SteppIR 2 Element Yagi User manual

40m - 30m Dipole Kit
Instruction Manual for the 2-3-4 Element Yagi
(Patent #6,677,914)
Yagi  Dipole  Vertical
Rev: Q 01/16/08
SteppIR Antennas
2112 -116th Ave NE, Suite 2-5 , Bellevue, WA 98004
Tel: [phone] Fax: [phone]
Tech Support: 425-891-6134
www.steppir.com

SteppIR Antennas 40m - 30m Dipole Kit 2
Abbreviations
EST Element Support Tube
EHU Element Housing Unit
FTP Fiberglass Telescoping Pole
QDB Quick Disconnect Boots (rubber)
ERT Element Return Tube
SteppIR Antenna Information Web Sites (as of 8/03/06)
http://steppir.com/
http://groups.yahoo.com/group/steppir/
FTP
QDB
ERT
EHU
EST

SteppIR Antennas 40m - 30m Dipole Kit 3
40m - 30m Dipole Overview
The 40m - 30m dipole is simply a driven element that functions as a dipole from 6.8 MHz to
13.8 MHz and as the driven element for the yagi array from 13.8 MHz to 54 MHz. It has no
effect on the performance of the yagi. The yagi works the same with or without this option.
A dipole for 40m would normally be about 64 feet long but we have shortened it to 39 feet
by looping the element tip back towards the boom. This is a form of linear loading and is
very efficient, however, nothing comes for free and with this dipole you lose about .37 db on
40m over a full size dipole. This is hardly measurable at the receiving station end so it is a
very reasonable trade off. On 30m since the copper tape barely turns the corner back toward
the boom it essentially performs like a full sized dipole.
On 40m folding the element back nearly double (the tape comes within about 3.5 feet of the
boom on each side) very conveniently makes the impedance 25 ohms, a 1.0:1 match for our
yagi Balun/Unun. On the 30m, however, we have a full sized dipole whose impedance is
very much dependant on the height above ground so there is a varying degree of mismatch.
Below 40 feet or so you will find the SWR as high as 2.6:1 but at greater heights it can drop
to as low as 1.6:1 SWR.
This small amount of mismatch can easily be handled by the internal tuners on most trans-
ceivers. At 10 MHz SWR values in this range result in insignificant loss, so the antenna will
perform very well on 30m. You will find that on 40m even at heights below 40 feet you will
get a very good match with this type of shortened dipole. If the SWR seems to be too high
try adjusting the driven element length using the “Create Modify” function.
Note: By using the “Create Modify” function to fully extend either the reflector or director 1
on 30m you can create a very short director for the dipole resulting in .5 db gain and
lowering the SWR by about .2. You can then save it and it will be permanent. You
could also save it in both directions (180
° and normal), lengthen the reflector in the
180 ° and the director 1 in the normal direction and now have it reversible. If SWR is
the biggest concern try
lengthening both the re-
flector and director 1 to
get the lowest SWR.
Warm Regards,
Mike Mertel
Michael (Mike) Mertel - K7IR
President
First Prototype Sweep

SteppIR Antennas 40m - 30m Dipole Kit 4
Boom
Element Housing Unit
Element Support Tube
Stepper Drive Motor
Copper Beryllium Tape
Element Return Tube

SteppIR Antennas 40m - 30m Dipole Kit 5
Topic Page
Abbreviations 2
40m - 30m Dipole Overview 3
Table of Contents 5
Parts List 6
For Upgrade of Existing Antenna
Remove Existing Driven Element - 2 Element 7
- 3 Element 8
- 4 Element 9
Install 40m - 30m Return Loop
Install the Element Return Mounting Bracket 10
Assemble the Return Mounting Kit 11
Install Boom Counter-weights (4 Element Retrofit ONLY) 12
Install the Element Housing Unit 14
Install CPVC Liner Tubes 14
Prepare the Fiberglass Telescoping Poles (FTP) 16
Assemble the Sweeps to the Poles 18
Attach the 40 - 30 EST’s to the EST & ERT 21
Antenna Layout Drawing - 2 Element 22
- 3 Element 23
- 4 Element 23
New Antenna Specifications 24
Appendix A - 6m Passive (Early 3 Element Reconfiguration) 25
Appendix B - Controller (Upgrade) 26
Appendix C - CPU (Firmware chip) Replacement Procedures 27
Appendix D - Controller Firmware Version 6.7 or Later 30
Appendix E - Troubleshooting Guide 33
Appendix F - Replacing the Driven Element Bracket 39
SteppIR Warranty 41

