procedure. Let glue set for at least 1 hour. Figure 3.12 shows the completed support tubes.
Repeat for the other three support tubes
Apply a thin layer of the provided glue to the outside of the bare ends of the 39-7/8” CPVC support
tube.
On one end glue on the inner support tube with rubber coupler and foam Seal ring 10-1617-01
On the other end glue the 49” CPVC inner support tube with the coupler. Follow figure 9.01 for gluing
procedure. Let glue set for at least 1 hour.
Repeat for the other DIR1 element half
Figure 9.01
CPVC for REF and DIR 3 Elements
49”
39-7/8”
70-2025-13 49” CPVC Inner Support
Tube with coupler
49”
70-2025-13 49” CPVC Inner Support
Tube with coupler
10-1509-02
Diverter Cone
70-2025-23 39-7/8” CPVC
Inner Support Tube
39-7/8”
CPVC for Director 1 Element
70-2025-23 39-7/8” CPVC
Inner Support Tube
63-7/8”
Black Rubber Coupler
Foam Seal Ring
10-1617-01 63-7/8” CPVC inner support tube with
rubber coupler and foam seal ring
Inner CPVC Assembly
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52
CHAPTER TEN
SECTION 10.0
ATTACHING TELESCOPING POLES TO EHU’S
Items required:
QTY 6: Telescoping poles with 40/30m sweep assembly attached to them
QTY 4: Regular telescoping poles for the Driven element and DIR2
QTY 4: Inner support CPVC tube for REF and DIR3, complete assembly with diverter cone
QTY 2: Inner support CPVC tube for DIR1, complete assembly with rubber coupler and foam sealing ring
To secure the telescoping poles to the Element Housing Unit, first slide a rubber boot over the
base section of the telescoping pole. Refer to figure 10.01 for assembly.
Before attaching the 30m/40m sweep element make sure the colored adhesive label on
the sweep will point upward when the element is mounted. In addition, always do a
visual check to be certain the holes are indeed pointing downward.
Slide the CPVC and Diverter Cone assembly inside the telescoping pole as shown in
figure 10.01
Insert the assembly far enough that the flange of the Diverter Cone is flush with the base of
the telescoping pole.
There is no inner liner for the return side of the 30m/40m loop.
Slide the telescoping pole with diverter cone assembly inside the EST of the element housing
until it bottoms out. The procedure will be the same for both REF and DIR 3.
Slide the rubber boot over the metal ring on the EST of the element housing. Make sure the
large hose clamp on the rubber boot slides over the metal ring on the EST of the element
housing unit (EHU).
The smaller hose clamp of the rubber boot should be outside of the black raised ring on the
telescoping pole.
Once the rubber boot is in the correct location, tighten both hose clamps. Due to cold flow of
the rubber you should retighten the hose clamps after 30 minutes. Repeat the same process
for each telescoping pole for REF and DIR 3.
Procedure for attaching telescoping poles to DIR2 EHU
To secure the telescoping poles to the element housing unit, first slide a rubber boot over the
base section of the telescoping pole. Use Figure 10.01 for assembly. There is no inner support tube on this element.
Slide the telescoping pole inside the EST of the element housing. Make sure the pole goes all
the way in until it is completely inserted in the EHU.
Slide the rubber boot over the metal ring on the EST of the element housing. Make sure the large hose
clamp on the rubber boot slides over the metal ring on the EST of the Element housing.
The smaller hose clamp of the rubber boot should be outside of the black raised ring on the
telescoping pole.
Once the rubber boot is in the correct location tighten both hose clamps. Due to cold flow of
the rubber you should retighten the hose clamps after 30 minutes.
Repeat the same process for the other telescoping pole.
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53
CHAPTER TEN
SECTION 10.0
ATTACHING TELESCOPING POLES TO EHU’s (continued)
ATTACH TELESCOPING POLE ASSEMBLIES TO REFLECTOR AND DIR3
NOTES:
Figure 10.01 shows the REF element but the DIR 2 element is assembled in
the same manner. The DIR 1 element is assembled much like the return side of the element
shown below.
LAST MINUTE CHECK OFF LIST
1. Check that all fasteners are secure, especially the EHU saddles and boom bolts.
2. Do all of the sweeps have the colored adhesive dot pointing upward (holes downward)?
3. Tighten the boom truss wire clips one last time.
4. Tighten the rubber boot hose clamps one last time.
5. Check all taping for loose ends.
6. Have all trusses been tightened?
Figure 10.01
Telescoping Pole
Return EST
Small Hose Clamp
Large Hose Clamp
30/40 Element Housing Unit
Locking Ring
(molded to telescoping pole)
Diverter Cone and
CPVC Assembly
Rubber Boot
NOTES:
Make sure to completely insert the
telescoping pole assembly until you
feel a firm stop against the diverter
inside the element housing.
