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SteppIR DB36 Assembly Manual Download Page 65

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www.steppir.com/support  

  Tel: 425.891.6134  

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Page  65 

Mounting the fiberglass spreaders 

Attach the black fiberglass sweep spreaders (PN 10-1503-21) to the sweep couplers.   There is a con-

cave mounting area on each side of the plastic couplers. Position the fiberglass spreader so that the 

holes align with the  couplers as shown in 

figure 10.13

.

  When installing the fiberglass spreader, you 

will want the spreader to be underneath the plastic coupler as shown in 

figure 10.14

.

  The loop has 

been turned upside down in this picture so you can see the detail.  The spreaders will be longer than 

the couplers on each side of the loop as shown in 

figure 10.15

.  This is done on purpose to ensure 

plenty of fiberglass material is on each side of the screw.   

 

Insert #10 x 2” pan-head machine screw (PN 60-0156) through each of the coupler halves and the fi-
berglass rod.  This screw must be placed so that the Philips head of the machine screw is seated inside 

the concave groove on the top coupler as shown in 

figure 10.15 

and the  Nylock nut (PN 60-0014) is 

secured against the fiberglass material as shown in 

figure 10.14

.  The machine screws are longer than  

normal by design so that you can get the nut on in the initial stages of the process. 

 

Tighten the Nylock nuts firmly.  Be sure to use anti-seize on these screws or they very likely will gall 

and have to be replaced.  Repeat the above steps for the remaining sweeps.  

Figure 10.16 

shows a 

completed sweep assembly. 

FIG.  10.15 

FIG.  10.14 

FIG.  10.13 

FIG.  10.16 

CHAPTER TEN 

SECTION 10.1 

ELEMENT SUPPORT TUBE PREPARATION (continued)  

 MOUNT THE FIBERGLASS SPREADERS ON THE SWEEP COUPLERS 

Summary of Contents for DB36

Page 1: ...ge This assembly manual is intended to be printed in full COLOR If the manual is printed in black and white many im portant details could be lost DB36 Yagi Assembly Manual REV 10 5c 06 05 2014 2112 116th Ave NE 1 5 Bellevue WA 98004 l Tel 425 453 1910 l email sales steppir com ...

Page 2: ...ad 17 5 sq ft 1 63 sq m Wind rating 100 mph Adjustable elements 4 Power Rating 3000 watts continuous Feed points 1 Frequency coverage 6 95 54 MHz 3 5 4 5 3 MHz 6 95 54 MHz w opt 80m dipole Control cable 16 conductor shielded 22 AWG 80m option 24 conductor Frequency DB36 Gain dBi DB36 Front to rear dB 80M optional 1 35 NA 40M 7 2 21 30M 8 2 18 20M 9 27 21 5 17M 9 88 26 5 15M 10 21 27 1 12M 10 43 21...

Page 3: ...sembly 19 21 CHAPTER TWO 22 26 SECTION 2 0 Element housing unit placement 22 EHU center to center spacing measurements 23 SECTION 2 1 A look inside the EHU 24 EHU wiring 25 26 CHAPTER THREE 27 39 SECTION 3 0 Driven element return tube assembly 27 Attach the element mounting plate to boom 28 29 SECTION 3 1 Prepare the element support tubes EST s for mounting 30 31 SECTION 3 2 Attach the EST s to th...

Page 4: ...ew drawing 45 Mount Director 2 EHU onto the boom 46 SECTION 6 1 Return tube assembly Director 2 47 CHAPTER SEVEN 48 50 SECTION 7 0 Mast plate assembly overview 48 Attach the mast plate to the boom 49 50 CHAPTER EIGHT 51 54 SECTION 8 0 Attach the boom truss mast to the mast plate 51 SECTION 8 1 Phillystran truss 52 53 SECTION 8 2 Attach the Phillystran truss to the boom truss mast 54 CHAPTER NINE 5...

Page 5: ...ION 11 0 Prepare the CPVC inner guide tube and diverter cone 67 SECTION 11 1 Secure the element support tube EST to the EHU 68 69 CHAPTER TWELVE 70 73 SECTION 12 0 Installing the truss support mast 70 SECTION 12 1 Attach the truss couplers 71 SECTION 12 2 Routing the Dacron truss cord 72 73 CHAPTER THIRTEEN 74 75 SECTION 13 0 OPTIONAL 6m passive element kit 74 75 CHAPTER FOURTEEN 76 78 SECTION 14 ...

Page 6: ... in addition would have vastly improved performance over existing fixed length Yagi s The ability to tune the antenna to a specific frequency without regard for band width results in excellent gain and front to back at every frequency The patented folded dipole loop elements on the DB36 allow for outstanding performance on 40m and 30m with element lengths that are 40 shorter than a full sized Yagi...