40m - 30m Dipole Kit
(RETROFIT 3E) PARTS LIST
ITEM QTY PART # DESCRIPTION
1 72-0009-02 40M - 30M DIPOLE KIT
DRIVEN ELEMENT KIT
BOX 1 1 72-0027-01 ELEMENT HOUSING UNIT (DRIVEN)
1 72-0009-03 PVC GLUE PACK
2 72-0027-02 SWEEP ASSEMBLY (RETURN LOOP)
ELEMENT RETURN TUBE KIT
1 72-0027-03 FIBERGLASS TUBE, 1.75" OD x 12"
1 10-1505-01 ELEMENT RETURN BRACKET
BOX 2 4 70-2025-02 3/4” CPVC LINER TUBE WITH COUPLING (2-43.5” & 2- 49” LONG)
4 72-0023-06 FIBERGLASS TELESCOPING POLE (FTP), 18 FOOT
HARDWARE
BAG 1 16 60-0014-01 6-32 X 7/8 PANHEAD SCREWS
16 60-0014 6/32 NYLOK NUT
4 60-0014 4-40 X 3/4 PANHEAD SCREW
8 60-0021-01 4-40 X 5/8 PANHEAD SCREW
12 60-0022 4-40 NYLOK NUT
2 60-0003 1-3/4 U-BOLT W/SADDLES
2 60-0093 5/16 X 2-3/4 BOLTS
6 60-0046 5/16 NYLOK NUTS
7 60-0019 10-32 NYLOK NUTS
2 60-0091 1/4-20 X 3-3/4 BOLT (4 Element Retrofit Only)
2 60-0030 1/4 NYLOK NUT (4 Element Retrofit Only)
8 60-0041 1/4 FLAT WASHER (4 Element Retrofit Only)
BAG 2 4 60-1006-01 QUICK DISCONNECT (RUBBER BOOT) 1.5” TO 1.25” - W/CLAMPS
1 09-0002 CW 85 ELECTRICAL TAPE (66 ft)
1 20-4003-01 CPU CHIP W/LATEST FIRMWARE & 40 - 30 BUTTON LABEL
2 72-xxxx-01 COUNTER-WEIGHT BAR 2-1/2” x 12” x 1/2” (4 Element Retrofit Only)
SteppIR Antennas 40m - 30m Dipole Kit 6

SteppIR Antennas 40m - 30m Dipole Kit 7
Remove Existing Driven Element: (For Retrofit Installation ONLY)
•Retract all elements:
•Using the controller:
•Go to “Setup” mode and press ‘Select’
•Using the ‘Up’ - ‘Dn’ buttons find “Retract Elements” and press ‘Select’
•Using the ‘Up’ - ‘Dn’ buttons find “Yes” and press ‘Select’
•Wait for the “ * ” to stop flashing
•The elements are now retracted
•Disconnect the coax and control cable for the driven element
•Loosen the clamps holding the two rubber boots securing the fiberglass poles
•Remove the two fiberglass telescoping poles (FTPs) from the driven element
housing (Drawing 1 - 3 or 5)
•Remove the driven element housing (EHU) unit from its mounting plate
(Drawing 1 - 3 or 5)
Note: For customers who purchased a 3 element antenna before March 2003 your element
housing brackets may have been of a different design. If you have the original style
element housing bracket (approximately 4-1/4” across the top) you will need to in-
stall a new style element housing bracket on your boom before you can mount the
new 40m - 30m dipole driven element housing unit (see Appendix F).
REMOVE
Driven FTPs & EHU
Drawing 1
Driven
Director
2 Element 20m - 6m
Driven
Director Drawing 2
New 40m - 30m Dipole Loop
2 Element 40m - 6m

