SteppIR Dream Beam 36 Assembly Manual Download

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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

Dream Beam 36

Assembly Manual

Summary of Contents for Dream Beam 36

Page 1: ...2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 Dream Beam 36 Assembly Manual ...

Page 2: ... 3 4 Aluminum saddle 16 60 0065 5 16 X 3 1 2 SS Hex Bolt 16 60 0046 5 16 Nylock Nuts 35 60 0112 10 32 X 1 4 SS set screw Boom Saddle Hardware Kit Bag 1 72 0019 01 Inventory check QTY Part Description 4 10 1601 22 2 Aluminum saddle 10 10 1601 32 2 1 4 Aluminum saddle 8 60 0066 5 16 X 4 SS Hex Bolt 4 60 0065 5 16 X 3 1 2 SS Hex Bolt 12 60 0046 5 16 Nylock Nuts Boom Saddle Hardware Kit Bag 2 72 0019 ...

Page 3: ...44 201 Phillystran 1 60 0044 176 Phillystran 2 10 1055 01 60 Dacron rope with 2 crimped loops 2 10 1055 01 285 Dacron rope with 1 crimped loop Truss Hardware Kit Bag 2 72 0021 21 Inventory check QTY Part Description 2 20 6020 8 8 position terminal connector 1 20 6020 01 1 position terminal connector 1 10 1029 01 Connector Protector 1 N A terminal housing with cap 1 60 6000 40 SS hose clamp marked ...

Page 4: ...8 10 SS washer 10 60 0019 10 32 Nylock Nut 4 60 0046 5 16 Nylock Nut 4 60 0075 5 16 X 3 1 4 SS hex bolt DIRECTOR 2 10 60 0017 10 32 X 3 4 SS Screw 10 60 0018 10 SS washer 10 60 0019 10 32 Nylock Nut 4 60 0046 5 16 Nylock Nut 4 60 0075 5 16 X 3 1 4 SS hex bolt DIRECTOR 1 12 60 0017 10 32 X 3 4 SS Screw 12 60 0018 10 SS washer 12 60 0019 10 32 Nylock Nut 4 60 0046 5 16 Nylock Nut 4 60 0114 5 16 X 3 ...

Page 5: ... 16 60 0014 6 32 Nylock Nut 4 60 0020 4 40 X Panhead screw 8 60 0021 01 4 40 X 5 8 Panhead 12 60 0022 4 40 Nylock DIRECTOR 2 16 60 0014 01 6 32 x 7 8 Panhead Screw 16 60 0014 6 32 Nylock Nut 4 60 0020 4 40 X Panhead screw 8 60 0021 01 4 40 X 5 8 Panhead 12 60 0022 4 40 Nylock DRIVEN 16 60 0014 01 6 32 x 7 8 Panhead Screw 16 60 0014 6 32 Nylock Nut 4 60 0020 4 40 X Panhead screw 8 60 0021 01 4 40 X...

Page 6: ...1 60 0112 10 32 SS set screw 2 60 0075 5 16 X 3 1 4 SS hex bolt 2 10 1601 02 1 3 4 Solid Saddles 2 60 0046 5 16 Nylock Nuts 2 60 0028 1 4 X 2 1 4 SS hex bolt 2 60 0034 3 8 SS washer 2 60 0116 1 4 Regular nut 2 60 0030 1 4 Nylock nut 2 60 0094 3 16 SS Quick Link 2 60 0107 3 16 SS eyebolt with nut and washers 2 60 0111 10 24 Nylock nut for eye bolts 1 60 0117 Cable clip with adhesive back 2 10 1613 ...

Page 7: ...1 09 0001 Electrical Tape 1 60 0112 Set Screw 39 Element Truss Kit Option for REF and DIR 2 Located in Antenna Sweep Box If you have this option you will have two of these kits 72 0018 01 BOX NAMES AND SIZES WITH CONTENT 7 1 2 72 7 1 2 Antenna Boom Box Part Number Description Part Number Description 2 10 1202 01 1 3 4 X 72 Boom Section 1 70 2028 01 66 3 8 EST extension with ring 2 10 1202 11 2 X 7...