Due to cold flow of the rubber, make
sure to re-tighten all rubber boots 30
minutes after initially tightening.
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54
CHAPTER TEN
SECTION 10.0
ATTACHING TELESCOPING POLES TO EHU’s (continued)
ATTACH TELESCOPING POLES TO DIR 1
NOTES:
Make sure while installing the CPVC with foam seal ring and black rubber coupler, that the “THIS
WAY UP” sticker is facing upward. This will align the slot in the foam ring to be facing up inside the
EST extension. This slot is to allow the element to breath and provide ventilation for any condensation that builds up inside the fiberglass poles.
To straighten the 30m/40m telescoping pole assembly the poles can be twisted inside the EST
extensions before the rubber boots are tightened. To check for straightness, sight along the boom to
check if the sweep assembly is aligned correctly.
To secure the telescoping poles to the Element Housing Unit, first slide a rubber boot over the
base section of the telescoping pole. Use figure 10.02 for assembly.
Slide the CPVC Inner Support Tube assembly for director 1 (about 156” long), that you glued
in figure 9.01, inside a 30m/40m telescoping pole assembly as shown in figure 10.02.
There will be no CPVC for the return side of the 30m/40m loop.
Slide the rubber coupler and foam sealing ring inside the EST extension. The rubber coupler
should align with the CPVC protruding out of the driven element housing.
Locate the SS hose clamp 016 (60-6000-15). Place the hose clamp over the rubber coupler
before fitting the coupler onto the driven element.
Once the rubber coupler is seated flush against the driven element housing and the “THIS
WAY UP” sticker on the rubber coupler is facing upward, slide the hose clamp up against the
housing and tighten. This will leave the Driven CPVC assembly protruding from the EST
extension.
Slide the 30m/40m telescoping pole assembly over the CPVC assembly and into the EST
extensions.
Slide the rubber boot over the metal ring on the EST extensions. The large hose clamp on
the rubber boot must slide over the metal ring on the EST extension.
The smaller hose clamp of the rubber boot should not slide over the locking ring on the telescoping pole.
Once the rubber boot is in the correct location tighten both hose clamps. Due to cold flow of
the rubber you should re-tighten the hose clamps after 30 minutes.
Repeat the same process for all other poles on the driven element.
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55
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56
Black Rubber coupler
Foam Sealing Ring
SS hoseclamp 016
(60-5000-15)
Locking Ring
Qty 4: Rubber Boot
EST Extensions
Driven CPVC Assembly
wn
ho il
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Cu r ins
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2 -1
Director 1 Housing Unit
Director 1 Telescoping pole assembly
NOTE: Mark the center of the
splice and insert each return
extension (70-2028-01) to the
mark, then tighten aluminum
QTY 1: 10-1630-21
2”x12” Stress
relief tube (slides over OD of
EST extension)
3”
BO
OM
Return EST
Note: Stress relief tube should be
centered to the middle of the
aluminum saddle
QTY 4: 10-163011
2”x3” Stress relief tube (slides
over OD of EST extension)
EST Extensions
Large Hose Clamp
Small Hose Clamp
ing
op
sc l y
e
l
Te mb
e
m
40 Ass
/
m ole
0
3 P
CHAPTER TEN
SECTION 10.0
ATTACHING TELESCOPING POLES TO EHU’s (continued)
Figure 10.02
CHAPTER ELEVEN
SECTION 11.0
OPTIONAL 80M DIPOLE ASSEMBLY
The 80m dipole option is a wire dipole that runs above and parallel to the boom. One end of the wire dipole connects to the reflector element center, the other end connects to director 2. This forms an “H” shaped dipole, as
shown below in figure 11.01.
The two passive elements act as large capacity hats that are tunable via the SDA 100 controller. This capacity loading is very efficient, so the DB42 dipole is only -0.7 dB below a full sized dipole on 80m. The dipole wires connected
to the passive elements have no effect whatsoever on the performance of the antenna when using the Yagi on other
frequencies, because the wires are connected at the zero current point in the center of each element.