Page 7: ...is missing or has been damaged in shipment 3 Do a complete inventory of every part nut and bolt Yes it takes time but it also allows you to noti fy SteppIR if anything is missing and allow time to get it to you before you start assembly of the antenna There is nothing more frustrating than realizing that something is missing just hours be fore you want to install the antenna 4 Go back to the Stepp...

Page 8: ...heck the antenna on each band for some sign of resonance within the frequency range Leave the antenna on the default frequency and tune the analyzer to see where the dip occurs It will be somewhere below the lower band edge on each band with the antenna 3 or 4 feet above the ground on sawhorses Also don t ex pect to see a 1 1 SWR here just look for a good indication of resonance Once it has been d...

Page 9: ... 1 10 1501 23 Lid with drain hole Driven element 1 70 3420 01 20m Passive EHU 2 70 3422 01 30 40m Passive EHU w terminal lug 4 10 1502 12 EHU Gasket 1 71 0007 DB36 Instruction manual 1 71 0010 SDA 100 Instruction manual 1 NA SDA100 Controller 1 20 8033 01 Power supply 24V external 1 21 5003 01 16 Wire control cable___________ FT SDA100 OPTIONS 1 01321 Transceiver interface 1 01322 Tuning relay 1 0...

Page 10: ...10 1202 32 2 1 2 x 72 Boom section PN is not marked on boom 1 10 1618 41 1 3 4 x 48 Boom truss support mast 2 70 2029 01 60 3 4 EST with ring 2 70 2028 01 66 3 8 EST with ring 1 10 1630 21 2 x 12 Slotted aluminum sleeve 4 10 1630 11 2 x 3 Slotted aluminum sleeve 2 10 1617 01 64 CPVC w foam sealing ring and rubber coupler 6 70 2025 23 39 7 8 CPVC inner guide tube 6 70 2025 13 49 CPVC inner guide tu...

Page 11: ...on Patch 40 60 0018 10 SS Washer 36 60 0019 10 32 SS Nylock Nut 1 60 0110 1 4 20 x 1 1 4 SS Bolt 4 60 0029 1 4 20 x 3 SS Bolt 4 60 0063 1 4 20 x 3 1 4 SS Bolt 4 60 0100 1 4 20 x 3 1 2 SS Bolt 60 60 0041 1 4 SS Washer 13 60 0030 1 4 SS Nylock Nut 1 60 0103 5 16 x 3 SS Bolt 36 60 0065 5 16 x 3 1 2 SS Bolt 18 60 0114 5 16 x 3 3 4 SS Bolt 8 60 0066 5 16 x 4 SS Bolt 8 60 0115 5 16 x 4 1 2 SS Bolt 70 60...

Page 12: ... 60 0048 3 16 Wire Thimble 4 10 1613 01 1 Alum Spacer 12 10 1613 11 1 4 Aluminum Spacer 2 60 6000 15 SS Hose Clamp 016 2 60 0083 1 4 x 4 SS Turnbuckle 2 60 0159 5 16 x 8 SS Turnbuckle 2 10 1606 01 Element Support Reinforcement Plate 2 10 1607 11 Truss Attachment Plate DB36 HARDWARE BOX BILL OF MATERIALS continued PN 72 0100 DB36 SADDLE BOX BILL OF MATERIALS PN 72 0102 QTY PART NUMBER DESCRIPTION 2...

Page 13: ...ctor Protector 4 10 1509 02 Diverter Cone for CPVC inner guide 8 10 1510 01 Element Truss Clamps halves 4 60 0044 00 Phillystran Cap black DB36 MISC PARTS BOX BILL OF MATERIALS PN 72 0104 DB36 OPTIONAL 6M PASSIVE ELEMENT KIT PN 72 1002 QTY PART NUMBER DESCRIPTION 2 10 1019 31 Mounting Plate 4 60 0001 1 U bolt 8 60 0030 1 4 Nylock Nut 4 60 6000 60 1 2 SS Hose Clamp 2 10 1601 03 1 75 Aluminum Saddle...

Page 14: ...KLE 1 60 0110 1 4 x 1 1 4 HEX HEAD BOLT 1 60 0030 1 4 NYLOCK NUT 2 60 0065 5 16 x 3 1 2 HEX HEAD BOLT 2 60 0046 5 16 NYLOCK NUT 2 60 0033 5 16 FLAT WASHER 1 21 7001 01 75 FT 1 8 DACRON ROPE 16 60 0014 6 32 NYLOCK NUT 16 60 0014 01 6 32 x 7 8 PAN HEAD SCREW 2 60 0158 1 8 THIMBLE 4 60 0157 1 8 WIRE CLAMP 1 10 1028 01 ANTI SEIZE PACKET 1 09 0001 ELECTRICAL TAPE 1 60 0112 SET SCREW DB36 OPTIONAL END E...

