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Page 42

SECTION 4.5

FINAL ASSEMBLY

FINAL ASSEMBLY

When the CPVC inner guide tubes are completed, they will need to be inserted into the telescoping

poles and secured to the Driven EHU.

Figure 4.60

below gives an overview of this procedure, with de-

tailed instructions following on the next page.

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Summary of Contents for UrbanBeam Yagi

Page 1: ...banBeam Yagi Assembly Manual REV 1 03 08 23 2018 13406 SE 32nd Street Bellevue WA 98005 l Tel 425 453 1910 l email sales steppir com 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 ...

Page 2: ... 4 ft2 0 41m2 Wind rating 100 mph Adjustable elements 2 Power Rating 3000 watts continuous Feed points 1 Frequency coverage 6 8 MHz 54 MHz Control cable 12 conductor shielded 22AWG Frequency Gain dBi Front to Back dB Front to Rear dB 40M 1 61 9 55 F S 30M 1 772 9 63 F S 20M 6 50 16 5 12 0 17M 6 6 21 12 6 15M 6 6 24 6 14 0 12M 6 7 18 5 15 7 10M 6 65 14 8 14 8 6M 6 15 4 0 4 0 UrbanBeam Yagi Specific...

Page 3: ...Antenna Overview 15 Section 1 Boom Mast Plate Assembly 16 25 Overview 16 EHU Boom Locations 17 EHU Placement 18 EHU Overview 19 EHU Wiring 20 21 Director EHU Drawing 22 Attaching Director Mounting Plate EHU to Boom 23 Driven EHU Drawing 24 Attaching Driven Mounting Plate EHU to Boom 25 Section 2 Mounting the Boom to the Mast Plate 25 28 Mast Plate to Boom Overview Drawing 26 Attaching Boom to Mast...

Page 4: ...ts for Loop Tubes 36 Attaching Sweep Couplers to Sweep Tubes 37 Attaching Poles Loop Tubes to Sweeps 38 Joining the Loop Halves Together 40 Prepare the CPVC inner guide tube diverter cone 41 Section 5 Final Assembly 42 46 Securing the element tubes to the EHU 43 Mounting the UrbanBeam to the Tower Mast 45 Last Steps 45 Section 6 Troubleshooting 47 48 Troubleshooting tips 47 Section 7 Miscellaneous...

Page 5: ...Support steppir com support Tel 425 453 1910 support steppir com Page 5 Notes ...

Page 6: ...Support steppir com support Tel 425 453 1910 support steppir com Page 6 Notes ...

Page 7: ...spection Make sure nothing 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 notify 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 before you want to install the anten...

Page 8: ...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 saw horses Since it is so close to the ground don t expect to see a 1 1 SWR here just look for a good indi cation of resonance something in the range of 1 5 1 to 3 1 Once it has been determined this part of the antenna is working correctly do the following Se lect the lowest band...

Page 9: ...erproof telescoping pole joints 1 20 6208 01 25 pin D SUB connector only used if no D SUB splice purchased 1 20 6209 01 Backshell for 25 pin D SUB connector 4 10 1703 01 1 OD x 18 Polyethylene sweep tube 4 10 1701 01 Metal loop struts connects between adjacent sweep couplers 2 70 2030 01 EHU aluminum mounting plate with foam aligning insulating gasket 10 60 0112 10 32 SS set screw one set screw pe...

Page 10: ...1 72 0060 01 UrbanBeam Loop Hardware kit 1 72 0061 01 UrbanBeam Mast Plate hardware kit 1 72 0041 01 Glue tape and anti seize kit use anti seize on ALL stainless fasteners 1 72 0062 01 UrbanBeam Element Hardware kit ANTENNA OPTIONS Voltage suppressor lighting arrestor OPTION 1 06112 12 pin voltage suppressor 20 8052 01 1 01501 Connector Junction Box 70 2034 1 03322 12 conductor control cable _____...

Page 11: ...ap blue 0 50 x 10mil used for 40 30 loop 5ft roll 1 09 1025 11 16 conical grinding stone pole tip preparation 2 10 1702 01 Loop Splice 5 inch 6 60 6000 50 Type M 312 10 SS Hose Clamp 312 UrbanBeam Loop Hardware Kit 72 0060 01 PREAMBLE QTY PART NUMBER DESCRIPTION 4 10 1601 03 1 75 x 75 Aluminum Saddle Half 4 10 1601 22 2 00 x 75 Aluminum Saddle Half 4 60 0065 5 16 x 3 5 Hex head bolt SS 4 60 0114 5...

