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SteppIR HFT540C Assembly Manual
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SteppIR HFT540C Assembly Manual

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HFT540C
Assembly Manual
REV 2.0.4 7/2/2021
13406 SE 32nd St. Bellevue, WA 98005 | www.steppir.com | 425.453.1910 | sales@steppir.com

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Summary of Contents for SteppIR HFT540C

  • Page 1 HFT540C Assembly Manual REV 2.0.4 7/2/2021 13406 SE 32nd St. Bellevue, WA 98005 | www.steppir.com | 425.453.1910 | sales@steppir.com...
  • Page 2 Lighter or hot knife (for cutting Dacron). • Multimeter • SWR Analyzer • Wrenches (open-end/box-end) • Socket Set and Rachet • Tape Measure • Hammer/Mallet Estimated assembly time: 5 days (with 2 installers) Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 3 Nut, 5/16, Nylock 60-0046 Pan Screw, 10-32 x .625" 60-0113 Pan Screw, 10-32 x .75" w/locking strip 60-0101 Pan Screw, 10-32 x 1" w/locking strip 60-0101-01 Pan Screw, 10-32 x 1.25" w/locking strip 60-0101-02 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 4 Boom Truss Boom, 2.5" OD x 36" 10-1618-61 Boom Truss Mast, 2.5" OD x 48" 10-1618-71 Boom Splice 10-1203-41 Element Mounting Plate - Lower 10-1605-31 Element Mounting Plate - Upper 10-1605-41 Guy Line Grip, (PLP-2739) 60-7016 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 5 70-6010-01 DB25 Field Splice DB42 100W Power Supply 70-3000-11 EHUs Item Part Number Quantity HFT540C 20m Driven w/Normal Passive Relay 70-3413-01 HFT540C 40/30 Passive 70-3414-01 HFT540C 40m Driven w/Normal Driven Relay 70-3415-01 HFT540C 40m Driven w/Normal Passive Relay 70-3412-01 EHU Lid (packaged with EHUs)
  • Page 6 Stress Relief Sleeve, 2.5" ID x 3" OD 10-1630-41 Options Item Part Number Quantity Filter, suppressor unit, 8 position, 50v 20-8052-41 Filter, suppressor unit, 16 position, 50v 20-8052-51 Control Cable, 24c (customer specifies length) Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 7 DIRECTOR 1 (6.8—8.225MHZ) DIRECTOR 2 (8.225—13.315MHZ) DIRECTOR 3 (13.315—30MHZ) INACTIVE (6.8—8.225MHZ) DIRECTOR 1 (8.225—13.315MHZ) DIRECTOR 2 (13.315—30MHZ) DRIVEN (6.8—13.315MHZ) DIRECTOR 1 (13.315—30MHZ INACTIVE (6.8—13.315MHZ) DRIVEN (13.315—30MHZ) REFLECTOR (6.8—30MHZ)
  • Page 8 ANTENNA OVERVIEW—DIMENSIONS 40 ft Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 9 Step 6: Set the poles aside so that the glue can dry, undisturbed. Support the end so that the pole dries with the element straight Work time: 20 min Handle (Set) Time: 4 hours Full cure: 48 hours Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 10 4" Square Boom Section - 9ft 10-1200-21 4" Square Boom Section - 6ft 10-1203-41 Boom Splice 60-7003 Hex Bolt, 5/16 x 3/4in 60-0033 Washer, 5/16 60-7023 Plug for Square Tube, Black 20 ft-lb Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 11 We recommend placing the sawhorses under the 9ft boom sections near the joint with the 10ft section. • Orient the boom with the drain holes (located at either end of the boom) facing down. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 12 53.75 136.5 Driven Element Mounting Plate 203.2 Director 1 Element Mounting Plate 426.7 Mast Plate MAST 533.4 Director 2 Element Mounting Plate 726.4 Truss Attachment 397.75 1010.3 Director 3 Element Mounting Plate 1176 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 13 2. The plate should be oriented with the wider spaced tapped holes closer to the boom center. The imaginary black arrow shown on the plate should point towards the center of the boom regardless of where the plate is located. NARROWER SPACING WIDER SPACING CENTER OF BOOM Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 14 The position of the element plates is very important as the performance of the antenna depends on accurate element placement! • Note the orientation of each element plate, they are NOT all the same. Center of Boom (Mast Plate