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Page 18

CHAPTER ONE

SECTION 1.0

BOOM ASSEMBLY

Our boom pieces are all drilled on a very precise drill press. This ensures that all the bolts are snug

when assembled. It is always better to be too tight than too loose. If your boom ever gets damaged

or destroyed we can send the specific replacement boom piece(s) required. Always apply an anti-seize

lubricant to stainless steel bolts that are using stainless steel nuts. This will prevent the two from gall-

ing together. Galling of stainless steel is common and has nothing to do with the quality of the materi-

al. 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

1. 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. Failure to do so may cause the tubes to seize inside each

other.

2. Match the boom pieces as shown in

figure 1.01

below and slide each boom piece together until the

pre-drilled holes align.

3. Secure the correct bolts and washers onto the boom as shown in

figure 1.02

4. Repeat this for each section until the boom is completely assembled.

5. Secure the 7/16” eyebolt as shown in

figure 1.01

and

figure 1.03

. Note that in the event of a tight

fit, it is acceptable to use a mallet to drive the eyebolt in as shown in

figure 1.04

1-3/4”

Boom Section

10-1202-01

2”

Boom Section

10-1202-11

2-1/4”

Boom Sec-

tion

10-1202-21

2-1/2” Boom

Section

10-1202-71

3” Boom

Section

10-1202-81

2-1/2” Boom

Section

10-1202-71

2-1/4” Boom

Section

10-1202-21

2” Boom

Section

10-1202-11

1-3/4” Boom

Section

10-1202-01

7/16” Eyebolt

QTY 1: 60-0029
1/4” x 3” Hex bolt

and

QTY 5: 60-0041

1/4” Flat washer

QTY 1: 60-0063
1/4”x3-1/4” Hex bolt

and

QTY 5: 60-0041

1/4” Flat washer

QTY 1: 60-0100
1/4”x3-1/2” Hex bolt

and

QTY 5: 60-0041

1/4” Flat washer

QTY 1: 60-0066
5/16”x4” Hex bolt

and

QTY 2: 60-0033

5/16” flat washer

QTY 1: 60-0063
1/4”x3-1/4” Hex bolt

and

QTY 5: 60-0041

1/4” Flat washer

QTY 1: 60-0029
1/4” x 3” Hex bolt

and

QTY 5: 60-0041

1/4” Flat washer

QTY 1: 60-0100
1/4”x3-1/2” Hex bolt

and

QTY 5: 60-0041

1/4” Flat washer

Be sure the
10-1203-21

Boom sleeve
is in place

Be sure the
10-1203-21

Boom sleeve
is in place

Note: Check the following page for information on washer placement

FIG. 1.01

BOOM ASSEMBLY OVERVIEW

Содержание DB42 MonstIR PRO

Страница 1: ... 116th Ave NE 1 5 Bellevue WA 98004 Tel 425 453 1910 www 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 REV 10 0 02 20 2013 Mikhail Mogutuv DB42 4 stack ...

Страница 2: ...ble elements 5 Power Rating 3000w Key Down 1500w on 80m option Feed points 2 Frequency coverage 6 8 MHz 54 MHz 3 5MHz w 80m option Control cable 25 conductor shielded 22AWG Gain Front to rear by band Gain dBi Forward DIR Front to rear db forward Gain dBi Reverse DIR Front to rear dB reverse 80M option 1 7 NA 1 7 NA 40M 8 0 25 5 8 0 23 2 30M 9 0 12 4 9 0 12 4 20M 10 1 22 0 10 0 23 2 17M 10 8 23 2 1...

Страница 3: ...rking the boom 20 Boom marking table 21 CHAPTER TWO MOUNTING THE EHU s ON THE BOOM 22 25 SECTION 2 0 Center to center spacing measurements 22 Section 2 1 Element housing unit EHU wiring overview 23 Wiring the EHU 24 25 CHAPTER THREE DIRECTOR 1 EHU 36 38 SECTION 3 0 Director 1 EHU and return tube assembly drawing 26 Attach the element mounting plate to boom 27 28 SECTION 3 1 Element support tube ES...