Page 15: ... 4 ALUM SADDLE 2 60 0028 1 4 X 2 1 4 SS BOLT 2 60 0030 1 4 X 20 NYLOK NUT 2 60 0116 1 4 X 20 REGULAR NUT 2 60 0034 3 8 SS WASHER 2 60 0094 3 16 SS QUICK LINK 2 60 0037 21 4 X 5 16 GALVANIZED EYEBOLT 4 60 0033 5 16 SS WASHER 2 10 1613 01 1 ALUMINUM SPACER 3 10 1607 11 TRUSS ATTACHMENT PLATE 1 21 6301 60 6 COAX JUMPER CABLE 1 21 5001 01 3 4 CONDUCTOR 22 GA CABLE 1 09 0001 ELECTRICAL TAPE 66 X 3 4 1 ...

Page 16: ...strong bond between the bolt and nut can prevent removal of fasteners Unfortunately little is known on how to control it but here are two ways to minimize this effect Decreasing installation RPM speed will cause less friction and decrease heat generation Lubrication used prior to assembly can dramatically reduce or eliminate galling Recommended lubricants should contain higher amounts of molybdenu...

Page 17: ...he 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 disassemble as needed for transportation to the tower area Be sure to refer to the DB36 configuration drawing on the following page so that you can fully under stand how the antenna oper...

Page 18: ...ECTOR ALL BANDS DRIVEN ALL BANDS REFLECTOR 20M 6M NOT USED 40M 30M DIRECTOR 1 20M 6M NOT USED 40M 30M REFLECTOR ALL BANDS DIRECTOR 2 20M 6M DIRECTOR 40M 30M DRIVEN ALL BANDS NOT USED 20M 6M REFLECTOR 40M 30M FORWARD DIRECTION Normal REVERSE DIRECTION 180 deg BOOM MAST PLATE Optional 6m Passive Element Optional 6m Passive Element ...

Page 19: ...too tight than too loose Always apply an anti seize lubri cant to stainless steel bolts that are using stainless steel nuts This will prevent the two from galling together Galling of stainless steel is common and has nothing to do with the quality of the material Refer to the galling information in the Preamble section of this manual Each bolt has a specific length for the particular tubing it is ...

Page 20: ...he 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 tow er The 1 4 boom bolts require 5 washers as shown below in figure 1 02 CHAPTER ONE SECTION 1 0 BOOM ASSEMBLY continued BOOM BOLT EZ EYEBOLT DETAIL When securing the EZ Eyebolt to the boom five 3 8 flat washers PN 60 0034 are used as a spacer as shown...

Page 21: ...f the boom as shown in figure 1 06 Apply Noalox to the outside of the 2 1 4 boom piece and slide into the 2 1 2 boom piece as shown in figure 1 07 Insert the 1 4 x 3 1 2 hex head bolts PN 60 0100 bolts through the 3 pieces 2 1 2 boom boom reinforcing sleeve 2 1 4 boom along with the 1 4 washers 60 0041 Thread the 1 4 Nylock nuts PN 60 0030 onto the bolts and tighten firmly as shown in figure 1 08 ...

Page 22: ... measurements When you are facing the boom portion of the mast plate the orientation will always be with the reflec tor to the left of the mast plate and the directors to the right of the mast plate We refer to all draw ings in this manual with that in mind CHAPTER TWO SECTION 2 0 MOUNTING THE EHU s ON THE BOOM ELEMENT HOUSING UNIT EHU PLACEMENT 40m EHU return Reflector EHU 40m EHU return Driven E...

Page 23: ...when assembling your SteppIR DB36 Ya gi Use figure 2 02 for placement of each of the elements Start from the left edge of the boom and meas ure from there As you assemble each of the element housing units EHU s refer to this drawing We recommend this se quence 1 Secure the element mounting plates to the boom using the correct saddles and fasteners be sure to use anti seize on all stainless steel f...

Page 24: ...ntroller damage can occur This is the number one cause of antenna installation failures so please be sure to heed the advice CHAPTER TWO SECTION 2 1 MOUNTING THE EHU s TO THE BOOM continued ELEMENT HOUSING UNIT EHU WIRING OVERVIEW Control cable tray for routing cable out of EHU 4 position EHU terminal header Element support tube Balun the balun is only inside the driven element Spring reel for cop...

Page 25: ...nector protector before inserting into the terminal plug Figure 2 13 shows what the connector protector will look like The terminal header assembly consists of the terminal header and the terminal plug as shown in figure 2 15 The plug is shipped loosely attached to the header Remove this plug when wiring and firmly plug back in when completed Follow the wire sequence in figure 2 15 for each EHU Be...

Page 26: ...ray starts as shown in figure 2 17 Using the coax seal and cut into 1 inch strips as shown in figure 2 18 You will need three strips The remainder can be used to seal the driven element SO239 connectors should you wish to Apply coax seal on top of the control cable and work it around the cable and on top of the cable tray as shown in figure 2 19 This will help keep water from entering into the EHU...