Goes Here) Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 15 Tighten the hex bolts to 11 ft-lb with the torque wrench on the nut side. 11 ft-lb MARKING ON BOOM Use anti-seize on all SS hardware! Part Number Description 10-1605-31 Element Mounting Plate—Lower 10-1601-91 Backing Plate Hex Bolt, 5/16 x 7” 60-0215 60-0046 Nut, 5/16, Nylock Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 16 Use anti-seize on all SS hardware! Part Number Description 10-1021-51 HFT540 Mast Plate Square Saddle, 4” 10-1601-71 Hex Bolt, 3/8 x 7” 60-7002 60-0050 Nut, 3/8, Nylock Pan Screw, #10-32 x 1” w/locking strip 60-0101-01 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 17 SS hardware! Part Number Description Saddle, 3” 10-1601-61 Hex Bolt, 5/16 x 5” 60-0141 60-0046 Nut, 5/16, Nylock Pan Screw, #10-32 x 1” w/locking strip 60-0101-01 Set Screw, 10-32 x 1/4” 60-0112 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 18 Connector Junction Box 70-3001-01 Coax Switch Box Hex Bolt, 5/16 x 2.75” 60-0093 60-0033 Washer, 5/16 60-0046 Nut, 5/16, Nylock Pan Screw, #10-32 x .75”, w/locking strip 60-0101-01 60-0113 Pan Screw, #10-32 x 0.625 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 19 Use electrical tape to cover the end of the trimmed green wire, to ensure that there is no opportunity for an electrical short to occur. Figure 10.07 shows the completed control wire prep. FIG. 10.05 FIG. 10.06 FIG. 10.07 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 20 Alternatively, a tie wrap works well. FIG. 10.10 FIG. 10.11 SHIELD ⦸  BLACK  ⦸ DO NOT USE  ⦸ WHITE  ⦸  ⦸ FIG. 10.12 FIG. 10.13 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 21 (note that these instructions were borrowed from a different antenna so the mounting scenario will be different). FIG. 10.21 FIG. 10.20 FIG. 10.22 FIG. 10.23 FIG. 10.24 FIG. 10.25 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 22 6 Conductor 6 Conductor 6 Conductor 4 Conductor 24’ 1” 9’ 8” 6’ 6” 13’ 10” 20’ 3” • Make sure to pair each control cable with the appropriate EHU after you cut it. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 23 FIG. 3.11 FIG. 3.13 6 Pin Header Wiring Sequence 4 Pin Header Wiring Sequence (EHU’s with Relays) (EHU’s without Relays) BLACK GREEN WHITE BLUE BROWN BLACK GREEN WHITE TERMINAL PLUG FIG. 3.14 TERMINAL HEADER Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 24 Make sure that you are using the correct length of control cable for each EHU! It is much easier to correct a mistake before you install the lid. FIG. 3.17 FIG. 3.15 FIG. 3.16 FIG. 3.18 FIG. 3.19 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 25 SS hardware! Part Number Description 10-1501-23 Cover for EHU, w/drain hole 10-1502-01 EHU Gasket Pan Screw, 10-32 x 3/4” 60-0017 60-0017-10 Flat Head Screw, 10-32 60-0018 Washer, 10-32, Flat 60-0019 Nut, 10-32, Nylock Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 26 Director 2 (D2) Director 1 (D1) Driven (DVR) Reflector (REF) 40m Driven 40m Driven 20m Driven 40/30 Passive 40/30 Passive Normal Driven relay Normal Passive relay Normal Passive relay 70-3414-01 70-3415-01 70-3409-01 70-3413-01 70-3414-01 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 27 EHU INSTALL—70FT ELEMENTS Part Number Description EHU (see previous page for correct type) Aluminum Spacer, #10 ID x .5” height 10-1613-13 60-0018 Washer, #10 Pan Screw, #10-32 x 1.25” w/locking strip 60-0101-02 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 28 EHU INSTALL—50 AND 36FT ELEMENTS Part Number Description EHU (see previous page for correct type) Aluminum Spacer, #10 ID x .25” height 10-1613-12 60-0018 Washer, #10 Pan Screw, #10-32 x 1” w/locking strip 60-0101-01 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 29 CONNECTING CONTROL CABLE TO THE OPTIONAL DB25 FIELD SPLICE The DB25 Field Splice provides a convenient solder-less connection of the control cable to the SteppIR controller. Follow the steps below to connect it to your control cable.