Страница 4: ...DIRECTOR 2 44 45 SECTION 6 0 Director 2 EHU assembly drawing 44 Mount the Director 2 EHU on the boom 45 CHAPTER SEVEN DIRECTOR 3 EHU 46 48 SECTION 7 0 Director 3 EHU and element return assembly drawing 46 Mount the Director 3 EHU on the boom 47 SECTION 7 1 Return tube assembly Director 3 48 CHAPTER EIGHT MAST PLATE AND DOUBLE TRUSS 49 57 SECTION 8 0 Mounting the mast plate to the boom 49 50 SECTIO...

Страница 5: ...assive elements to the boom 62 CHAPTER TEN COAX SWITCH HOUSING 63 66 SECTION 10 0 Mounting the coax switch housing 63 SECTION 10 1 Coax switch wiring 64 SECTION 10 2 Sealing and securing the coax switch housing 65 SECTION 10 3 Attach the coax jumpers and feed line 66 CHAPTER ELEVEN WIRING THE CONNECTOR JUNCTION BOX 67 75 SECTION 11 0 Mount the connector junction box onto the boom 67 SECTION 11 1 W...

Страница 6: ...N 83 85 SECTION 13 0 Prepare the CPVC inner guide tube and diverter cone 83 SECTION 13 1 Attach the EST to the EHU 84 85 CHAPTER FOURTEEN 40 30 ELEMENT TRUSS KIT 86 89 SECTION 14 0 Installing the truss support mast 86 SECTION 14 1 Attach the truss couplers 87 SECTION 14 2 Routing the Dacron truss cord 88 89 CHAPTER FIFTEEN SECURE CABLES MOUNT DB42 ON TOWER MAST 90 92 SECTION 15 0 Secure the cables...

Страница 7: ... for notification your antenna is being shipped Your antenna has arrived What is the first thing to do 1 If the antennas is to arrive on Wednesday DO NOT plan an antenna party for Saturday 2 Even if you plan to install the antenna weeks later the first thing to do is to unpack the antenna and do a complete inspection Make sure nothing is missing or has been damaged in shipment 3 Do a complete inve...

Страница 8: ...he antenna If you don t have an analyzer try to borrow one It will save you a lot of time and worry Check 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 Als...

Страница 9: ...nt that you do an inventory of the items that were shipped to you Nothing is worse than discovering a day before a planned installation that there are missing parts We do our very best to en sure that you receive everything needed for construction of your antenna but better to be safe than sorry inventory your parts well in advance of your installation The items in blue represent options available...

Страница 10: ... COAX SWITCH BOX BRACKET 1 21 5001 01 65 FT 4 COND 22AWG CABLE NEEDS TO BE CUT TO LENGTHS 1 21 5013 01 40 6 COND 22AWG CABLE NEEDS TO BE CUT TO LENGTHS 1 21 6301 80 8 COAX JUMPER CABLE Used for D1 1 21 6301 96 11 6 COAX JUMPER CABLE Used for DRV 1 21 6301 98 15 COAX JUMPER CABLE Used for D2 1 10 1050 21 COUNTER WEIGHT STEEL W POWDER COAT 4 70 1007 01 FOAM ELEMENT END PLUG ASSY 1 10 1028 21 ANTI SE...

Страница 11: ...0 1156 01 30 40M SWEEP 160PSI 6 10 1503 21 31 75 Black Fiberglass rods drilled 4 10 1630 11 2 IN X 3 IN ALUM SLEEVE 1 10 1630 21 2 IN X 12 IN ALUM SLEEVE 2 70 2028 01 66 3 8 EST EXT WITH ALUM RING 2 70 2029 01 60 3 4 EST EXT WITH ALUM RING 1 10 1018 11 1 3 4 X 48 BOOM TRUSS MAST 1 10 1618 21 1 3 4 X 36 BOOM TRUSS SUPPORT HARDWARE KIT QTY PART NUMBER DESCRIPTION 16 60 0014 01 6 32 X 7 8 SS PAN HEAD...