SteppIR Antennas 40m - 30m Dipole Kit 8
REMOVE
Driven FTPs & EHU
Reflector
Driven
Director
3 Element 20m - 6m
Drawing 3
Director
Driven
Reflector
New 40m - 30m Dipole Loop
3 Element 40m - 6m
Drawing 4

SteppIR Antennas 40m - 30m Dipole Kit 9
4 Element 40m - 6m
New 40m - 30m Dipole Loop
Director 2
Director 1
Driven
Reflector
Drawing 6
REMOVE
Driven FTPs & EHU
Reflector
Director 2
Director 1
Driven
4 Element 20m - 6m
Drawing 5

Install 40m - 30m Return Loop:
Install the Element Return Mounting Bracket: (For Retrofit Kit ONLY)
Note: The element return bracket comes installed when ordered with a new antenna.
•Drilling instructions
•Measure & mark the boom to install the return bracket per Drawing 7, 8 or 9.
•Secure the return bracket firmly in place with some type of clamp (Picture 1).
•Make sure to level the bracket with respect to the driven element bracket using
either a level or actually mounting the element and eyeballing it.
•Drill four 5/16” holes, two in from each side, through the bracket and the boom
using the pre-drilled pilot holes in the bracket as a guide (Picture 1).
Warning: Make sure that the bracket does not slip or twist while drilling.
Keep the drill straight while drilling to produce a clean round hole.
It may be helpful to drill both holes for one bolt and then install
that bolt providing more positive alignment for the second hole.
•Install the two 5/16” bolts with Nylok nuts & tighten. These bolts should fit as
snug as possible in the holes.
Note: For the 2 element boom only you will need to move the mast plate from its original
position in the center of the boom to make room for the return bracket. It can be lo-
cated in any of the four (4) positions indicated in Drawing 7. It only needs to be
moved enough to clear the return bracket. If you will be installing the optional 6m
passive element - only positions #2 or #3 can be used.
SteppIR Antennas 40m - 30m Dipole Kit 10
4 8 .0 0
50.25
4 8 .0 0
4 .2 5
19 6 .5 0
4 8 .0 0 48.00
2 .2 5
9 4 .0
10 2 .5 0
25.00
2 0 .7 5
Driven
Reflector
Director
Return
3 Element
Drawing 8
8" splice
.75 12.00 48.00 .75
18.60
Director Driven
Return
4
21
3
18.60
2 Element
Drawing 7

•Assemble the Return Mounting Kit
•Install return element cross tube and U-bolts as seen in Picture 3 (center an
aluminum sleeve under each U-bolt but do not tighten yet).
Note: Some of the U-bolt saddles have come from the supplier with the ears bent out-
ward (Picture 2-A). It is recommended that you bend then straight so that they
center on the reinforcing ring more securely and safer (Picture 2-B). The sad-
dles will need to be pressed on securely (or tapped on with a hammer) until
they bottom out.
•Measure the return tube offset to
match the offset of the driven ele-
ment housing tube (Drawing 10).
•Tighten the U-bolts securely.
SteppIR Antennas 40m - 30m Dipole Kit 11
84.00 114.00 186.50
42.5067.5046.25
25.00
42.50 67.50 46.25
72.00
Reflector Return Driven
Director 1
Director 2
4 Element
Drawing 9
A B
Picture 2
Picture 1
Return
Bracket
Driven Bracket
Level
Drill Bit
* Not Actual Spacing *
Return Kit
Pre-Drilled
Pilot Holes (4)
(2 Per Side)