Page 8: ...using REF 1 N A Connections Box Option 1 N A Antenna Controller 1 N A 80m Dipole Option QTY 4 30m 40m Telescoping Poles QTY 2 2 Regular Telescoping Poles QTY 8 30m 40m Telescoping Poles Inside the Antenna Box Options Manuals Connector Box 80m Dipole Kit Controller Glue Kit Silicone Kit DVN DIR 1 DIR 2 REF Power supply 60 12 1 2 7 1 2 Part Number Description Part Number Description 1 70 1001 61 DB ...

Page 9: ...ly in sets of 2 1 72 0025 01 DB 36 Mast Plate Hardware Kit 2 10 1015 11 12 return EST for DIR 2 and REF 1 72 0030 01 DB 36 Sweep Hardware Kit 1 72 0019 01 Boom Saddle Hardware Kit Bag 1 1 72 0031 01 DB 36 Element Plate Kit 1 72 0019 21 Boom Saddle Hardware Kit Bag 2 2 72 0032 01 Rubber boot Kit 1 72 0020 01 Boom Assembly Kit 2 72 0018 01 39 Element Truss Kit Option only if ordered 24 32 7 1 2 Tool...

Page 10: ...ts level is not very impor tant but aesthetically no one likes a crooked antenna If you do not have a large open area at the tower base you can pre assemble the antenna somewhere else and then disassemble it to whatever degree is necessary and move it out to the tower for final assembly The most important aspect of getting the antenna straight is to get the Element Housing Units EHU mounted level ...

Page 11: ...l so that only the shank is engaged in the tubing Use 5 washers per bolt to secure the bolt Figure 2 Apply a thin film of connector protector or a spray on lubricant i e WD 40 Dry Lube 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 below and slide the boom pieces toget...

Page 12: ...nits EHU with gaskets in the Antenna Box QTY 1 Driven EHU 30m 40m This is the only EHU that has a plastic lid QTY 2 Director 2 Reflector EHU 30m 40m both are identical QTY 1 Director 1 EHU 20m Locate the following parts for assembling the EHU s located in the Antenna Sweep Box QTY 2 Return Element Support Tube EST QTY 3 10 1608 01 Element Return Plate Small Locate the following kits to assembly th...

Page 13: ... 30m 40m housing s REF DVN and DIR 2 pay close attention to the orientation of the EHU boxes when mounting them onto the boom They must be EXACTLY as shown in Figure 3 The REF and DVN are mounted so the housing is outside of the sweep but the DIR 2 is mounted the opposite way This is critical for achieving the best possible performance from the antenna 12 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98...

Page 14: ...o allow leveling adjustments Level the plates to the boom first so that the eye of the EZ eye is on the top side of the boom Then attach the EST extensions once the plates are secured Tighten boom saddle bolts to 20ftlbs 27 09Nm Tighten the EST exsention saddle bolts to 7 ftlbs 9 5Nm This will prevent the fiberglass from cracking or breaking Follow Figure 4 for correct assembly of EST extensions F...

Page 15: ...this figure Torque EST exstension saddle bolts to 7 ft lbs 9 5Nm this torque will prevent the fiberglass from breaking and cracking Return EST Assembly Driven Mounting Plate Assembly QTY 8 5 16 X 3 1 2 bolt 60 0065 Element Return Plate 10 1608 01 QTY 12 1 3 4 Aluminum Saddle 10 1601 02 QTY 4 1 4 Aluminum Spacer 10 1613 11 QTY 4 5 16 X 3 3 4 bolt 60 0114 QTY 4 5 16 X 4 bolt 60 0066 QTY 4 5 16 X 4 1...

Page 16: ...4 fiberglass Once the element has been mounted make sure to check that both the element plate and return plate are level All elements can be adjusted by loosening the saddles and rotating the element until it is level to the other elements of the antenna QTY 6 10 32 X 3 4 SS screw 60 0017 QTY 6 10 32 Nylock nut 60 0019 QTY 1 Driven element housing QTY 1 Driven gasket 10 1016 31 QTY 1 Driven housin...