Страница 12: ... 3 16 WIRE CLIPS 8 60 0048 3 16 WIRE THIMBLE 4 10 1613 01 1 ALUM SPACER 12 10 1613 11 1 4 ALUM SPACER 8 60 0044 00 PHILLYSTRAN CAP BLACK 2 60 6000 15 SS HOSE CLAMP 016 2 60 0083 1 4 x 4 SS TURNBUCKLE 4 60 0070 3 8 x 6 GALV TURNBUCKLE ALUMINUM SADDLES QTY PART NUMBER DESCRIPTION 36 10 1601 03 1 3 4 ALUMINUM SADDLE HALF 28 10 1601 22 2 ALUMINUM SADDLE HALF 4 10 1601 32 2 1 4 ALUMINUM SADDLE HALF 6 1...

Страница 13: ...CPVC INSULATOR 6 10 1026 58 36 X 375 ALUMINUM TUBE NO HOLES OPTIONAL 39 FT END TRUSS KIT QTY PART NUMBER DESCRIPTION 1 10 1054 02 36 TRUSS SUPPORT ARM 2 10 1601 03 1 3 4 ALUMINUM SADDLE HALF 8 10 1510 01 ELEMENT TRUSS CLAMP HALF 2 60 0083 4 STAINLESS TURNBUCKLE 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...

Страница 14: ... 16 NYLOK NUT 2 10 1601 02 1 3 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 4 X 5 16 GALVANIZED EYEBOLT 4 60 0033 5 16 SS WASHER 2 10 1613 01 1 ALUMINUM SPACER 2 10 1607 01 TRUSS ATTACHMENT PLATE 1 216301 70 4 COAX JUMPER CABLE 1 21 5001 01 5 4 CONDUCTOR 22 GA CABLE 1 09 0001 E...

Страница 15: ...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...

Страница 16: ...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 Be sure to refer to the DB42 configuration drawing on the following page so that you can fully under stand how the antenna ope...

Страница 17: ...TIVE 40M 30M REFLECTOR 20M 6M DIRECTOR 40M 30M REFLECTOR ALL BANDS Optional 6m passive element BOOM MAST PLATE DRIVEN 20M 6M NOT ACTIVE DIRECTOR 1 20M 6M DRIVEN 40M 30M DIRECTOR 2 20M 6M NOT ACTIVE 40M 30M FORWARD DIRECTION Normal REVERSE DIRECTION 180 deg DIRECTOR 3 20M 6M DIRECTOR 40M 30M DIRECTOR 3 20M 6M DIRECTOR 40M 30M Optional 6m passive element Optional 6m passive element PREAMBLE RELAY RE...

Страница 18: ...iece together until the pre drilled holes align 3 Secure the correct bolts and washers onto the boom as shown in figure 1 02 4 Repeat this for each section until the boom is completely assembled 5 Secure the 7 16 eyebolt as shown in figure 1 01 and figure 1 03 Note that in the event of a tight fit it is acceptable to use a mallet to drive the eyebolt in as shown in figure 1 04 1 3 4 Boom Section 1...

Страница 19: ...Z eyebolt resists when you insert it into the boom you can use a hammer or mallet as long as you strike it with something that will not damage the eyebolt as shown in figure 1 04 BOOM BOLT EZ EYEBOLT DRAWINGS FIG 1 02 Inserting the boom bolts into the boom See prior page for the specific bolt lengths required for each boom section QTY 3 60 0041 1 4 Flat washers QTY 1 60 0030 1 4 Nylock nut QTY 2 6...

Страница 20: ...own in figure 1 12 and figure 1 13 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 in figure 1 10 is the same configuration on each side 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 E...

Страница 21: ...4 509 91 cm Director 1 218 25 inch 218 1 4 554 35 cm 49 ft Element truss 230 75 inch 230 3 4 586 11 cm Director 1 return 243 9 inch 243 7 8 619 51 cm Mast plate 260 0 inch 660 4 cm Antenna switch 277 5 inch 277 1 2 704 85 cm OPTIONAL 6m director 2 350 75 inch 350 3 4 890 91 cm Director 2 434 5 inch 434 1 2 1103 63 OPTIONAL 6m director 3 441 875 inch 441 7 8 1122 4 cm Boom truss clamp 474 75 inch 4...

Страница 22: ...e center to center spacing is correct when assembling your SteppIR Ya gi Use figure 2 01 for placement of each of the elements Start from the left edge of the boom and measure from there As you assemble each of the element housing units EHU s refer to this drawing We recommend this sequence 1 Secure the element mounting plates to the boom using the correct saddles and fasteners be sure to use anti...