SteppIR Antennas 40m - 30m Dipole Kit 12
Install Boom Counter-weights (4 Element ONLY):
On the 4 element antenna ONLY you will need to install a pair of counter-weights to the side
of the Director 2 element mounting bracket (Picture 3B) to balance the boom after the in-
stallation of the 40m - 30m dipole kit. These are powder coated steel bars weighing approxi-
mately a total of 8.2 pounds.
Locate: (Picture 3A)
•Two steel bars 2-1/2” x 12” x 1/2” (counter-weights)
•Two 1/4-20 x 3-3/4” bolts
•Two 1/4-20 Nylok nuts
•Eight 1/4” flat washers
Suggested Installation Steps (retrofit only):
•On a retrofit installation you should not need to remove the element housing unit
(EHU) from the element mounting bracket but do be careful with the weight of
the EHU and the FTP’s attached when you remove the existing bolts.
•Remove the first 1/4” bolt from the Director 2 element mounting bracket and in-
stall it back into its hole from the other side of the bracket. This will support the
bracket while you remove the second bolt.
•Remove the second 1/4” bolts from the Director 2 element mounting bracket.
•Put two 1\4” flat washers on each of the new 1/4-20 x 3-3/4” bolts.
•Position the first counter-weight by lining up the holes so that the end of the
weight is even with the end of the element mounting bracket (Picture 3B) and in-
stall a new 1/4-20 x 3-3/4” bolts with the two flat washers through the empty
hole.
•Now install the second new 1/4-20 x 3-3/4” bolts with the two flat washers
through the second hole pushing out the old bolt that you temporarily installed
from the other side.
•Put the second counter-weight over the two new bolts sticking out.
•Install two flat washers on each bolt and then the new Nylok nuts and tighten.
•The end results should look like Picture 3B.
•This completes the installation of the counter-weights.
Picture 3
12
3
4
5
6
7
Drawing 10

SteppIR Antennas 40m - 30m Dipole Kit 13
Picture 3B
4 Element Counter-Weight Assembled
for the 40m - 30m Dipole Option
Director 2 - Element
Mounting Bracket
Counter-Weight
Bars Installed
Picture 3A
Director 2 - Element Mounting Bracket
Counter-Weight Bar (2)

SteppIR Antennas 40m - 30m Dipole Kit 14
Install the Element Housing Unit (EHU):
Warning: (For a retrofit installation only) Mount the new 40m - 30m driven element hous-
ing unit (EHU) in the SAME orientation as the old unit that you removed. Also
refer to Drawing 2 - 4 or 6.
•Install the driven element housing unit onto the element bracket with bolts in
holes 1 through 7 (Drawing 10) and tighten. Use the seven (7) new 10-32
Nylok nuts and the existing screws. (For a retrofit installation only) hole # 7 will
need to be drilled through the aluminum element bracket (with a # 6 or a 13/64”
bit) before the bolt can be installed and tightened.
•If the mounting holes in the new EHU do not line up with the holes in the element
mounting bracket you may need to loosen the two horizontal bolts [Picture 1
(Driven Bracket)] that secure the element mounting bracket to the boom and
then insert the screws in the EHU and tighten. Be sure to retighten the two hori-
zontal bolts when you are finished mounting the EHU.
•The remaining three bolts do not pass through the aluminum element plate but be
sure they are tight also.
Note: With a retrofit installation this is the point where you want to reconnect
the control cable and run the “Test Motors” procedure outlined in the
main antenna installation manual to verify the wiring is correct and eve-
rything is functioning before final assembly.
Installing CPVC Liner Tubes:
Locate:
•Four pieces of 3/4” CPVC liner extension tubing
(picture 4 & 5 only has 2 shown in picture) with
CPVC coupling installed, two poles for each side.
•One CPVC glue kit
•One or more good assistants
•Using the supplied glue and cotton tips, apply the
glue onto any area where there is a CPVC connection. Be sure and place the glue
onto the outside of the CPVC tubing and NOT ON THE INSIDE OF THE COU-
PLER. Then slide the coupler onto the CPVC so that none of the glue goes onto the
inside of the CPVC, this would cause a potential blockage inside the tube.
•Glue the two CPVC sections together so that the 43.5” section can be glued to the
element housing and the 49” will slide into the Fiberglas Telescoping Pole first. Let
it dry for ten minutes.
•Repeat this process for the other side.
Picture 4
43.5” CPVC
49” CPVC