Page 27: ... 60 0046 5 16 Nylock nut L 4 60 0115 5 16 x 4 1 2 Hex head bolt E 4 10 1613 01 1 Aluminum spacer M 4 10 1601 11 2 x 3 Stress relief tube insert on OD of fiberglass EST F 8 60 0065 5 16 x 3 1 2 Hex head bolt N 1 10 1630 21 2 X 12 Stress relief tube insert on OD of fiberglass EST G 1 10 1605 11 Element mounting plate P 2 70 2029 01 1 3 4 X 60 3 4 EST tube H 4 10 1601 32 2 1 4 Aluminum saddle half Q ...

Page 28: ...36 delivers on the 40m and 30m bands while being 40 shorter than a full sized Yagi on those bands The construction of the Driven element is the most complex portion of the DB36 installation process To make life easier for the installer we have condensed this procedure into four separate sections Figure 3 02 shows the items required for installing the element mounting plate for the Driven element D...

Page 29: ...y if there is only one person doing this step Figure 3 06 shows the clamp in place with the upward lip of the mounting plate facing the Reflector side of boom Figure 3 07 shows how the two reinforcing plates PN 10 1606 01 will be positioned underneath the ele ment mounting plate Place two of the 2 1 4 aluminum saddles onto the 5 16 x 4 hex head bolts follow with a reinforcing plate on the bottom o...

Page 30: ...ed on the outside diameter OD of the 1 3 4 fiberglass EST tube to keep the saddles from crushing when the aluminum saddles are secured in place This will be covered in more detail later in this section Key QTY Part Number Description L 4 60 0115 5 16 x 4 1 2 Hex head bolt E 4 10 1613 01 1 Aluminum spacer B 4 60 0114 5 16 x 3 3 4 Hex head bolt C 4 10 1613 11 1 4 Aluminum spacer D 8 60 0046 5 16 Nyl...

Page 31: ...head bolts PN 60 0115 through the saddle halves and insert the 1 aluminum spacers onto the hex head bolts Attach this assembly to the element mounting plate by inserting the thread ends of the hex head bolts as shown in figure 3 13 Loosely thread on the 5 16 Nylock nuts PN 60 0046 Repeat for the second assembly Locate four 1 4 aluminum spacers PN 10 1613 11 These are used on the low or furthest si...

Page 32: ...ion Using a tape measure mark 1 2 from the flush edge of the EST tube as shown in figure 3 22 Repeat for the EST for the other side of the EHU Figure 3 23 shows the prepared EST Insert the end of the EST that has the reinforcing sleeves on it through the 2 saddles located on the mount ing plate Position the EST so that the mark you made 1 2 from the edge of the EST is now lined up with the edge of...

Page 33: ...d to fasten the lid Six of these screws utilize the Nylock nuts and will be positioned with the threads pointing upward as shown in figure 3 30 The remaining four 10 machine screws are used to attach the Driven EHU to the element mounting plate and will be cov ered in more detail in the next step Place the gasket material so that it aligns with the holes in the EHU lid as shown in figure 3 30 Plac...

Page 34: ...tic EST tube that protrudes out of the EHU should be roughly aligned with the center of the EST extension tube as shown in figure 3 34 Insert the 10 x 3 4 machine screws the ones with the locking strip as shown in figure 3 35 with the threads pointing downward Be certain that there is a 10 flat washer between the top flange of the EHU and the head of the machine screw Align with the PEM nuts and t...

Page 35: ...of the guide tube that has the pre installed foam centering rings and the black rubber coupler on it PN 70 2025 33 The foam centering rings have a slot in them as shown in figure 3 41 It is important that these slots are facing upward when inserting into the element support tube EST The slots are used as vents to assist in preventing condensation from forming internally Because you will not be abl...

Page 36: ...ding out of the EST and rotate the tube as needed while pushing the guide tube in until the black rubber coupler bottoms out against the EHU as shown in fig ure 3 47 Tighten the hose clamp firmly as shown in figure 3 48 Wait 20 minutes and then tighten it again to guard against cold flow of the plastic Repeat for the other side of the EHU Figure 3 49 shows the completed inner guide tube assembly F...

Page 37: ...ock nut K 8 10 1601 22 2 Aluminum saddle half N 1 10 1630 21 2 x 12 Stress relief sleeve Q 2 70 2028 01 1 3 4 x 66 3 8 EST return tube F 1 10 1608 01 Element return plate CHAPTER THREE SECTION 3 5 DRIVEN ELEMENT continued RETURN TUBE ASSEMBLY DRIVEN Figure 3 51 shows an overview of the return tube assembly for the Driven element F x 8 K C C D x 8 K K K C C Q N Q J FIG 3 51 ...