Страница 23: ... respective EHU or the antenna will not function correctly and the electronic controller could be damaged This brings up an important note NEVER DO ANY WIRING WHEN THE ELECTRONIC CON TROLLER IS CONNECTED TO THE CONTROL CABLE Even if the power is turned off of the con troller damage can occur This is the number one cause of antenna installation failures so please be sure to heed the advice Figure 2...

Страница 24: ...l cable should look like when you are finished with the trimming Dip each of the copper wires into connector protector before inserting into the terminal plug Figure 2 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 2 14 The plug is shipped loosely attached to the header Remove this plug when...

Страница 25: ... point which the tray starts as shown in figure 2 16 Using the coax seal and cut into 1 inch strips as shown in figure 2 17 You will need 3 strips The re mainder 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 as shown in figure 2 18 This will help keep water from entering into the EHU Apply the coa...

Страница 26: ...0 1613 11 1 4 Aluminum spacer N 4 10 1613 01 1 Aluminum spacer F 1 10 1605 11 Element support plate P 12 10 1601 22 2 Aluminum saddle half G 1 10 1630 21 2 x 12 stress relief tube Q 2 60 0141 5 16 x 5 Hex head bolt H 1 10 1608 01 Element return plate R 2 70 2029 01 1 3 4 X 60 3 4 EST tube I 4 10 1601 61 3 Aluminum saddle half T 2 70 2028 01 1 3 4 x 66 3 8 EST tube J 2 10 1606 01 2 1 4 x 0 125 Rein...

Страница 27: ...performance the DB42 delivers on the 40m and 30m bands while being 40 shorter than a full sized Yagi on those bands The construction of the Director 1 element is the most complex portion of the DB42 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 fo...

Страница 28: ... 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 2 aluminum saddles onto the 5 16 x 4 hex head bolts follow with a reinforcing plate on the bottom of each saddle as shown in figure 3 08 Attach four 5 16 Nylock nuts PN 60 ...

Страница 29: ...e 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 A 4 60 0115 5 16 x 4 1 2 Hex head bolt B 4 10 1613 01 1 Aluminum spacer C 4 60 0114 5 16 x 3 3 4 Hex head bolt D 4 10 1613 11 1 4 Aluminum spacer E 8 60 0046 5 16 Nylock nut F 8 10 1601 22 2 Aluminum s...

Страница 30: ...e respective saddle halves and insert the 1 aluminum spacers onto the hex head bolts as shown in figure 3 14 The inner saddle pairs closest to EHU for each side will be inserted through the mounting plate 1 4 spacers and the reinforcing plate as shown in figure 3 15 Locate four 1 4 aluminum spacers PN 10 1613 11 These are used on the low or furthest side of the EHU when facing the boom with the re...

Страница 31: ...e two re inforcing rings should be aligned so that they are in the same downward position 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 s...

Страница 32: ...Nylock nuts and will be positioned with the threads pointing upward as shown in figure 3 30 Note that two of the Nylock screws are flat headed as shown in figure 3 30 Key F The remaining four 10 machine screws are used to attach the Driven EHU to the element mounting plate and will be covered in more detail in the next step Place the gasket material so that it aligns with the holes in the EHU lid ...

Страница 33: ...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 PN 60 0101 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 nut...

Страница 34: ...ction 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 ...

Страница 35: ...protruding 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 asse...

Страница 36: ...embly for Director 1 Key QTY Part Number Description A 4 60 0114 5 16 x 3 3 4 Hex head bolt B 4 60 0115 5 16 x 4 1 2 Hex head bolt C 8 60 0046 5 16 Nylock nut D 4 10 1601 22 2 Aluminum saddle half E 4 10 1601 41 2 1 2 Aluminum saddle half F 1 10 1630 21 2 x 12 Stress relief sleeve G 2 70 2028 01 1 3 4 x 66 3 8 EST return tube H 1 10 1608 01 Element return plate D D D C x 8 E E E D E G F G F FIG 3 ...

Страница 37: ... Be sure that the return tube is protruding out approx imately 2 5 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 saddle...

Страница 38: ...ition 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 75 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 c...

