SteppIR Dream Beam 42 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 42

Assembly Manual

Craig Thompson K9CT DB42 Stack

Summary of Contents for Dream Beam 42

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 42 Assembly Manual Craig Thompson K9CT DB42 Stack ...

Page 2: ...2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 0 0 10 0 23 24 2 20 5 5 6 7 7 0 0 0 0 1 20 1 3 4 0 1 ...

Page 3: ...2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 0 1 2 3 4 4 2 3 5 3 0 3 0 6 0 ...

Page 4: ...tems 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 1 ...

Page 5: ...2 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 DB42 Parts Pick List continued ...

Page 6: ...3 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 0 0 0 DB42 Parts Pick List continued ...

Page 7: ...4 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 0 1 2 1 3 4 5 6 6 5 6 57 0 8 0 0 4 9 0 4 DB42 Parts Pick List continued ...

Page 8: ...ave 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...

Page 9: ...led holes align Secure the correct bolts and washers onto the boom as shown in figure 1 2 Repeat this for each section until the boom is completely assembled The final step is to secure the eyebolt as shown in figure 1 1 and figure 1 2 See washer placment in figure 1 2 for 1 4 and 5 16 boom bolts 1 4 X 3 Hex Bolt 60 0029 and five 1 4 flat washer 60 0041 1 4 X 31 4 Hex Bolt 60 0063 and five 1 4 fla...

Page 10: ... Director 1 EHU 30m 40m Driven This is the only EHU that has a plastic lid QTY 2 Director 3 and Reflector EHU 30m 40m Passive both are identical QTY 1 Driven EHU 20m with relay default to passive QTY 1 Driven EHU 20m with relay default to Driven Locate the following parts for assembling the EHU s QTY 2 Return Element Support Tube EST QTY 3 10 1608 01 Element Return Plate Small QTY 3 Element mounti...

Page 11: ...our mark using figure 1 3 below 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 in relation to the EZ Ey...

Page 12: ... 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 9 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 Figure 1 4 REFLECTOR DRIVEN DIRECTOR 1 40M driven DIRECTOR 2 180 Driven Antenna Element Placement DIRECTOR 3 BOOM TRUSS Boom truss attachment Cent...

Page 13: ...bes as shown in figure 1 6 once the plates are secured Place the stress relief tubes over the applicable EST extensions as shown in figure 1 6 and figure 1 7 Tighten boom saddle bolts to 20ft lbs 27 09Nm Tighten the EST extension saddle bolts to 15 ft lbs 20 34Nm Follow figure 1 5 and figure 1 7 for correct assembly of EST extensions Place the Stress Relief Tubes over the applicable EST extensions...

Page 14: ...11 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 The items below will be used when performing the steps on page 11 12 and 13 ...

Page 15: ...116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 0 1 2 0 3 04 5 5 6 0 3 7 3 7 3 6 5 3 8 8 84 8 8 84 1 0 5 8 5 5 91 8 8 8 5 8 4 8885 5 8 5 Director 1 Assembly Figure 1 6 ...

Page 16: ...ITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 QTY 2 2 x 3 Stress relief splice 10 1630 11 QTY 1 2 x 12 Stress relief splice 10 1630 21 QTY 2 2 x 3 Stress relief splice 10 1630 11 Note Figure 1 7 ...

Page 17: ...ver 40m 10 1022 21 QTY 4 10 32 X 3 4 SS screw with nylon locking strip 60 0101 QTY 4 10 SS washers 60 0018 QTY 4 1 4 aluminum spacer 10 1613 11 The best location to place the level when leveling the Driven Element Support Plate is along the lip of the element plate Director 1 EHU Preparation Mounting Director 1 Housing NOTES With the 1 4 aluminum spacers 10 1613 11 fig 1 8 under the EHU the plasti...

Page 18: ...15 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 The items below will be used when performing the steps on page 14 ...