Page 38: ...sure that the return tube is protruding out approx imately 2 25 inches away from the aluminum saddle edge on each side as shown in figure 3 54 Be sure to position the slotted portion of the stress relief tube so that if faces downward as shown in figure 3 55 Tighten the saddles to a maximum of 7 ft lb 9 5Nm This is very important The aluminum saddles can crush the fiberglass tubes if the saddles a...

Page 39: ...osition the EST so that the mark you made is flush with the stress relief tube as shown in figure 3 60 Repeat for the other EST Be sure that the stress relief tube is centered on the return plate The end of the tube should be 2 25 inches from the aluminum saddle on each end of the return plate as shown in figure 3 61 Tighten the saddles to no more than 7 ft lbs Figure 3 62 and figure 3 63 show the...

Page 40: ...E x8 FIG 4 01 WARNING Extra bracket used in this section if installing the 80m dipole Refer to the 80m dipole instruc tions for further detail Key QTY Part Description A 10 60 0017 10x 3 4 Machine screw B 10 60 0018 10 Flat washer C 10 60 0019 10 Nylock nut D 12 60 0065 5 16 x 3 1 2 Hex head bolt E 12 60 0046 5 16 Nylock nut F 1 70 3422 01 Reflector EHU G 1 10 1502 12 Element housing gasket H 1 70...

Page 41: ...ide as shown in figure 4 04 Tighten the saddles to a maximum of 7 ft lb 9 5Nm This is very important The aluminum saddles can crush the fiberglass tubes if the saddles are too tight DO NOT put a set screw in the aluminum saddles that are used on the fiberglass return tube material Measure 3 7 8 from the left edge of the boom to the center point of the return tube as shown in fig ure 4 05 Level the...

Page 42: ...e gasket with the holes on the mounting plate Place the Reflector EHU PN 70 3422 01 onto the mounting plate as shown in figure 4 12 and attach using the 10 x 3 4 machine screws PN 60 0017 10 flat washers PN 60 0018 and 10 Nylock nuts PN 60 0019 as shown in figure 4 13 Be sure that the flat washer is between the machine screw head and the EHU housing as shown in figure 4 14 Tighten the Nylock nuts ...

Page 43: ...TOR 1 EHU DIRECTOR ONE EHU OVERVIEW DRAWING A x10 B x10 C x10 D D D D E E E E F G H J J J J Key QTY Part Description A 10 60 0017 10x 3 4 Machine screw B 10 60 0018 10 Flat washer C 10 60 0019 10 Nylock nut D 4 60 0114 5 16 x 3 3 4 Hex head bolt E 4 60 0046 5 16 Nylock nut F 1 70 3420 01 Director 1 EHU G 1 10 1502 12 Element housing gasket H 1 70 2030 11 Element mounting plate J 4 10 1601 32 2 1 4...

Page 44: ...e Director 1 EHU PN 70 3420 01 onto the mounting plate as shown in figure 5 04 and attach using the 10 x 3 4 machine screws PN 60 0017 10 flat washers PN 60 0018 and 10 Nylock nuts PN 60 0019 as shown in figure 5 05 Be sure that the flat washer is between the machine screw head and the EHU housing as shown in figure 5 06 Tighten the Nylock nuts enough to compress the gasket material but do not ove...

Page 45: ...030 11 Element mounting plate J 12 10 1601 22 1 3 4 Aluminum saddle half K 1 10 1608 01 Element return plate L 1 10 1015 11 EST Return tube D A x10 B x10 C x10 D D D E x8 D x8 G H J J J J J J J J J J J K L J E E E E F CHAPTER SIX SECTION 6 0 DIRECTOR 2 EHU DIRECTOR 2 EHU OVERVIEW DRAWING Figure 6 01 shows an overview of the Director 2 EHU assembly which is covered in more detail on the following p...

Page 46: ...03 shows the mounting plate attached to the boom Place the EHU gasket PN 10 1502 01 onto the mounting plate as shown in figure 6 04 Align the gasket with the holes on the mounting plate Place the Director 2 EHU PN 70 3422 01 onto the mounting plate as shown in figure 6 05 and attach using the 10 x 3 4 machine screws PN 60 0017 10 flat washers PN 60 0018 and 10 Nylock nuts PN 60 0019 as shown in fi...

Page 47: ... as shown in figure 6 13 Insert the element return tube PN 10 1015 11 as shown in figure 6 14 Be sure that the return tube is protruding out approximately 2 25 inches away from the aluminum saddle edge on each side as shown in figure 6 15 Tighten the saddles to a maximum of 7 ft lb 9 5Nm This is very important The aluminum saddles can crush the fiberglass tubes if the saddles are too tight DO NOT ...