The 80m dipole is an option that can be purchased for the DB42 Yagi. It can be installed during the process of
building the DB42, or it can be installed afterwards. This option should only be installed with the antenna on the
ground.
When the 80m dipole option is purchased, truss assemblies for each of the 39 foot end loop elements are included.
In the process of assembly, you will be using hardware from the DB42 standard antenna kits, truss assembly kits and
the 80m dipole kit.
Refer to SECTION 11.10 for mounting the truss and truss support that will be required for supporting the 80m dipole.
Figure 11.01 below shows the working components used when the antenna is on 80m.
Figure 11.01
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57
CHAPTER ELEVEN
SECTION 11.0
OPTIONAL 80M DIPOLE ASSEMBLY
80M DIPOLE ASSEMBLY
NOTES:
The reflector EHU and Director 3 EHU should be installed as shown in chapter 2 of this manual with one exception when the optional 80m dipole is purchased, the truss attachment plate needs to be installed on each side of the
boom as shown in figure 11.02.
When installing the truss attachment plate, use the longer bolts included in the 80m dipole kit in place of the standard bolts included with the DB42 hardware as shown in figure 11.02. The standard length bolts will not be used,
remove them from the assembly process.
Mount the tensioning eye-bolt to the truss attachement assembly as shown in figure 11.03. Secure it loosely, using
only 2 or 3 threads. These will be tightened later.
Figure 11.02
Figure 11.03
"
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!""
#
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Tensioning Eye-Bolt Detail
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58
CHAPTER ELEVEN
SECTION 11.0
OPTIONAL 80M DIPOLE ASSEMBLY (continued)
80M DIPOLE ASSEMBLY
NOTES:
We recommend you install each of the 39 ft loop element truss supports first as shown in figure 11.04, but do
not attach the dacron rope to the truss supports until after the 80m dipole installation is completed. This keeps the
dacron ropes for the truss supports from getting in your way.
Follow the instructions in Chapter 11, section 2 for installing the truss supports.
Once the truss supports are attached to the boom as shown in figure 11.04, install the dipole attachment post
assembly as shown in figure 11.05. The post itself will be tightened firmly using the 1/4” standard nut and the
nylock nut. leave a small amount of space between the 3/8” washer and the 1/2” aluminum space to accomodate
the wrapping of the Dacron rope, covered later in this section.
Repeat for each side of boom.
ASSEMBLING THE TRUSS SUPPORTS
(USED FOR THE 80M DIPOLE FLEXIBLE WIRE)
Figure 11.04
Figure 11.05
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%#&"
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59
CHAPTER ELEVEN
SECTION 11.0
OPTIONAL 80M DIPOLE ASSEMBLY (continued)
80M DIPOLE ASSEMBLY
NOTES
Follow figure 11.06 for mounting the 80m dipole antenna switch.
Secure the stainless steel quick links to the mounting plate of the antenna switch.
DO NOT attach the lid of the antenna switch until wiring is completed, it will make wiring difficult and the cover is
almost impossible to remove once you attach the hinges.
Be certain you mount the antenna switch so that the top edge of the saddles are 22-1/4” above the top of the
boom.
MOUNTING THE DIPOLE ANTENNA SWITCH
Figure 11.06
DETAIL
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60
OPTIONAL 80M DIPOLE ASSEMBLY (continued)
CHAPTER ELEVEN
SECTION 11.0
80M DIPOLE ASSEMBLY
NOTES:
The Dacron rope will come in one continuous piece. Loop one end of the piece through the truss attachment plate eye-bolt as
shown in Figure 11.07. Tie 3 half hitch knots. Figure 11.07A shows how to make a single half hitch. To make multiple half
hitches, simply repeat. Leave about 2” of dacron rope leader after the third half hitch knot. Tape the leader to the rope as
shown in figure 11.07 and melt the ends to avoid fraying.
Pull the Dacron rope tightly towards the truss attachment post and loop the rope around the post one full wrap as shown in
figure 11.08, keeping tension on the rope. The rope must be between the stainless steel washer and the aluminum spacer, as
shown in figure 11.08A.
Keeping tension on the rope, pull the rope to the quick links that you have already installed on the antenna switch mounting
plate. Insert through the link, pulling tight and tie 3 half hitch knots. Leaving approximately 2” of leader, cut the Dacron rope.
You will use the remaining rope for the other half of the support line. Following the same steps.
On each end of the dipole conductor support line, tighten the tensioning eyebolts so that the support line is tight enough to support the blue Ultra-flex dipole conductor wire.