  • Page 30 ⦸ Green/ Black Stripe ⦸ ⦸ Red / White Stripe ⦸ White / Red Strip ⦸ Red / Black Stripe ⦸ Red / Green Stripe ⦸ Not Used ⦸ G (Shield Goes Here) Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 31 The remaining 11 wires of the 24 conductor cable used (Pins 14-24). Pin 25 is NOT FROM GROUND USED. 4 wire control cable; the green wire needs to be trimmed and taped; R1 is NOT COAX SWITCH USED. 3 total wires used, plus shield wire. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 32 ⦸ ⦸ Green ⦸ ⦸ White ⦸ Shield J1 PLUG J2, J3, J5 PLUG ⦸ ⦸ Black ⦸ ⦸ ⦸ ⦸ Green ⦸ ⦸ White ⦸ ⦸ Blue ⦸ ⦸ Brown ⦸ Shield Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 33 ORANGE / GREEN STRIPE ⦸ WHITE / BLACK-RED ⦸ RED / BLACK-WHITE ⦸ BLACK / WHITE-RED ⦸ WHITE / RED STRIPE ⦸ RED / BLACK STRIPE ⦸ RED / GREEN STRIPE ⦸ NOT USED Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 34 Note that the R4 position on the J5 plug and R1 position on the J6 plug are not used! J5 PLUG J6 PLUG ⦸ ⦸ Shield ⦸ ⦸ COM Black ⦸  Not used ⦸ ⦸ White ⦸  Not used Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 35 Your results may be slightly higher or lower but the readings for the elements should be consistent. If your results do not match the results of the table below, check your wiring and/or contact SteppIR for assistance. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 36 Step 8: Close relay 3. Check for continuity between the Coax IN and OUT 2. Make sure that there is no connection be- tween IN and OUT 1 or OUT 3. Step 9: Exit the relay test menu. Power off the controller and disconnect the power and control cable. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 37 “OUT2” and “OUT3” center pins. Also, there should be a dead short between “OUT2” and “OUT3” cen- ter pins and ground. (chassis) 14. If any of these tests fail check your wiring and correct any mistakes. 15. DISCONNECT the control cable. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 38 EHUs and you will hear a ratcheting sound for approximately 70 seconds. When finished the con- troller and antenna are now synchronized. 25. This concludes the test and verifies the antenna is wired correctly and all the relays operate properly. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 39 OUT 1 COAX JUMPER TO DRIVEN EHU 11 FT 6 IN OUT 2 COAX JUMPER TO DIRECTOR 1 EHU 4 FT OUT 3 COAX JUMPER TO DIRECTOR 2 EHU 8 FT COAX ANTENNA SWITCH Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 40 Prepare 8 of the 10 poles this way. Two of the poles must be prepared differently from the others, with aluminum sleeves being installed on the poles BEFORE the heat shrink is applied (see the following page for details). Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 41 Foam Plug Assembly Reinforcing Sleeve, 1.75” OD x 2.75” Length 10-1630-51 ASSEMBLE THE 36FT ELEMENT AND CPVC Part Number Description 70-2025-43 CPVC Assembly with 1.35" foam ring + washer hose w/out coupler 62.25” Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 42 Apply the glue to the outer diameter ONLY before inserting into the coupler and twisting. Work quickly as the glue will dry quickly and become less effective ASSEMBLE THE 50 FT ELEMENT AND CPVC Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 43 Part Number Description 70-2022-01 CPVC 3/4 x 89" w/out coupler 70-2021-01 CPVC 3/4 x 89" w/coupler 70-2025-53 CPVC Assembly with 2" foam ring + washer hose ASSEMBLE THE 70 FT ELEMENTS AND CPVC Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 44 Spacer, 3/8” ID x 3/4” Tall, Aluminum 10-1613-21 60-0046 Nut, 5/16, Nylock 60-0033 Washer, 5/16 Important information regarding the assembly is shown on the following page, read both pages before completing this step of the assembly. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 45 Center the aluminum sleeves on the saddles. Orient the sleeves with the slot horizontal as shown. (note that the black vinyl caps and hose clamps shown here will be installed in a later step) Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 46 Saddle, 2” 10-1601-22 10-1605-41 Element Mounting Plate—Top Hex Bolt, 5/16-18 x 7”, SS 60-0215 Spacer, 5/16 x 1”, Aluminum 10-1613-01 60-0046 Nut, 5/16, Nylock 60-0033 Washer, 5/16 Spacer, 5/16 x 1/4”, Aluminum 10-1613-11 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 47 Saddle, 1.75” 10-1601-03 Hex Bolt, 5/16 x 6” 60-7004 60-0046 Nut, 5/16, Nylock Spacer, 5/16” x 1” Aluminum 10-1613-01 60-0033 Washer, 5/16 Spacer, 5/16” x 1/4” Aluminum 10-1613-11 Hex Bolt, 5/16 x 5.5” 60-0204 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 48 The 70ft Element assembly is show below. The hose clamps and vinyl cap sizes will vary on the 70, 50, and 36ft element, see the following page for details. • Butt the vinyl cap up against the reinforcing sleeve, do not install the cap under or over the sleeve. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 49 60-6000-35 Hose Clamp, #48 60-6000-15 Hose Clamp, #16 VINYL CAP INSTALL—36FT ELEMENT Key QTY Part No Description Vinyl Cap, 1.5” x 1.5”, with hole 60-7024 60-6000-20 Hose Clamp, #24 60-6000-15 Hose Clamp, #16 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 50 Press the poles in until they “bottom out”. • Secure the rubber boot by tightening the hose clamps. Tighten twice, waiting at least 15 minutes between to allow the rubber to “cold-flow”. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 51 Hex Bolt, 1/2” x 2.5” 60-7000 Washer, .5” ID x 1.5” OD 60-7012 Set Screw, #10-32 x 1/4” 60-0112 Vinyl Cap, 2.5” x 1.5”, Black, w/o hole 60-7022 60-6000-35 Hose Clamp, #48, SS Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 52 Use anti-seize on all SS hardware! Key QTY Part No Description Boom Truss Assembly Hex Bolt, 5/16 x 4.5”, SS 60-0115 60-0046 Nut, 5/16, Nylock Saddle, 2.5” 10-1601-41 Set Screw, #10-32 x 1/4” 60-0112 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 53 30 ft-lb Use anti-seize on all SS hardware! Key QTY Part No Description 10-1601-81 Boom Truss Attachment Square Saddle Hex Bolt, 3/8 x 6.5”, SS 60-7001 10-1601-71 Square Saddle 60-0050 Nut, 3/8, Nylock Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 54 TRUSS THE BOOM—OVERVIEW Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 55 • Zip tie the ends of the grips to prevent them from loosening and place a rubber cap on both ends of the Phillystran. 3.0” 1/2” Thimble Rubber Cap Yellow Mark Guy Grip Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 56 • Remember to re-install the cotterpin on the 1/2” shackle to secure the bolt. • Key QTY Part No Description Shackle, 1/2”, SS 60-7007 60-7009 Shackle, 15/32, Twisted Phillystran Assembly (from previous step) Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 57 Place a level near each end of the boom so that you can tell when the boom is level. • Once the boom has been leveled, use the provided locking wire to lock the twisted shackle bolts and the turnbuck- les. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 58 Hex Bolt, 5/16-18 x 4" Nut, 5/16”, Nylock 60-0046 Washer, 5/16” 60-0033 10-1613-11 Spacer, 1/4", Aluminum 60-0115 Hex Bolt, 5/16-18 x 4.5" Set Screw, #10-32 x 1/4” 60-0112 Turnbuckle, 5/16” x 8”, eye to eye, SS 60-0159 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 59 Element Truss Attachment Plate - 2in 10-1607-21 Element Truss Attachment Plate - 2in 60-7048 Thimble, 3/16, SS 60-0029 Hex Bolt, 1/4-20 x 3 60-0030 Nut, 1/4-20, Nylock 60-0078 Hex Bolt, 1/4-20 x 1.75 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 60 TRUSS THE ELEMENTS—PHILLYSTRAN—OVERVIEW Part Number Description Phillystran 2100i (230” - 70ft element, 115” - 50ft element) 21-8002 60-0045 Wire Clip, 3/16 60-0044 Rubber cap 09-0001 Electrical tape Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 61 11. When the elements are level, secure the turnbuckles with the provided locking wire to prevent them from loosening. 12. Install the rubber cap on the loose ends of the phillystran and then wrap the ends with electrical tape to secure them. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 62 TRUSS THE ELEMENTS—DACRON—OVERVIEW Part Number Description Dacron, 3/16" (336” - 70ft element, 220” - 50ft element) 21-7002-01 60-7015 Double cable clamp, 3/16" 60-0175 Lock Washer, 10-32, Split, S/S (installed on cable clamp) 09-0001 Electrical Tape Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 63 12. When the elements are level, secure the turnbuckles with the provided locking wire to prevent them from loosening. 13. Use a lighter to melt the loose ends of the Dacron so that the rope Electrical tape doesn’t unravel and then wrap electrical tape around them to se- cure them. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 64 For best results, use a pair of safety wire pliers as shown below. • For instruction on using the safety wire pliers refer to this youtube video: https://www.youtube.com/watch?v=FJ- bkk_lIXQ Boom Truss Turnbuckles Element Truss Turnbuckles Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 65 Note the band correction factor and SWR after tuning. Tune to the next frequency and repeat until the table has been filled out. Step 4: When finished, snap a picture of the results and send it to commercial-forms@steppir.com. Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 66 Print a copy of this page, fill it out, and email a photo of it to commercial-forms@steppir.com Controller Frequency Resonant Frequency Minimum SWR (MHz) (at controller freq.) (MHz) 30.000 20.000 15.000 13.000 10.000 7.000 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...
  • Page 67 (after Band Cor.) 29630 28540 27090 25640 24190 23100 22380 21650 20930 20200 19480 18750 18030 17300 16580 15850 15130 14400 13680 12950 12230 11500 10780 10050 9440 8950 8460 7990 7510 7040 Tech Support: consumer.steppir.com/support | 425.453.1910 | support@steppir.com...