Page 12: ...anBeam Element Hardware Kit 72 0062 01 ASSEMBLY KITS BILL OF MATERIALS continued PREAMBLE QTY PART NUMBER DESCRIPTION 10 60 0017 10 32 x3 4 Stainless steel machine screw 10 60 0018 10 SS washer 10 60 0019 10 32 Nylock nut EHU Housing Hardware Kit 72 0054 21 QTY PART NUMBER DESCRIPTION 1 72 0009 03 Glue kit 1 09 0001 66 PVC electrical tape 1 10 1028 01 Anti Seize 2 10 1509 02 Diverter cone 1 10 102...

Page 13: ...tenna operates In addition the configuration drawing identi fies EHU placement which is important as you progress in your installation of the antenna If you have a flat surface that is at least 48 long you can use it to make sure the two EHUs are in the same plane If you do not the use of a level for adjusting the Element Housing Units EHUs is highly recommended This is a surprisingly accurate and...

Page 14: ...emoval 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 molybdenum disulfide such as graphite which is very commonl...

Page 15: ...nts used for 40m and 30m are 50 shorter than a full size dipole element with very little sacrifice in performance 0 6dB The UrbanBeam is a dipole on 40m and 30m The UrbanBeam performs as a 2 element Yagi on 20m 6m Assembly of the UrbanBeam can be broken into phases Prepare the Boom with EHUs Mast Plate and Connector Tube or optional Connector Box Prepare the Element Tubes Loop Tubes Final Assembly...

Page 16: ...a channel weatherproofed with co ax seal The EHUs are then assembled to mounting plates which are in turn attached to opposite ends of the boom with clamps It s important to pay attention to the orientation of the EHUs on the boom making sure that the ESTs where the loop elements attach are positioned to be closest to the ends of the boom EHU MOUNTING OVERVIEW The Boom Assembly consists of the EHU...

Page 17: ...nts Start from the left edge of the boom and measure from there As you assemble each of the element housing units EHU refer to this drawing We recommend this sequence 1 Secure the driven and director element mounting plates to the boom using the correct saddles and fasteners be sure to use anti seize on all stainless steel fasteners Tighten enough to hold them in place but loose enough so you can ...

Page 18: ...EHUs on the boom One is a Driven element on 40 meters through 6 me ters while the other is a Director on 20 meters through 6 meters For the purpose of building the antenna we refer to the elements as Director and Driven elements as shown in Figure 1 01 below All the drawings in this manual are oriented so that you are looking inward at boom with the director to the left and the driven to the right...

Page 19: ...ower is turned off of the controller damage can occur This is the number one cause of antenna installation failures so please be sure to heed the advice Figure 1 02 gives an overview of the inside of a SteppIR EHU Control cable tray for routing cable out of EHU on edge of case Element support tube EST Balun the balun is only inside EHUs that are driven elements EHU terminal header Spring reel for ...

Page 20: ...or before inserting into the terminal plug Figure 1 12 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 1 14 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 1 14 for each EHU Be careful to en...

Page 21: ...ing the coax seal and cut into 1 inch strips as shown in Figure 1 17 You will need 3 strips The re mainder can be used to seal the driven element SO 239 connectors should you wish to Apply coax seal on top of the control cable and work it around the cable as shown in Figure 1 18 This will help keep water from entering into the EHU Apply the coax seal to the remaining areas of the wire tray as show...

Page 22: ...tailed instructions follow 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 0065 5 16 x3 1 2 Hex head bolt E 4 60 0046 5 16 Nylock nut F 1 70 3420 01 Director EHU G 1 10 1502 01 Element housing gasket H 1 10 1015 11 Element mounting plate J 4 10 1601 03 1 3 4 Aluminum saddle half FIG 1 20 PREPARING THE BOOM ASSEMBLY Director ...

Page 23: ...0 32 mounting screws Align the gasket with the holes on the mounting plate Place the EHU PN 70 3420 01 onto the mounting plate and attach it 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 1 33 Be sure that the flat washer is between the machine screw head and the EHU housing as shown in Figure 1 34 Tighten the Nylock nuts en...

Page 24: ...ly PREPARING THE BOOM ASSEMBLY Driven EHU A x10 B x10 C x10 G H J J J J E E E E F D D D D 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 0065 5 16 x3 1 2 Hex head bolt E 4 60 0046 5 16 Nylock nut F 1 70 3403 01 Driven EHU G 1 10 1502 01 Element housing gasket H 1 10 1015 11 Element mounting plate J 4 10 1601 03 1 3 4 Alumin...