Page 17: ...nt be over the center of the boom The electrical center is the 1 4 bolt mounted in the housing This is important to the performance of the antenna Return EST Assembly Reflector Element Housing Assembly Reflector EHU QTY 1 30m 40m Element Housing gasket 10 1502 01 Truss Attachment Plate 10 1607 01 QTY 1 Element Mounting Plate with 30m 40m aligning gasket 10 1609 03 1 3 4 boom section Return EST 10 ...

Page 18: ...igure 9 Use a level to check the EHU before tightening the aluminum saddles to the boom NOTES Make sure to attach the element the the element plate before attaching the plate to the boom This will help during the assembly process Also make sure the mounting orientation of the housing in relation to the mast plate and other ele ments is correct The elements electrical center must be directly over t...

Page 19: ...bolt mounted in the housing This is important to the performance of the antenna Return EST Assembly Director 2 Assembly Director 2 EHU QTY 1 30m 40m Element Housing gasket 10 1502 01 Truss Attachment Plate 10 1607 01 QTY 1 Element Mounting Plate with 30m 40m aligning gasket 10 1609 03 1 3 4 boom section 10 1202 01 Return EST 10 1015 11 Element Return Plate 10 1608 01 First attach the Director 2 El...

Page 20: ... boom such that the EZ Eye bolt is centered in the eye olt mount ed to the 2 1 4 boom section Use Figure 11 for the first part of the mast plate assembly Figure 10 QTY 6 3 8 Nylock Nut 60 0050 QTY 1 3 8 regular Nut 60 0049 QTY 4 3 8 SS washer 60 0034 QTY 2 2 1 2 SS U bolt and saddle 60 0006 QTY 2 11 1 2 Mast Plate 10 1610 01 QTY 1 3 8 X 4 EZ Eye bolt SS all thread 60 0085 Director 2 and Director 1...

Page 21: ...if you have the connector box option mount it on the pole saddles as shown in the connec tor box manual When assembling the mast make sure to align the hole at the top of the mast so that the Tunrbuckle bolt figure 14 bolt would be perpendicular to the boom For correct height of the boom truss support mast mast simply rest the bottom of the boom truss support mast on top of the boom QTY 1 30 Boom ...

Page 22: ...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 Cut extra Phillystran leaving a 2 end past wire clip number four In...

Page 23: ...ike it isnt straight looking down from one end to the other adjsut the vertical angle of the boom truss support mast until the boom is straight With the truss attachement plates already secured to the boom you just need to secure the turnbuckle side of the truss to the mast pole Assemble the truss to the mast pole as per Figure 14 This process is much easier with two people one to lift the end of ...

Page 24: ... could result in damage that causes a short circuit Also do not clamp anything over the cables that could possibly pinch or damage the cable When taping the cable start on the ends of the boom and work towards the mast plate This will allow you to trim the cable to the exact length if desired Unscrew the SS hose clamp 056 60 6000 40 so that it can be fitted around the boom Use the SS hose clamp to...

Page 25: ... Make sure you are in an open area so not to damage the pole or yourself Notes Per the manufacturers specifications the silicone tape has a shelf life of 12 months before it is used and should be stored in a cool dry environment Silicone tape will not stick to other surfaces It only bonds to itself be sure to remove all the connector protector residue from your hands before handling silicone tape ...

Page 26: ...ts that you just covered with electrical tape The silicone tape should over hang the electrical tape by 1 2 on both sides of the joint Make one full wrap to start out continually stretching the tape a minimum of 100 of its unstretched length When laying the tape down make sure it is smooth and rub tape so that it will bond to itself better When wrapping the tape around the joints apply one complet...

Page 27: ...C A B C 40in 102cm 31in 79cm 22in 56cm Note Measurements are taken when the tape is unstretched and laying natu rally Tape should be stretched to 50 when being applied to the fiberglass poles Use same wrapping method as regu lar poles Once the pole is extended and within the correct length specified on the previous page the joints can be taped as follows Start the tape with one complete wrap of el...

Page 28: ...in The polycarbonate plastic is very strong so don t worry about breaking it within reason of course Make sure the screwdriver tips do not protrude into the hole for the pole tip where they could damage the O ring Figure 17A Carefully insert the telescoping pole tip completely into the Sweep Coupler Verify your mark is lined up with edge of the Sweep coupler If you have trouble getting the tip all...