Page 19: ...ke sure to align the element to the boom correctly which direc tion it is facing affects the polarity of the antenna Use a level to ensure that the mounting plates are level in retro spect with each other before attaching the EHU s This bolt should be directly over center of boom FIGURE 1 10 DB 42 20M Driven Element Reflector 2 OD Boom Section 10 1202 11 QTY 10 60 0017 10 x 3 4 SS screw NOTE The d...

Page 20: ...17 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 The items below will be used when performing the steps on page 15 ...

Page 21: ...o align the element to the boom correctly which direc tion it is facing effects the polarity of the antenna Use a level to ensure that the mounting plates are level in retro spect with each other before attaching the EHU s This bolt should be directly over center of boom Mast Plate 2 1 4 OD Boom Section 10 1202 21 QTY 10 60 0017 10 x 3 4 SS screw NOTE The driven element and director 2 look identic...

Page 22: ...19 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 The items below will be used when performing the steps on page 16 ...

Page 23: ...20 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 0 1 2 3 4561 7 The items below will be also be used when performing the steps on page 16 ...

Page 24: ...eturn EST 10 1015 11 Element Return Plate 10 1608 01 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 1 12 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 ...

Page 25: ...22 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 The items below will be used when performing the steps on page 17 ...

Page 26: ... shown in figure 2 2 See figure 2 2 for attaching the DB42 to the tower mast While we show you how to do this here we rec ommend 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 ot...

Page 27: ...he 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 Truss Support Mast 10 1618 01 QTY 4 10 1601 02 1 3 4 Aluminum Saddles QTY 4 60 0100 5 16 X 3 1 2 SS bolt Director 1 Direc...

Page 28: ...25 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 The items below will be used when performing the steps on page 19 ...

Page 29: ...he clamps and the strength will not be compromised but we don t recommend it from an aesthetic point of view 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 ...

Page 30: ...ple one to lift the end of the boom while the other person attaches the turnbuckle to the mast pole ASSEMBLING THE DOUBLE TRUSS TO THE TRUSS SUPPORT POLE COLOR CODE 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 BLUE 6 Galvanized turnbuckle 60 0070 2 GREEN 3 8 x 3 Eyebolt w Nylock nut 60 0037 60 0050 2 2 Suggest...

Page 31: ...28 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 0 1 Figure 3 1 ...

Page 32: ...29 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 01 2 3 4 0 ...

Page 33: ... 3 3 WARNING DO NOT USE ANY PETROLEUM BASED LUBRICANTS SUCH AS ANTISEIZE WITH THESE COUPLERS AS IT WILL DESTROY THEM USE INCLUDED TEFLON GREASE INSTEAD ON THE SWEEP COUPLER FASTENERS WARNING DO NOT USE ANY PETROLEUM BASED LUBRICANTS SUCH AS ANTISEIZE WITH THESE COUPLERS AS IT WILL DESTROY THEM USE INCLUDED TEFLON GREASE INSTEAD ON THE SWEEP COUPLER FASTENERS ...

Page 34: ... 31 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 Foam Plug for 20m Telescoping Pole Tips ...

Page 35: ...ort Tube with the coupler Follow figure 3 13 for glu ing procedure Let glue set for at least 1 hour Figure 3 12 shows the completed support tubes Apply a thin layer of the proved glue to the outside of the bare ends of the 39 7 8 CPVC support tube On one end glue on 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 co...

Page 36: ...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 shou...

Page 37: ...Check all taping for loose ends 6 Have all trusses been tightened 34 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 Figure 3 14 Small Hose Clamp Large Hose Clamp Diverter Cone and CPVC Assembly Rubber Boot Locking Ring molded to telescoping pole Return EST 30 40 Element Housing Unit Telescoping Pole NOTES Make sure to completely insert the telescopi...

Page 38: ...r 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 elem...

Page 39: ... w n f o r i n s i d e d e t a i l Figure 3 15 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 Director 1 Telescoping pole assembly QTY 1 10 1630 21 2 x12 Stress relief tube slides over OD of EST extension NOTE Mark the center of the splice and insert each return extension 70 2028 01 to the mark then tighten aluminum QTY 4 10 1630...