Page 48: ...1 shows an exploded drawing of the boom and mast plate assembly along with the EZ Eye sys tem This parts explosion is a useful referral tool as you complete the steps in this section CHAPTER SEVEN SECTION 7 0 ATTACH MAST PLATE TO THE BOOM MAST PLATE ASSEMBLY OVERVIEW A B D D E K F F F F H H H H G I I I I J J B D D FIG 7 01 C Key QTY Part Description A 1 60 0142 7 16 x 5 Threaded EZ Eye bolt B 2 60...

Page 49: ... that you can visually SEE the boom with the mast plate behind it as it is mounted on the mast plate these 4 holes should be on the upper right side Insert the 7 16 x 5 threaded bolt through the two identical mast plates PN 10 1610 22 as shown in figure 7 04 Secure with the 7 16 standard nut PN 60 0161 and 7 16 lock washer PN 60 0160 as shown in figure 7 05 Tighten firmly Thread the second 7 16 st...

Page 50: ... flat washers onto the threaded bolt as shown in figure 7 10 Insert a 7 16 Nylock nut onto the 7 16 x 5 threaded bolt as shown in figure 7 11 Tighten the Nylock nut until it is resting near the galvanized washers as shown in figure 7 12 Use a short level as shown in figure 7 13 and attach a wrench on each of the 3 8 leveling nuts as shown in figure 7 14 Adjust the nuts as needed to level the boom ...

Page 51: ...r half of the saddle onto the hex head bolts Thread on the 5 16 Nylock nuts PN 60 0046 for the left side of the saddles when facing the boom as shown in figure 8 04 The hex head bolts on the right side of the saddles circled in yellow are used to install the connector junction box Install the connector junction box on the saddles so that the lid of the junction box opens from the bot tom as shown ...

Page 52: ...own Figure 8 11 shows the Phillystran layout with appropriate fasteners This drawing will be helpful when working through the following section A A A A A A A A A A A A A A A A B B F F F F C C D D E E D D Key QTY Part Description A 16 60 0045 3 16 Wire rope clip B 2 10 1607 11 Truss attachment plate C 2 60 0159 5 16 Stainless turnbuckle D 4 60 0044 Phillystran end cap E 30 FT 21 8002 Phillystran 21...

Page 53: ...he middle hole on the truss attachment plate as shown in figure 8 14 Loop the Phillystran around the thimble until approxi mately 8 of the Phillystran is on the dead side as shown in figure 8 15 Figure 8 16 shows how to position the two pieces of Phillystran cable into the wire clip saddle Position the first of the four wire clips PN 60 0045 so that the wire clip is as close to the thimble as poss...

Page 54: ...gure 8 21 and trim with a utility knife While holding the Phillystran so that it remains tight position the first of the four wire clips PN 60 0045 so that the wire clip is as close to the thimble as possible as shown in figure 8 22 Tighten the wire clips alter nating between each nut so that the tightening force is evenly distributed Hold each portion of the Phil lystran in place while tightening...

Page 55: ...rong configuration due to the many differ ent configurations used for our various antennas While we try to make sure this does not happen if it does the fix is an easy one Unscrew the 4 Nylock nuts as shown in figure 9 01 You will need a Phillips screwdriver for the other end of the screw located inside the junction box enclosure Be careful to avoid damaging the circuit board that the screw rests ...

Page 56: ...4 shows detailed wiring information for each of the connector junctions inside the box Be sure to dip each of the exposed wires into the included connector protector before inserting into the terminal strip inside the junction box Figure 9 15 shows in detail the diagram for connecting the 16 wire control cable to the P1 and P2 plugs inside the junction box Figure 9 16 shows the wiring for the opti...

Page 57: ...8 19 20 21 22 23 24 25 J2 PLUG DIR1 J3 PLUG REF P2 Plug 16 WIRE CONTROL CABLE B R G W S B R G W S B R G W S B R G W S J6 PLUG 80m J4 PLUG DIR2 CHAPTER NINE SECTION 9 1 WIRING THE CONNECTOR JUNCTION BOX continued CONNECTOR JUNCTION BOX LAYOUT BLACK RED GREEN WHITE SHIELD 4 wire control cable key FIG 9 14 S 4 3 2 1 SHIELD S WHITE 4 NOT USED 3 NOT USED 2 BLACK 1 OPTIONAL 80M Dipole J6 ...

Page 58: ...PLUG LOCATED INSIDE CONNECTOR BOX WHITE with BLACK STRIPE WHITE with RED STRIPE WHITE with GREEN STRIPE WHITE with ORANGE STRIPE NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED 16 WIRE CONTROL CABLE 14 15 16 17 18 19 20 21 22 23 24 25 P2 PLUG LOCATED INSIDE CONNECTOR BOX CHAPTER NINE SECTION 9 1 WIRING THE CONNECTOR JUNCTION BOX continued CONNECT THE 16 WIRE CONTROL CABLE T...