Страница 39: ...1 3 4 Boom FIG 4 01 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 x3 1 2 Hex head bolt E 12 60 0046 5 16 Nylock nut F 1 70 3421 01 Reflector EHU G 1 10 1502 01 Element housing gasket H 1 10 1015 11 Element mounting plate J 12 10 1601 03 1 3 4 Aluminum saddle half K 1 10 1608 01 Element return plate L 1 10 1015 1...

Страница 40: ...ers Place the EHU gasket PN 10 1502 01 onto the mounting plate as shown in figure 4 03 Align the gasket with the holes on the mounting plate Place the EHU PN 70 3406 01 onto the mounting plate 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 04 Be sure that the flat washer is between the ma chine screw head and th...

Страница 41: ...y 2 5 inches away from the aluminum saddle edge on each side as shown in figure 4 14 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 Measure 30 inches from the center point of the Director EHU to the center point of the element return tube as shown in figure 4 13 Level the return bracket assem...

Страница 42: ...m 6m operation the element below acts as the Driven On 40m 30m operation this element is not used at all and Director 1 becomes the Driven element 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 3412 01 Driven Element EHU G 1 10 1502 01 Element housing gasket ...

Страница 43: ... the Driven EHU PN 70 3412 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 be tween 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...

Страница 44: ...ctor 2 EHU Detailed instructions follow Key QTY Part Description A 10 60 0017 10x3 4 Machine screw B 10 60 0018 10 Flat washer C 10 60 0019 10 Nylock nut D 4 60 0114 5 16 x3 3 4 Hex head bolt E 4 60 0046 5 16 Nylock nut F 1 70 3408 01 Director 2 EHU G 1 10 1502 01 Element housing gasket H 1 70 2030 11 Element mounting plate J 4 10 1601 32 2 1 4 Aluminum saddle half DIRECTOR 3 DIRECTOR 1 B x10 A x1...

Страница 45: ...the Director 1 EHU PN 70 3420 01 onto the mounting plate as shown in figure 6 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 6 05 Be sure that the flat washer is between the machine screw head and the EHU housing as shown in figure 6 06 Tighten the Nylock nuts enough to compress the gasket material but do not o...

Страница 46: ... J J K L J E E E E F 1 3 4 Boom COUNTER WEIGHT N GOES HERE Key QTY Part Description A 10 60 0017 10x3 4 Machine screw B 10 60 0018 10 Flat washer C 10 60 0019 10 Nylock nut D 8 60 0114 5 16 x3 1 4 Hex head bolt E 12 60 0046 5 16 Nylock nut F 1 70 3421 01 Director 3 EHU G 1 10 1502 01 Element housing gasket H 1 70 2030 11 Element mounting plate J 12 10 1601 22 1 3 4 Aluminum saddle half K 1 10 1608...

Страница 47: ...all stainless steel fasteners Figure 7 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 7 04 Align the gasket with the holes on the mounting plate Place the Director 3 EHU PN 70 3421 01 onto the mounting plate as shown in figure 7 05 and attach using the 10 x 3 4 machine screws PN 60 0017 10 flat washers PN 60 0018 and 1...

Страница 48: ...s as shown in figure 7 13 Insert the element return tube PN 10 1015 11 as shown in figure 7 14 Be sure that the return tube is protruding out approximately 2 75 inches away from the aluminum saddle edge on each side as shown in figure 7 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...

Страница 49: ... aluminum plates that are 0 25 thick than a single plate that is 0 50 thick There is no compromise in strength by doing so The DB42 employs a special system called the EZ Eye for both mounting and leveling the boom The EZ Eye is also used in preventing the boom from shifting during high winds Figure 8 01 Shows an exploded drawing of the boom and mast plate assembly along with the EZ Eye sys tem Th...

Страница 50: ... on the upper left side Insert the 7 16 x 5 threaded bolt through the two identical mast plates PN 10 1610 23 as shown in figure 8 04 Secure with the 7 16 standard nut PN 60 0161 and 7 16 lock washer PN 60 0160 as shown in figure 8 05 Tighten firmly Thread the second 7 16 standard nut onto the bolt until there is approximately 3 4 of clearance between the two standard nuts as shown in figure 8 06 ...