Page 25: ...eners Place the EHU gasket PN 10 1502 01 onto the mounting plate as shown in Figure 1 22 Remove all chads from the holes for the 10 32 mounting screws Align the gasket with the holes on the mounting plate Place the EHU PN 70 3403 01 onto the mounting plate and attach it 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 1 23 Be ...

Page 26: ...ware Kit E E E E F F F H H H H J F FIG 2 00 PREPARING THE BOOM ASSEMBLY Mast Plate Key QTY PART NUMBER DESCRIPTION J 1 10 1021 43 8 x 8 x 0 250 Aluminum mast plate Part of 72 0061 01 Mast Plate Hardware Kit H 4 10 1601 03 1 75 x 75 Aluminum Saddle Half 4 10 1601 22 2 00 x 75 Aluminum Saddle Half E 4 60 0065 5 16 x 3 5 Hex head bolt SS G 4 60 0114 5 16 x 3 75 Hex head bolt SS F 8 60 0065 5 16 18 SS...

Page 27: ...level the boom to the mast plate The EHU plate must be level also or this won t work When the mast plate is level with the boom tighten all of the saddle nuts firmly Don t forget to install the set screws in the saddles as shown in Figure 2 13 Only the exposed half of the saddles will require a set screw Use the 10 32 x 5 16 SS panhead screws to hold the 2 mast saddle halves in place on the mast p...

Page 28: ...or the UrbanBeam the two locations where it fits are under the EHUs We suggest mounting the Terminal Housing under the Director EHU Wherever it is mounted the hose clamp is used to go around the Terminal Housing and the location where it is mounted Regardless of the mounting orientation make sure that the hole in the end cap of the terminal housing will be facing downward when the antenna is mount...

Page 29: ...to the appropriate terminal as shown in Figure 3 02 Consult Figure 3 11 for the correct wiring sequence Insert the two stainless steel screws into the circuit board Slide the two plas tic spacers onto the screws 4 Insert the first half of the strain relief clamp onto the two screws half round cutout facing upward on the two screws as shown in Figure 3 03 Be careful not to pull the wires out of the...

Page 30: ... Follow Figure 3 11 for the correct wiring Note that the shield wires are all connected together as one single wire and use a single position terminal strip separate from the other terminal blocks Be careful not to over tighten the screws on the terminal blocks Perform all of the WIRING AND MECHANICAL EHU next page tests on the antenna to ensure wiring is correct then complete the following steps ...

Page 31: ...r antenna controller in addition to causing poor performance Once all of the EHUs are correctly wired and each EHU is being properly con trolled by the SDA100 the initial testing is completed PREPARING THE BOOM ASSEMBLY WIRING EHUS TO CONTROL CABLE SECTION 3 1 Driven EHU Director EHU Black Red Green White Black Red Green White Male 25 pin D sub Black Brown Red Orange Yellow Green Blue Violet White...

Page 32: ...The band button allows a complete cycle out then in to home with one keystroke The purpose of this test is threefold It determines that you have the right control cable wires connected to the correct EHU i e the Driven control wires are moving the Driven element It indicates that the motors are running in the right direction Out makes the tape move out If any of the four motor wires are swapped th...

Page 33: ...from the tip of the pole to the butt end as shown in Figure 4 01 Use a hack saw or similar cutting blade that is suitable for fiberglass Circular pipe cut ters used by plumbers work well too Set aside the cut off piece as it will be used in Section 4 1 Using the included conical drill bit chamfer the ends of the poles as shown in Figure 4 02 The drawing in Fig ure 4 03 shows the proper depth to ch...

Page 34: ...gure 4 08 Step 3 You should use enough tension to wrap 2 1 2 turns around the pole The first layer is only stretched slightly Figure 4 09A with the last 1 1 2 turns pulling the tape a little harder so it makes it to 2 1 2 turns Figure 4 09B This isn t very critical but it s better to not stretch it too tight and thin Try to keep the edges as even as possible Apply pressure to the wraps with your f...

Page 35: ...upport steppir com support Tel 425 453 1910 support steppir com Page 35 SECTION 4 0 TELESCOPING POLE PREPARATION continued PREPARE THE TELESCOPING POLES FOR SWEEPS continued FIG 4 09A FIG 4 09C FIG 4 09B ...

Page 36: ...trip remnant showing overall size differences between the thin and thick end and preparations of the ends Cut the pole remnant to 41 5 cutting off material from the thicker end This is cut 2 See Figure 4 11 Chamfer both ends of the tube using the supplied chamfering bit Prepare the thinnest end in the same way the telescoping pole tips were prepared in Section 4 0 with elec trical tape silicone ta...