Page 59: ... to trim the red and green wire on each end of the control cable and tape over it to avoid potential electrical shorts CHAPTER NINE SECTION 9 2 WIRING THE CONNECTOR JUNCTION BOX continued OPTIONAL 80M DIPOLE WIRING SCHEMATIC FIG 9 16 5 4 3 2 1 S 4 3 2 1 WHITE SHIELD DO NOT USE BLACK DO NOT USE J2 HEADER 80M DIPOLE SWITCH BOX J6 HEADER 80M DIPOLE SWITCH BOX REFLECTOR EHU LUG DIRECTOR 2 EHU LUG J6 P...

Page 60: ...he placing of the wire into the terminal headers Tinning the wires also works well 3 Connect each wire to the appropriate terminal as shown in figure 9 22 Consult figure 9 27 on the next page for the correct wiring sequence Insert the two stainless steel screws into the circuit board Slide the two plastic spacers onto the screws 4 Insert the first half of the strain relief clamp onto the two screw...

Page 61: ...the case of the 25 pin connector and then put the backshell on 16 WIRE CONTROL CABLE DB36 NO 80m option If you have the 8om dipole option refer to the separate manual BLACK RED GREEN WHITE BROWN BLUE ORANGE YELLOW VIOLET GREY PINK CREME NOT USED WHITE with BLACK STRIPE WHITE with RED STRIPE WHITE with GREEN STRIPE WHITE with ORANGE STRIPE NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT U...

Page 62: ... poles before continuing Debris inside the telescoping poles can lead to failure of the EHU Secure polyolefin heat shrink to the telescoping pole joints On all the telescoping fiberglass elements we now include double wall polyolefin heat shrink PN 03630 Each telescoping pole uses 3 of the polyolefin heat shrink pieces Once finished the seal is secure and waterproof This product requires a heat gu...

Page 63: ... silicone tape wrap so that it is flush with the electrical tape as shown in figure 10 08 Step 3 Firmly pull the silicone tape as you go around the pole The silicone tape will stick only to itself This tape is used to form the seal between the pole tip and the plastic sweep tube The silicone tape will deform as you pull it to about half it s original width try to keep the edges as even as possible...

Page 64: ...URE THAT THE DRAIN HOLES FOR THE PLASTIC SWEEP TUBE ARE POINTING DOWNWARD BEFORE INSTALLING THE COUPLERS Apply anti seize to the threads and place the Ny lock nuts on Tighten nuts until there is approximately a 0 25 gap between the two coupler halves as shown in figure 10 12 Repeat for other side of sweep tube The couplers are designed to re form the plastic sweeps to lock them in place do not be ...

Page 65: ...y of fiberglass material is on each side of the screw Insert 10 x 2 pan head machine screw PN 60 0156 through each of the coupler halves and the fi berglass rod This screw must be placed so that the Philips head of the machine screw is seated inside the concave groove on the top coupler as shown in figure 10 15 and the Nylock nut PN 60 0014 is secured against the fiberglass material as shown in fi...

Page 66: ...dge of the electrical tape butts up against the plastic coupler as shown in figure 10 22 It is acceptable for a small amount of blue silicone wrap to protrude outside of the joint as shown in figure 10 23 Finish tightening the four screws on the outside corners of the plastic coupler Tighten evenly in an automobile X type pattern as shown in figure 10 24 If you do not tighten evenly you could pote...

Page 67: ...ly push the 39 7 8 CPVC tube into the diverter cone end as shown in figure 11 04 Let the glue dry at least 20 minutes before moving it Apply glue evenly around the outside diameter of the 39 7 8 CPVC tube as shown in figure 11 05 Apply approximately 3 4 deep as per prior step Locate the 49 CPVC tube PN 70 2025 13 with coupler as shown in figure 11 06 Push the 39 7 8 tube firmly into the coupler as...

Page 68: ...y Key QTY Part Description A 4 10 1006 22 Quick disconnect boot B 4 10 1013 02 Telescoping pole C 2 NA Inner guide tube assembly consisting of diverter cone 39 7 8 and 49 CPVC Plastic tube glued together They are only used on the EHU side of the 40 30 loop D 4 NA Quick disconnect boot locking ring these are molded into the base section of each telescoping pole and are used to keep the pole from sl...

Page 69: ...tion of unpainted pole protruding This is OK as it is shielded from the sun by the quick disconnect boot There is a raised ar ea called a locking ring that is molded onto the base section of each of the telescoping poles These are there so that the quick disconnect boot cannot slide off in the event of high winds Figure 11 16 shows the locking ring Align the telescoping pole on the return tube sid...

Page 70: ... bearing they are used for aesthetic improvement only With the 39 ft element truss a 1 3 4 aluminum saddle PN 10 1601 03 is used to secure the truss mast to the boom With the 49 ft element truss a 2 1 4 aluminum saddle 10 1601 32 is used With this exception all other steps are identical The Director 2 element is shown below for instructional purposes but the methodology will be the same for each o...