Страница 51: ...t is resting near the galvanized washers as shown in figure 8 12 Take care to liberally coat the bolt with anti seize when securing the Nylock nut The Nylon inside the nut causes friction which creates heat and this can lead to galling of the threads on the bolt Use a short level and attach a wrench on each of the 7 16 leveling nuts as shown in figure 8 13 Adjust the nuts as needed to level the bo...

Страница 52: ...dles 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 in figure 8 25 Note that there are more details on the connector junction box installa tion in Chapter Eleven Holding the connector junction box in place insert the 5 16 Nylock nuts onto the hex head bolts and ti...

Страница 53: ...truss mast plate on the truss mast is to loosely attach the saddles and then slide the mast plate onto the mast Locate the truss mast plate PN 10 1021 43 Insert four 5 16 x 3 1 4 hex head bolts PN 60 0075 and attach one half of the 1 75 aluminum saddles PN 10 1601 03 and in sert the 5 16 x 3 1 4 hex head bolts as shown in figure 8 31 Attach the other half of the saddles onto the bolts and loosely ...

Страница 54: ...the other half of the saddles onto the bolts and loosely thread on the 5 16 Nylock nuts PN 60 0046 as shown in figure 8 41 Slide the truss boom through the saddles taking care to align the centerpoint measurements with each other as shown in figure 8 42 Rotate the truss mast boom so that the holes on the ends are pointing downward These holes are used for installing eyebolts in the next step Be su...

Страница 55: ...inless steel hex head bolt PN 60 0152 a 3 8 Nylock nut PN 60 0050 and two 7 16 galvanized flat washers PN 60 0144 The flat washers are 7 16 so that they will completely cover the ends of the turnbuckles during the tightening process Be sure that each of the flat washers are on the outside of the appropriate eyebolt as shown in figure 8 53 Figure 8 52 shows the proper sequence for attaching the tur...

Страница 56: ... as possible as shown in figure 8 53 Again be sure that the U bolt portion of the wire clip is on the dead side and the saddle portion is on the live side Tighten the wire clips alternating between each nut so that the tightening force is evenly distributed Hold each portion of the Phillystran in place while tightening to ensure that a good mate is formed between the two cables Wait 20 minutes and...

Страница 57: ...ter one The placement of the truss attachment plates are located in between the two boom bolts that hold the 2 and 1 75 sections of the boom together as shown in figure 8 57 The boom is double walled at this point of attachment which limits flexing of the boom under loading situations Before threading on the Nylock nuts be sure to apply anti seize to the bolts Be sure the attachment plate is level...

Страница 58: ...f the items there will be two sets of a particular quantity of parts Whenever this occurs you will see an x 2 in the quantity column of the table below A A A A A A A A A A A A A A A A B C C B C C D D D D E E E E F F G G H H G G Key QTY Part Description A 16 x 2 60 0045 3 16 Wire rope clip B 4 10 1607 11 Truss attachment plate 2 per side C 4 10 1601 22 1 75 Aluminum saddle half D 4 60 0065 5 16 x 3...

Страница 59: ...dead side as shown in figure 8 63 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 Tighten the wire clips alternating between each nut so that the tightening force is evenly distributed Hold each portion of the Phillystran in place while tighten ing ...

Страница 60: ...e turnbuckles while holding the eye portion of the turn buckle from moving so that the Phillystran does not wind up as shown in figure 8 68 Repeat the process for each truss portion until the boom is level When the boom has been leveled it is necessary to secure the turnbuckles so that they cannot work loose Using leftover Phillystran insert the end through they eyebolt then through the body of th...

Страница 61: ...ctions 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 firmly together Using a measuring tape as shown in figure 9 02 measure the 3 8 aluminum pieces and mark with a permanent ink...

Страница 62: ...igure 9 08 shows a mounting detail drawing Remember center to center spacing is more important than any other measurement if you want your antenna to function as it should Refer to the measurements that were marked in chapter one section 1 1 We have included the center to center lengths again here for your convenience as shown in figure 9 09 Refer to figure 9 09 for the correct size of aluminum sa...