Page 29: ...r the Driven Element Apply a thin layer of the provided glue to the outside of the bare ends of the 43 CPVC sup port 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 18 for gluing procedure Let glue set for at least 1 hour Apply a thin layer of the proved glue to the outside of the bare ends of the 43 CPVC supp...

Page 30: ...eturn side of the 30m 40m loop Slide the Telescoping Pole with Diverter Cone assembly inside the EST of the Element hous ing until it bottoms out Procedure will be the same for both REF and DIR 2 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 ...

Page 31: ...ck all taping for loose ends 6 Have all trusses benn tightened 30 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 Figure 19 Small Hose Clamp Large Hose Clamp Boom Truss not shown for clarity Diverter Cone and CPVC Assembly Rubber Boot Locking Ring Return EST REF Element Housing Unit Telescoping Pole NOTES Make sure to completely insert the Telescopin...

Page 32: ... 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 sticking out of the driven element housing From kit the 49 Element hardware kit 72 0023 01 locate the SS hose clamp 016 60 500 15 Place the hose clamp over the rubber coupler before fitting the coupler onto the driven e...

Page 33: ...ing Ring Return EST Driven Element Housing Unit Foam Sealing Ring Black Rubber coupler THIS WAY UP sticker SS hoseclamp 016 60 5000 15 EST Extensions EST Extensions C u t a w a y s h o w n f o r i n s i d e d e t a i l Figure 20 3 0 m 4 0 m T e l e s c o p i n g P o l e A s s e m b l y 3 0 m 4 0 m T e l e s c o p i n g P o l e A s s e m b l y Driven Telescoping pole assembly ...

Page 34: ... other eye bolt Unscrew the SS nut from 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 22 Secure 3 4 SS ring to the short section of the Dacron rope as shown in Figure 23 Use the same procedure that was used to attach the eye bolts to the rope but position the SS ring in the midd...

Page 35: ...olt 60 0114 QTY 2 4 SS turnbuckle 60 0083 QTY 1 1 4 20 X 1 1 4 SS bolt 60 0110 QTY 1 1 4 20 nylock nut 60 0046 QTY 2 5 16 SS washer 60 0033 QTY 1 Truss support 10 1054 01 Telescoping Pole Fiberglass Rod 30m 40m sweep QTY 2 10 24 Nylock Nut 60 0111 QTY 1 3 16 SS eye bolt 60 0107 60 Dacron rope with 2 crimped loops 10 1055 01 with eye bolts secured on both ends 30m 40m Truss Support Assembly Truss E...

Page 36: ... Long and Short are both in this box Locate the following kits for assembling the Telescoping Poles The 6m passive kit will be attached to the 6m passive NOTES It is very important that your 6m passive elements are mounted in the correct location and are the correct length Figure 3 shows you the correct spacing for mounting the 6m passive ele ments Both elements are assembled the same way they are...

Page 37: ...uctions for mounting and wiring the connector box option 36 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 Follow Figure 25 for assemblying the 6m passive element The figure is showing the 6m long element You can use this same procedure for mounting the 6m passive short Make sure to check the tolal length of the 6m passive elements Long element 112 ...

Page 38: ... cables from the EHU s and control cable are correctly wired fit the termi nal strip into the terminal housing that has been mounted close to the mast plate To fit the terminals into the terminal housing place the two 8 position terminals parallel to each other and slide them into the terminal housing Make a couple of wraps of electrical tape around the control cable bundle where it will pass thro...

Page 39: ... the hum ming 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 lis tening 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 pre maturely If...

Page 40: ...hex bolt 60 0114 QTY 4 10 32 X 5 8 SS screw 60 0113 QTY 8 5 16 Nylock nut 60 0046 TOWER MAST QTY 8 2 Aluminum Saddle 10 1601 22 Follow Figure 24 for attaching the DB 36 to the tower mast First secure one half of the 2 saddles to the mast using the 10 32 SS screws This will help to align the tower mast to the mast plate Once the antenna is in position secure the other half of the saddles around the...

Page 41: ...2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 DREAM BEAM 36 LAYOUT ...

Page 42: ...1 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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