Page 71: ...13 Only the outer four holes of the truss coupler are used for attaching it as shown in figure 12 14 Note that the top portion of the coupler the portion facing skyward has a hole but this is also not used as shown in the second picture of figure 12 14 Align the truss coupler so that it is paral lel to the telescoping pole and tighten each nut The Dacron truss cord is provided in a single piece an...

Page 72: ...ugh the truss coupler refer to prior page for instructions pulling the cord tight so that there is no slack on either side of the cord The procedure for securing the Dacron truss cord on this end of the loop is exactly the same as the truss coupler you prepared initially At this point of the installation of the 40 30 loop element truss it is important to assemble the truss couplers and Dacron trus...

Page 73: ...e as shown in figure 12 27 Be sure to do this with ALL turnbuckles as this will prevent the turnbuckle from unwinding As a secondary measure we recommend looping rope or wire through the eye and frame of the turnbuckle as shown in figure 12 28 In addition to the leveling of the elements it is also important to ensure that the loops at the tip of the telescoping poles are parallel to the boom The b...

Page 74: ...t For D2A the proper measurement is 59 75 inches center to center from Director 2 The passive element consists of three sections of polished aluminum a single 58 long x 1 2 OD center piece with plastic insulator and two 36 long x 3 8 OD sections that telescope into each side of the 1 2 OD aluminum The 1 2 aluminum has slotted ends so that a stainless steel hose clamp can secure the two sections fi...

Page 75: ...ecure with 5 16 Nylock nuts PN 60 0046 but leave loose enough for leveling and center to center spacing of the element as shown in figure 13 05 and Chapter Two D2A 105 Overall Length Position two 1 3 4 aluminum saddle halves PN 10 1601 03 on the boom and insert two 5 16 x 3 1 2 hex head bolts PN 60 0065 Attach the 6m mounting plate with the bolt holes for the aluminum saddles facing towards the Re...

Page 76: ... most control cable three wraps for coax jumpers As a general rule applying tape approximately every two feet is adequate Other methods include the use of tie wraps Be careful when using tie wraps Be sure to purchase high quali ty UV rated tie wraps that are recommended for cable Most of the standard off the shelf tie wraps are not properly rated and will become brittle and may fail within a short...

Page 77: ... mast plate is set up on the DB36 so that the mating process from mast plate to tower mast is made as easy as possible The tower mast connection uses four sets of aluminum saddles to attach the antenna to the tower mast as shown in figure 14 10 In most cases the tower mast is 2 inches in diameter but occasionally the mast size may be different depending on the customers situation SteppIR offers sa...

Page 78: ...loose fastener is NOW not when that part it was supposed to hold falls out of the sky 7 Be sure that you have set screws in all the saddles where applicable Be sure they are tightened 8 Check all the quick disconnect boots to be sure they are as tight as possible and are in the correct position relative to the EHU and the telescoping poles 9 Check all wiring and coax jumpers to ensure that they ar...

Page 79: ...re having trouble It is best to set the DB36 to 20M be fore doing the calibrate function You only need to calibrate once To be certain that the antenna was in deed out of calibration check the SWR before you calibrate and check it again after you calibrate to see if there are any improvements If the SWR is unchanged the antenna was in calibration and is not the issue The lengths of the antenna are...

Page 80: ...bare 25pin dsub to plug into the SteppIR controller and then insert a paper clip to penetrate the pin hole Usually about 75 long will do the trick One paper clip being longer than the other also helps Again be careful NOT to short the pins Even if the controller is turned off there is always voltage going to the pins with a SteppIR controller We do this to lock the step per motors and minimize the...

Page 81: ...uct design specifications SteppIR Antenna s responsibility is strictly limited to repair or replace ment of defective components at SteppIR Antennas discretion Step pIR Antennas will not be held responsible for any installation or remov al costs costs of any ancillary equipment damage or any other costs in curred as a result of the failure of our products In the event of a product failure a return...

Page 82: ...com Information and questions about our products sales steppir com Phone Fax Phone 425 453 1910 9 30am to 4 30pm Pacific Standard Time Fax 425 462 4415 Tech Support 425 891 6134 10 00am to 5 00pm Eastern Standard Time Address Fluidmotion Inc SteppIR Antennas 2112 116th Ave NE Suite 1 5 Bellevue WA 98004 SteppIR Contact Information Manual written by John Mertel WA7IR with key contributions from Ada...

Page 83: ...Tech Support www steppir com support Tel 425 891 6134 support steppir com Page 83 ...

Page 84: ...Tech Support www steppir com support Tel 425 891 6134 support steppir com Page 84 2112 116th Ave NE 1 5 Bellevue WA 98004 Tel 425 453 1910 email sales steppir com ...

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