Attach the lug of the blue Ultraflex wire to the brass EHU studs. pull the Ultra-flex wire to the dacron support line, leaving
enough play to that it does not pull on the lug. Tape with electrical tape. Wrap the Ultra-flex 3 times per foot, as shown in
figure 11.08. Be sure to leave 4” of space between wraps when you pass the truss supports, taping each side of the space as
shown in figure 11.08. Continue wrapping until you reach the antenna switch. Tape the Ultraflex to the support line where
the leader ends. You will need to trim the Ultraflex for connection to the antenna switch.
Repeat for other side of dipole.
Figure 11.07
11.07A
Rope
Figure 11.08
Spacer
TAPE
TAPE
Washer
11.08A
!"
#
#
Tape the dipole conduc
$%#
Secure the lug of the dipole
conductorwire to each EHU
post. Weather protect connection with coax-seal or equivalent
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61
CHAPTER ELEVEN
SECTION 11.0
OPTIONAL 80M DIPOLE ASSEMBLY (continued)
80M DIPOLE ASSEMBLY
NOTES:
Be sure to tighten all coax connectors so they are snug. Weather-proof with a coax sealant.
Tape all cables to the appropriate boom or mast to prevent sagging, which could create tension on the cables.
DO NOT kink or curve the cable to a radius of less than 3 inches. Allow for natural bends and secure cables to the
boom of mast of the antenna.
Do not secure the cable to anything that has a sharp edge including aluminum saddles, bolts, mounting plates etc.
Connect the 4 ft coax jumper 21-6301-70 from the driven element EHU to the SO239 labeled “OUT” located on the
rear of the 80m diple switch as shown in figure 11.09B.
Connect the primary feed line (coming from the shack) to the SO239 labeled “IN” located on the rear of the 80m
dipole switch.
Connect the 4 conductor from the antenna switch terminal block to the connector junction box as shown in
figure 11.09. For more detail regarding wiring from junction box to the 80m dipole refer to chapter 5.
Figure 11.09
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See Chapter 5 for
more detailed
wiring schematic
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,
11.09B
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62
CHAPTER TWELVE
SECTION 12.0
OPTIONAL 39 FT TRUSS KIT FOR END ELEMENTS
1. Check and inventory that you received all the parts for the 39 ft 40M/30M truss option kit
#72-0018-31. You will use one kit for each of the end elements. The 39 ft truss installation is the same
procedure as with the truss installed on Director 1 in Chapter 3. If you ordered the 80m dipole option,
you may have already completed some of these steps in chapter 11.
2. Apply anti-seize to the threads of the 5/16” X 3-1/2” hex bolt ONLY.
DO NOT APPLY lubricants of any kind to ANY of the SS hardware used on the plastic loop sweeps!
3. Secure the truss support to the aluminum
saddles so that the head of the 5/16” bolt are
on the truss support side. (figure 12.02)
Secure the truss support and saddle assembly
around the boom so that its between the driven EST and return EST (figure 12.01)
Figure 12.01 Top View
EST
2 X 5/16” SS washer
BOOM
4. It is not critical which side of the boom the
truss support is on. Use the the boom as a line
to sight in the truss support so that it is perpendicular to the boom. This is also not critical
as long as you get it as close as possible.
5. Follow the assembly in (figure 12.01) to
mount the turnbuckles on the truss support.
6. Attach the eyebolts to the plastic couplers
for the loop as shown in figure 12.03.
Unscrew SS nut from eye bolt and discard; it is
not needed, you will be replacing it with a
Nylock nut. You will however, use the small SS
washers so be sure to keep for this assembly.
Secure the eye bolt to the coupler on your
30m/40m sweep. (figure 12.03 Assembly
View)
7. Locate the Dacron rope. The rope is a continuous length. We recommend you “cut as
you go”, meaning secure the rope for the first
portion of the truss, trim it; move on to the
next and trim, and so on. There is one piece
of 80 ft rope per kit.
1/4” SS nylock nut
2 x SS 4” turnbuckle
1/4” X 1-1/4” SS hex bolt
EST
Figure 12.02 Side View
30m / 40m truss support
2 X 1- 3/4”
Aluminum saddle
2 X 5/16” SS
nylock nut
2 X 5/16” X
3- 1/2” SS hex
bolt
Antenna Boom
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63
CHAPTER TWELVE
SECTION 12.0
OPTIONAL 39 FT TRUSS ASSEMBLY (continued)
39 FT TRUSS ASSEMBLY
8. Secure the 1/8” Dacron rope by threading
the loop of the rope through the eye of the
eye bolt and tying three half-hitch knots as
shown in figure 11.07A (Chapter 11). Finish
the knot by covering the half hitches with the
provided electrical tape. Repeat this procedure
for the other eye bolt.