Страница 63: ...m case with the holes in the mounting plate as shown in figure 10 02 Insert two 10 x 5 8 machine screws PN 60 01130 through the holes Philips head positioned on top Secure with two 10 Nylock nuts PN 60 0019 as shown in figure 10 03 A nut drive works well if you have one available Be sure the coax switch is level before tightening Do not forget to use a set screw on the exposed portion of the alumi...

Страница 64: ...en that was cut off in the earlier step Always dip your bare copper wire ends into the provided connector protector before securing to the ter minal connections Insert wires as shown in figure 10 12 Form a knot in the control cable as shown in figure 10 13 This will serve nicely as a strain relief Be careful not to over stress the control cable while forming your knot Additionally a tie wrap works...

Страница 65: ... as shown in figure 10 21 There is plenty of material and you will need to trim it as shown in figure 10 22 Lower the top half of the enclosure and position so that the mounting holes are lined up as shown in figure 10 23 Locate the flathead threaded screws included in the plastic baggie The screws will be inserted from the bottom of the housing as shown in figure 10 24 Tighten so that the lid is ...

Страница 66: ...HU NOTE The drawing shows the coax jumpers as being below the boom this is for illustration purposes only The coax jumpers should be taped against the antenna boom It is a good idea to label each coax jumper in case you ever need to re move them As a last step we recommend waterproofing the PL259 connectors using the included coax seal It is a good idea to first put a layer of tape over the PL259 ...

Страница 67: ...casions where you will receive a junction box with the mounting plate in the wrong configuration due to the many different 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 6 Nylock nuts as shown in figure 11 01 You will need a Phillips screwdriver for the other end of the screw located inside the junction box ...

Страница 68: ...included connector protector before inserting into the ter minal strip inside the junction box Figure 11 15 shows in detail the diagram for connecting the 16 wire control cable to the P1 and P2 plugs inside the junction box Figure 11 16 shows in detail the diagram for connecting the control cable from the coax switch to the junction box When connecting the wiring for J6 coax switch housing the gre...

Страница 69: ...ug DRIVEN J3 Plug DIR1 J4 Plug DIR3 J5 Plug DIR2 J6 Plug 80m P1 Plug P2 Plug B R G W S B R G W S B R G W Blu Br S B R G W Blu Br S B R G W Blu Br S WHITE BLACK RED GREEN WHITE BLUE BROWN B R G W S BLACK RED GREEN 4 wire control cable key 6 wire control cable key B R G W Blu Br S SHIELD SHIELD FIG 11 14 CHAPTER ELEVEN SECTION 11 1 WIRING THE CONNECTOR JUNCTION BOX continued WIRING THE CONNECTOR JUN...

Страница 70: ...LUE WHITE STRIPE BLUE RED STRIPE BLUE BLACK STRIPE BLACK RED STRIPE SHIELD WIRE 24 WIRE CONTROL CABLE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 P1 PLUG LOCATED INSIDE CONNECTOR BOX GREEN WHITE STRIPE GREEN BLACK STRIPE RED RED WHITE STRIPE ORANGE GREEN STRIPE WHITE BLACK RED RED BLACK WHITE BLACK WHITE RED WHITE RED STRIPE RED BLACK STRIPE RED GREEN STRIPE NOT USED 24 WIRE CONTROL CABLE 15 16 17 18 19 20 2...

Страница 71: ...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 To avoid confusion in wiring it is recom mended that the wires of the 4 conductor control cable that are not used are trimmed back from the connec tions Wires used going to J5 plug are shield black white and red Green is not used F...

Страница 72: ...te terminal as shown in figure 11 22 Consult figure 11 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 screws half round cutout facing upward on the two screws as shown in figure 11 23 Be careful not to pull the wires out of ...

Страница 73: ...RANGE RED STRIPE ORANGE BLACK STRIPE GREEN BLACK RED STRIPE ORANGE GREEN STRIPE WHITE BLACK RED RED BLACK WHITE BLACK WHITE RED GREEN WHITE STRIPE GREEN BLACK STRIPE RED RED WHITE STRIPE WHITE RED STRIPE RED BLACK STRIPE RED GREEN STRIPE NOT USED GND SHIELD GOES HERE GND SHIELD CAN GO HERE TO0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 G G FRONT ROW TERMINAL STRIP MIDDLE ROW...