Page 37: ... 22 Do not tighten enough to deform the polyethylene Repeat for other side of sweep tube Attach a coupler as shown in Figure 4 21 to one of the four 170 telescoping pole tips that has been prepared previously see Section 4 0 For aesthetic reasons it is nice to have all of the screws in the sweeps and metal brace be oriented the same To do this make two of the sweeps turn one way and two the opposi...

Page 38: ...FIG 4 34 FIG 4 32 FIG 4 33 Installing the Loop Tubes Slide the TIP end of Loop Tube has been cut to 41 5 and prepped per Section XX Repeat the steps in section 6 2 to tighten the 6 6 32 x 2 screws Installing the Metal Loop Brace Figure 4 39 shows a completed sweep assembly To install the Loop Brace use two 6 32 x 2 machine screws as shown in Figure 4 35 on the sweep clamp for the 170 pole side Tig...

Page 39: ...pport steppir com support Tel 425 453 1910 support steppir com Page 39 SECTION 4 3 LOOP PREPARATION continued ATTACH THE TELESCOPING POLES TO THE SWEEPS CONT D FIG 4 39 FIG 4 35 FIG 4 38 FIG 4 37 FIG 4 36 ...

Page 40: ...ile you posi tion and tighten the other outside hose clamp as you did on the other side of the Splice Be careful not to damage the 3M Grip tape already in place on the pole tips If necessary spread the slit in the Loop Splice slightly if the fit is so tight it won t slide onto the pole tip Don t spread it so aggressively as it breaks The last step is to position the third hose clamp so it covers t...

Page 41: ...as shown in Figure 4 43 Be sure you get even coverage all the way around the tube Cover about 3 4 of an inch deep as shown in Figure 4 43 Firmly push the 39 7 8 CPVC tube into the diverter cone end as shown in Figure 4 44 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 4 45 Apply ap proximately 3 4 deep ...

Page 42: ...ION 4 5 FINAL ASSEMBLY FINAL ASSEMBLY When the CPVC inner guide tubes are completed they will need to be inserted into the telescoping poles and secured to the Driven EHU Figure 4 60 below gives an overview of this procedure with de tailed instructions following on the next page ...

Page 43: ... shows the EHU placement for the Driven element the procedure is the same for the Di rector element except the Director does NOT have the guide tubes The parts required in the table below are shown for the Driven EHU assembly Key QTY Part Description A 2 10 1006 22 Quick disconnect boot B 2 10 1013 02 Telescoping pole C 2 NA Inner guide tube assembly consisting of diverter cone 39 7 8 and 49 CPVC ...

Page 44: ...g into the Driven EHU have the CPVC guide tubes inside of them until it bottoms out firmly in very rare cases the pole butt may need sanding to allow it to slide freely There may be a small portion of unpainted fiberglass pole protruding as shown in Figure 4 65 this is normal just make sure it is bottoming out on the diverter that is inside the EST tube The unpainted part of the pole will be prote...

Page 45: ...o sets of aluminum saddles to attach the antenna to the tower mast as shown in figure 5 00 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 saddle sizes in 1 3 4 2 2 1 4 2 1 2 and 3 Since the vast majority of installations of the URBANBEAM comes with the standard 2 inch sad dles that is the verb...

Page 46: ...e copper strip from extending or retracting you will get a harsh sound as the motors try to keep going but the tape is stuck 4 If any of these bad sounds occur try to locate the area where the problem is happening and in vestigate Repeat these steps again If all is OK proceed to step 6 5 Check all fasteners on the antenna to be certain that they are tight This may seem redundant but the time to di...

Page 47: ...ibrate function You only need to calibrate once To be certain that the antenna was indeed 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 incorrect Using the Cause Effect theory generally the first place to look...

Page 48: ... you have significantly different values at any point in the test process you can be reasonably certain that you have a damaged driver chip for that element Please be aware that in some cases we have seen driver chips partially damaged causing them to work part of the time This can be confusing in the test process If you do not have the optional 25 pin D Sub splice assembly see Section 3 0 when me...

Page 49: ...esign 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 auth...

Page 50: ... 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 425 453 1910 10 00am to 5 00pm Eastern Standard Time Address SteppIR Communication Systems 13406 SE 32nd Street Bellevue WA 98005 SteppIR Contact Information Manual written by John Mertel WA7IR with key contributions from Adam Blackme...

Page 51: ...Support steppir com support Tel 425 453 1910 support steppir com Page 51 ...

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