SteppIR Antennas 40m - 30m Dipole Kit 15
Note: You may need to prop up the CPVC until the glue sets.
Warning: This will leave you with the two liner extensions sticking out. Be very careful
not to hit or catch anything on these liners as this could damage the CPVC.
These liners will be covered with the installation of the Fiberglass Telescoping
Poles in the next operation. Be equally careful when sliding them into place.
•Prepare the special EST’s marked 30 - 40 as described in the “Prepare the Fi-
berglass Telescoping Poles (FTP)” section and “Assemble the Sweeps to the
Poles:” sections.
•Read the “Attach the 40 - 30 FTP’s to the EST & ERT”section before continu-
ing.
•Slide the entire CPVC extension into the Fiberglass Telescoping Pole, except for
6” to allow for gluing to the CPVC in the element housing, as shown in Drawing
11.
Note: It may take a number of attempts to get the CPVC liner tube to go past the second
section of the Fiberglass Telescoping Pole, allowing it to go in all the way (Drawing
11). Gently shaking the CPVC can be helpful. Take your time and be careful with it.
•Then you will glue the CPVC extension tube to the internal CPVC of the driven
housing (Picture 6)
•After the glue has been dried, then finish
the assembly as described in the “Attach
the 40 - 30 FTP’s to the EST & ERT”
section.
•Repeat these instructions for the other
side to finish the installation of the 40m -
30m loop assembly.
EHU
EHT
Bullet
CPVC Liner
Picture 6
EST Housing
Fiberglass Telescoping Pole with Internal CPVC for 40/30m Diagram
Rubber boot should be place onto the Fiberglass
Telescoping Pole so that it slides onto the EST
43.5 Inner CPVC 49 Inner CPVC
CPVC Coupler
Drawing 11

Prepare the Fiberglass Telescoping Poles
Locate:
•Four dark green fiberglass telescoping poles (Picture 13)
•Four quick disconnect boots with clamps (Picture 5)
•One roll of black vinyl electrical tape (Picture 11)
•Your tape measure
Note: The steel reinforcing rings on the first two pole sections provide extra strength in
potential high stress conditions.
The green fiberglass telescoping poles are all assembled in the same manner and, when
extended, keep the copper -beryllium tape safe from the weather. The copper-beryllium tape
is shipped retracted inside their respective element housing units (EHUs).
Repeat the following procedure for each telescoping pole
Telescope a pole to full length by jerking each section out very
aggressively with a twisting motion until it is extended as far as
possible. Each segment is tapered and should lock (jam) se-
curely in place when fully extended. It is especially important
on the 40 - 30 driven element that the poles are very firmly tele-
scoped. You don’t want them potentially twisting out of level
in the wind - that would not look good. Each poles length, when
fully extended, must be 17’ 8” +/- 1” in length as measured
from the butt (large) end of the pole to the tip. (Picture 13)
Caution: Verify the length for each pole before proceeding.
If a pole comes up a little short try collapsing the pole and start-
ing over, this time aggressively “jerk” each section out in-
stead of twisting. The pole cannot be damaged and you may
gain a minimum of 1/2” or more.
Picture 13
17’8” +/- 1”
SteppIR Antennas 40m - 30m Dipole Kit 16
Picture 5
Picture 11

If you have trouble collapsing a pole try carefully striking one end on a piece of wood or
other similar surface placed on the ground. If necessary you can use a hard plastic faced
mallet to drive the sections in.
Warning: Check all four sections of each pole for packing popcorn or any other
foreign object that could interfere with the copper tape movement.
There are NO foam plugs glued in the small end of these four special dark
green telescoping poles as there are in a regular pole. This is the correct
configuration for the four 40 - 30 poles.
Next wrap each joint on the fiberglass poles (Picture 15) with the vinyl electrical tape
(Picture 11). Use approximately: 40 in. On the first (large) joint
31 in. On the second (middle) joint
22 in. On the third (small) joint.
For each joint, stretch the tape tight (up to 50 %) as you wrap it. This should make at least
two passes. This new tape replaces the old electrical tape and silicone tape process we
used before. Each joint should have at least the full width of the tape on both sides of the
joint.
Exception: On joints with reinforcing rings, the tape must continue further so it extends a
minimum of one full tape width beyond the metal ring and onto the fiberglass
pole.
Start the tape with one complete wrap of electrical tape around the fiberglass telescoping
pole. The tape should be applied in half-lapped layers with sufficient tension to produce a
uniform wind (for most applications this tension will reduce the tape’s width to approxi-
mately 5/8 of its original width). In the beginning wrap the tape up-hill, taping from a
smaller diameter surface to a larger diameter surface then back down smoothing the tape
with your fingers as you go. Apply the tape with no tension on the last full wrap to prevent
flagging. At the end of the run, cut the tape with a knife or scissors and press it down flat.
Then run your hand over the tape again a couple of times to smooth it and firm up the bond-
ing.
At the factory when we quality check the poles to verify that they meet minimum
length we hold the butt (large) end and whip it like we were casting a fishing pole
with considerable force. This procedure can produce a significant difference in the
extended length of some poles as a last resort if nothing else works.
DO BE CAREFUL !!!
SteppIR Antennas 40m - 30m Dipole Kit 17
Picture 15