Страница 74: ...rifies that the Driv en element is selected to be the one power will be applied to in this mode 10 Next check the resistance between the two copper tapes on both D1 and D2 it should be very near a dead short This verifies they are switched to be passive elements by the internal relay board 11 The next test is to verify the antenna switch has selected the proper coax line 12 Using the ohm meter ver...

Страница 75: ...nter pin of the SO 239 labeled IN and the two pins of the terminal strip on the PCB board in the 80 m box labeled 80m Dipole probe the tops of the screws on the green terminal strip The center pin of the IN connector will still show a dead short to center pin of the OUT connector this is normal the balun makes it look like a dead short at DC but not at RF frequencies Remove the control cable Set c...

Страница 76: ...Tech Support www steppir com support Tel 425 891 6134 support steppir com Page 76 THIS PAGE INTENTIONALLY LEFT BLANK ...

Страница 77: ...per angle to chamfer to Be sure to clean out the interior of the fiberglass 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...

Страница 78: ...wrap so that it is flush with the electrical tape as shown in figure 12 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 while you wrap...

Страница 79: ...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 12 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 ...

Страница 80: ...process Push the pole until the edge of the electrical tape butts up against the plastic coupler as shown in figure 12 15 It is acceptable for a small amount of blue silicone wrap to protrude outside of the joint as shown in figure 12 16 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 12 17 If you do ...

Страница 81: ...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 12 22 and the Nylock nut PN 60 0014 is secured against the fiberglass material as shown in figu...

Страница 82: ...chamfering is re quired for the 20m 6m telescoping poles used for the driven element The fit of the plastic housing on the pole tip is purposely very tight so that the foam plug assembly will stay in place Before attaching the plastic housing spread a small amount of dish soap around the in side edge of the plastic housing as shown in figure 12 31 This helps the housing slide on easily and the soa...

Страница 83: ...y push the 39 7 8 CPVC tube into the diverter cone end as shown in figure 13 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 13 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 13 06 Push the 39 7 8 tube firmly into the coupler as ...

Страница 84: ... the same for the Director and Driven elements The parts required in the table below are shown for EACH complete loop assembly 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 disco...

Страница 85: ...n of unpainted pole protrud ing This is OK as it is shielded from the sun by the quick disconnect boot There is a raised area called a lock ing 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 13 16 shows the locking ring Align the telescoping pole on the return tube side ...

Страница 86: ...akes for a better overall profile for the Yagi These trusses do not have any impact on load bearing they are used for aesthetic improvement only The Director 2 element is shown below for instructional purposes but the methodology will be the same for the Reflector 39 ft and Director 1 element 49 ft loops The truss mast needs to be mounted so that it is centered on the halfway point between the EHU...

Страница 87: ... 13 Only the outer four holes of the truss coupler are used for attaching it as shown in figure 14 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 14 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 a...

Страница 88: ...ough 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 tru...

Страница 89: ...me as shown in figure 14 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 14 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 ...

Страница 90: ...t for 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 ...

Страница 91: ...5 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 saddle sizes in 1 3 4 2 2 1 4 2 1 2 and 3 Since the vast majority of installations of the DB42 will be utilizing the standard 2 inch saddles that is the verbiage used in the instructions that follow The 2 inch aluminum saddle halves PN10 1601...

Страница 92: ...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 6 Check all fasteners on the antenna to be certain that they are tight This may seem redundant but the time to discover a 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 a...

Страница 93: ...are having trouble It is best to set the DB42E 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 a...

Страница 94: ...Director or the Reflector our coax jumpers are manufactured by a company that specializes in these products so a defective jumper is relatively rare but it has happened To check the coax jumper cable measure the resistance between the center conductor of the PL 259 on the each end of the coax The coax jumper should measure a very low resistance of 3 ohms or less has continuity If the coax jumper h...

Страница 95: ...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...

Страница 96: ...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...

Страница 97: ...Tech Support www steppir com support Tel 425 891 6134 support steppir com Page 97 ...

Страница 98: ...Tech Support www steppir com support Tel 425 891 6134 support steppir com Page 98 2112 116th Ave NE 1 5 Bellevue WA 98004 Tel 425 453 1910 email sales steppir com ...

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