9. Lengthen the turnbuckles as long as possible without them coming apart. To attach the
loose end of the long Dacron rope you will
need to run the rope through the open eye of
the turnbuckle. Pull the rope tight enough so
that the telescoping poles are close to level.
Once the dipole loop is close to level secure
the rope to the turnbuckle by looping the rope
twice through the eye and tyeing 3 half hitches. Finish the knot by covering the half hitches
with the provided electrical tape.
Figure 12.03 Coupler
Top View
Drill one 3/16” hole in all couplers
in this location (not reqired for
new antennas).
3/16” SS eye bolt w/ rope
2 X SS washer
10-24 SS nylock nut
Assembly View
Figure 12.04 Truss Assembly
10. Use the turnbuckles to do any fine-tune
adjusting to your element. DO NOT pull the
elements up too high on your dipole truss. This
will cause the element to collect water and
damage your antenna. Do not allow your telescoping poles to make an “S “ shape if looking
from the truss support to the sweep. It should
be a gradual curve, but the tip of the sweep
should never be higher then any other part of
the telescoping pole. Lock down the turnbuckle
by tightening the small nuts on the turnbuckle.
11. Repeat steps 6-10 to complete the other
half of the truss support.
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CHAPTER THIRTEEN
SECTION 13.0
FINAL TESTING OF DB42 YAGI
It is highly recommended that the antenna be thoroughly tested before being installed on the tower.
Connect the control cable to the antenna and carefully inspect for loose wires that could cause short
circuits that could damage the controller.
Power up the controller and verify that it is in the elements RETRACTED mode.
Refer to the Operators Manual and place the controller In the “Create, Modify” mode.
Go to the REF element first (this is not critical, it just makes it easier to remember which elements
have been tested) and run the tape out as far as it will go. Listen carefully while doing this. The
sequence of sounds is as follows; First there is a slow ramp up for a few seconds that sounds like
distinct clicks followed by a smooth humming noise that persists until the end of the tape is near and
then you hear a very quick ramp down. If you hear any buzzing or rattling noise during the “humming” phase it may indicate a problem. Once the tape has stopped at maximum length physically
shake each element half and verify the tape is extended. Now run the tape all the way back in, listening again for the same sounds as before. If the tape was impeded for any reason when it was
extending it will then make a very loud ratcheting noise when the end of the tape comes home prematurely. If no problems were encountered repeat this procedure for each of the elements on the
antenna, otherwise refer to Startup Problems section.
Startup Problems:
A miswired cable is the most probable cause, check all of the wiring again.
Damaged driver chip in the controller. Note that certain miswires can cause damage to the driver
board. So if a miswire was found and you are still having trouble, the driver board could now be the
problem.
Faulty power supply
Mechanical blockage of the telescoping fiberglass tubes by packaging, debris or failure to remove
the rubber stopper from the butt end of the pole.
Mechanical failure of the EHU
Improper assembly; Telescoping pole not seated, 30m/40m Loop not assembled right, Telescoping
pole not extended to full length
Review the Troubleshooting guide for more ideas
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DREAM BEAM 42 LAYOUT
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STEPPIR ANTENNAS LIMITED PRODUCT WARRANTY
Our products have a limited warranty against manufacturers defects in materials or construction
for two (2) years from date of shipment. Do not modify this product or change physical construction without the written consent of Fluidmotion Inc, dba SteppIR Antennas.
This limited warranty is automatically void if the following occurs: improper installation, unauthorized modification and physical abuse, or damage from severe weather that is beyond the product
design specifications.
SteppIR Antenna’s responsibility is strictly limited to repair or replacement of defective components, at SteppIR Antennas discretion. SteppIR Antennas will not be held
responsible for any installation or removal costs, costs of any ancillary equipment
damage or any other costs incurred as a result of the failure of our products.
In the event of a product failure, a return authorization is required for warranty repairs. This can
be obtained at www.steppir.com. Shipping instructions will be issued to the buyer for defective
components, and shipping charges to the factory will be paid for by the buyer. SteppIR will pay for
standard shipping back to the buyer. The manufacturer assumes no further liability beyond repair
or replacement of the product.
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