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SteppIR Dream Beam 42 Assembly Manual
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SteppIR Dream Beam 42 Assembly Manual

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Dream Beam 42
Assembly Manual
Craig Thompson K9CT DB42 Stack
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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Summary of Contents for SteppIR Dream Beam 42

  • Page 1 Dream Beam 42 Assembly Manual Craig Thompson K9CT DB42 Stack 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 2 ".0 0 ( *! ! *0*     0 1   ! ! 20 1    !!( *!  3  %&' 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 3  2 3  5 3 * )      !  # ,  ) 0$   * 3 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 4 ')  * * ,  3,  & $% ,,  "           ) *  ) *  ) *  ) *  ) *  2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 5 " " " "%     "  ' %    #    # + % & () % 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 6        $ &      & " #   ' #$     )   $  $  2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 7 2 " % ') #  1 , !  !3  4 & 56 656 .57  !-0 8  +&  0 0 ! 4 *+) 9 %) ' & ! 0 , 4 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 8 There is one exception to this - do NOT use the anti-seize compound when connecting the plastic sweeps coupler to the pole ends. This will be covered in more detail later in the manual. 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...

  • Page 9: Boom Assembly

    1/4” flat washer flat washer 60-0041 flat washer 60-0041 washers 60-0041 1/4” X 3 1/2” Hex Bolt 60-0100, five 60-0041 1/4” flat washer 60-0041, Boom sleve 10-1203-21 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 10 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 mounting plate 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 11 !     %               "       !   "   2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 12 6m Opt. Dir 2 attachment (place on 3” boom) 6m Opt. Dir 3 6m Opt. Dir 1 BOOM TRUSS (place on 2” boom) (place on 2” boom) 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 13 This will affect the straightness of the rectly. This will affect the straightness of the element. element. 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 14    "  % !      !   )  !   *   '    " % ! "  '    '   " 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 15 $8 + 8 !!  + #  ! $!5 : $ !  + 8!  +! 4   8885!5,  8 + (: &!  +  !,!5 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 16 ÷   !" # #  #  $% &   '      ( # #) *  &+     2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 17 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 Figure 1.9 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 18 "  " ''  ' #                 ( ( " (    ( 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 19 Check the part number sticker inside the EHU and be certain that it matches the part number above. 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 20   "  '  ''  ' #                   (  ( 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 21 Check the part number sticker inside the EHU and be certain that it matches the EHU part num- ber shown above. 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 22 '     %  # !  '    '  %  '  &  #  $ !       % 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 23 (     &  ! "  (    (  &  (  '  !  % "       & 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 24 The return tube is located closest to the mast plate for both ele- QTY 12: 60-0046 QTY 10: 60-0019 ments. 5/16” Nylock nut 10-32 Nylock nut 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 25 &    '  $! # %  &     &  () " $!         2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 26    5    (      ' ( 0# &%  ( * +# + & Figure 2.2 , 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 27 We suggest using this saddle for installation of the Connector mast on top of the boom. Junction Box. Using the supplied connector junction box 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 28    $ !   $ % &              % &      2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 29 The trusses should level the boom with the turnbuckles having half of the threads still available to adjust up or down. This will allow you to do minor adjustments. 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 30 The boom should be close to level with the turnbuckles halfway tightened. This will allow you to make minor changes up or down to level the boom if needed. 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 31              /        Figure 3.1   2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 32         +         01 2$3 4 '0+    &   2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 33                          2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 34                #        $   2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 35 10-1617-01 64” CPVC inner support tube with 70-2025-13 49” CPVC Inner Support 70-2025-23 43” CPVC rubber coupler and foam seal ring Tube with coupler Inner Support Tube 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 36 Once the rubber boot is in the correct location tighten both hose clamps. Due to cold flow of the rubber you should retighten the hose clamps after 30 minutes. Repeat the same process for the other telescoping pole. 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 37 Diverter Cone and Due to cold flow of the rubber, make CPVC Assembly sure to re-tighten all rubber boots 30 minutes after initially tightening. Rubber Boot 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 38 SECURING TELESCOPING POLES TO DIRECTOR 1 NOTES: Make sure while installing the CPVC with foam seal ring and black rubber coupler, that the “THIS WAY UP” sticker is facing upward. This will align the slot in the foam ring to be fac ing up inside the EST extension.
  • Page 39 Figure 3.15 Director 1 Telescoping pole assembly 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 40 Repeat steps 6-12 to complete the other half of the truss support. Figure 4.1 for complete lay- out of 49’ driven element with truss. Figure 4.1 Truss Layout 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 41 5/16 x 3-3/4” Hex head bolt 15” QTY 2: ” Aluminum Saddle 10-1601-01 Figure 4.3 Truss Eyebolt Assembly QTY 1: 3/16” SS eye bolt 60-0107 QTY 1: 10-24 Nylock Nut 60-0111 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 42 Qty 1: 60-6000-05 3/4” SS hose clamp     Figure 4.5 QTY 2: 10-1601-61 QTY 2: 5/16” Nylock Nut 3” Aluminum saddle 60-0046 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 43 Connector Junction Box Installation Item QTY Part # Description Connector box assembly with lid and connector board 10 1615 01 60 0022 4 X 4-4 SS nylock nut 10 1053 02 Connector box aluminum mounting plate Connector board with connector and 4-40 screws with standoffs 10 1260 3 10 1029 01 Connector protector...
  • Page 44 Connector Junction Box Mounting / Wiring NOTE: Refer to figure 2.4 on page 18 of this manual for further instructions regarding mounting the connector junction box to the truss boom. FIGURE 5.2: CONNECTOR BOX MOUNTING Wiring from EHU’s to connector junction Controller splice Control wire color Connector box...
  • Page 45 Location for 6 wire connections the wiring order is: BK, COAX seal R, G, W, Blu, Br. SteppIR Use only, do not use this line for wiring! 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 46    The DB25 control cable splice allows for much more convenient connection of control cable to the SteppIR controller. By utilizing this connector splice, there is no need to cut the DB25 connector off and re-solder when running cable through con- duit.
  • Page 47 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. 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 48          ¢ ¤ £ ¦ ¥ ¨  out 1 To Director 2 Element To Director 1 Element 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 49 QTY 2: 60-0046 and gasket (as shown in figure 6.3). 5/16” Nylock nut When testing is completed, mount the housing and housing gasket and secure in place. 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 50 Figure 6.4 Coax Jumper Routing 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 51       '    ' / !   <         !  "  '   2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 52     #             *     2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...

  • Page 53: Preliminary Testing

    Mechanical failure of the EHU Improper assembly; Telescoping pole not seated, 30m/40m Loop not assembled right, Telescoping pole not extended to full length Review the Troubleshooting guide for more ideas 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 54 DREAM BEAM 42 LAYOUT 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...
  • Page 55 Shipping instructions will be issued to the buyer for defective components, and shipping charges to the factory will be paid for by the buyer. SteppIR will pay for standard shipping back to the buyer. The manufacturer assumes no further liability beyond repair or replacement of the product.
  • Page 56 2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: (425)-453-1910 FAX: (425)-462-4415...