Page 40: ...g on your own personal pref erence 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 th...

Page 41: ...1 15 QTY 2 60 0114 5 16 x 3 3 4 Hex head bolt 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 1 10 24 Nylock Nut 60 0111 QTY 1 3 16 SS eye bolt 60 0107 30m 40m Truss Support Assembly Truss Eyebolt Assembly Dacron truss rope ...

Page 42: ...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 1 4 on page 9 of this manual f...

Page 43: ...icking 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 2 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 Plug the correct connector into their...

Page 44: ...8 13 25 24 23 22 21 20 19 18 17 16 15 14 12 11 10 9 8 7 6 5 4 3 2 1 13 S S 19 Shield wire 24 Connect Pin numb P1 and P 5 pin D SUB o controller P2 C N P1 Suggested control cable wire colors Control wire color Connector box PIN numbers P1 and P2 Controller splice PIN numbers Wiring from EHU s to connector junction box REF J1 DRV J2 DIR1 J3 DIR2 J5 DIR3 J4 25 PIN CONNECTOR TO CONTROLLER 25 PIN CONNE...

Page 45: ...he 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 Figure 5 4 Wiring EHU Use this line for wiring For 4 wire connec tions the wiring order is BK R G W For 6 wire connections the wiring order is BK R G W Blu Br Reel Location for COAX seal NOTE Wire the cabl...

Page 46: ...r By utilizing this connector splice there is no need to cut the DB25 connector off and re solder when running cable through con duit 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 0 1 2 3 0 1 0 4 0 1 2 3 0 0 1 5 6 7 0 1 1 0 0 4 1 0 0 0 8 9 1 0 1 ...

Page 47: ... 56 80 O 7 P 6 62 032 21 9 Q RST UVV WXYZ X RZ _ a bc d d b be f g h i b jkb bka l m n o n o n o n o n o n o n o n o n o n o n o n o n o n o qp er n st t u v wsxy t n z xwt n z xwt n xwt t n t z u v t DB25 Splice to SDA100 Controller Wiring Diagram Figure 5 13 NOTE Refer to figure 5 13 for wiring of the DB42 control cable to the SDA 100 con troller ...

Page 48: ...6 748 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z _ a b c d e f g h i j k lnm oqp r s t u v w x y z w z w x To Driven Element From Radio or 80M Dipole option To Director 2 Element To Director 1 Element out 1 WIRING THE COAX ANTENNA SWITCH COAX ROUTING DIAGRAM FOR ANTENNA SWITCH Figure 6 1 Figure 6 2 ...

Page 49: ...head screw located in small ziplock bag QTY 2 60 0115 5 16 x 4 1 2 Hex head bolt QTY 2 60 0019 10 Nylock nut QTY 1 10 1619 01 Coax switch bracket REFLECTOR DIRECTOR 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 ...

Page 50: ...0m dipole option only Coax IN if no 80m dipole 80m Dipole coax switch box optional Figure 6 4 47 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 Coax Jumper Routing ...

Page 51: ...48 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 DB 42 PRE INSTALLATION TESTS 0 1 1 2 3 4 1 2 5 6 5 5 7 8 9 9 77 9 9 2 5 7 7 9 7 4 87 9 5 7 ...

Page 52: ...49 2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 01 2 3 4 5 6 7 8 9 4 5 6 7 2 ...

Page 53: ...ring 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 maturel...

Page 54: ...2112 116TH AVE NE SUITE 1 5 BELLEVUE WA 98004 WWW STEPPIR COM TEL 425 453 1910 FAX 425 462 4415 DREAM BEAM 42 LAYOUT 51 ...

Page 55: ...nd the product design specifications SteppIR Antenna s responsibility is strictly limited to repair or replacement of defec tive 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 ...

Page 56: ...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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