Assemble the Sweeps to the Poles:
Locate: 2 Sweep Assemblies (Picture 19)
2 3/8 x 28” White Fiberglass Rods
4 #4 x 3/4” Screws w/Nylok nuts
8 #4 x 5/8” Screws w/Nylok nuts
16 #6 x 7/8” Screws w/Nylok nuts
4 Telescoping Fiberglass Poles
1 Small container of silicone grease (Picture 25.5)
Layout two poles (fully extended and taped) parallel about 30” apart. The tip of each pole
will have an “O” ring seal (glued on) and a piece of adhesive non-skid attached to it (Picture
21). Their will also be one extra strip (spare) of non-skid tape in the hardware kit in case a
repair is needed. This material is to provide a very secure grip for the return loop fitting to
grab on to.
Get one of the sweep assemblies, making sure the label [THIS WAY UP] is on top (Picture
19) and the drain holes in the tip of the loop are to the bottom. Insert one of the pole tips into
each of the sweep fittings (Picture 25) making sure that they go in until they bottom out
(approximately 2-3/8”). The non-skid tape should go completely inside the fitting (Picture
27). It may be a good idea to mark the poles so you can see when they are fully seated.
WARNING: Petroleum base lubricants WILL damage the polycarbonate fittings (Picture
25). We recommend that you apply a thin film of the NON PETROLEUM
based silicone grease - (provided - Picture 25.5)to the “O” ring as it is in-
serted in the fitting.
SteppIR Antennas 40m - 30m Dipole Kit 18
Picture 19
Picture 21
Picture 25 Picture 26
Finished Assembly
Picture 25.5

SteppIR Antennas 40m - 30m Dipole Kit 19
Caution: Inserting the pole tip into the sweep fitting may be very tight. You may need to
insert a screwdriver into the gap on the edge of the fitting (Picture 25) and pry it
apart enough to push the pole home. Be careful not to damage the “O” ring seal or
the non-skid tape when inserting the poles.
Now insert one of the white fiberglass rods, one end into each fitting (Picture 26 & 29), into
the assembly and line up the holes.
Repeat this procedure for the other side.
Picture 27 is a cut-away to show the position of the pole tip and its components
as they fit together inside the sweep fitting.
Pole
Cut-Away View of Return
Bracket Fitting
Grip Tape
“O” Ring

Now, as seen in Picture 29, insert the four #6 screws and Nylok nuts in each of the fittings
and tighten to secure the fitting to the green poles. Be sure to place the nut into the side of
the fitting that is molded to capture the nut (Picture 28), Do not tighten yet.
Next insert the #4 screws and Nylok nuts used to properly secure the 3/8” white fiberglass
rod that stiffens the return loop assembly. The center screw is #4 x 3/4 and the other two
screws are #4 x 5/8 (Picture 29). When inserting the middle screw through the fiberglass
rod you may need to screw it in with a screw driver to get it to go through. Again observe
the correct side of the fitting to place the nuts. Now tighten all the screws.
Note: You may need to hold the nut down in the pocket with your finger when you first be-
gin tightening each screw.
When both return loop assemblies are properly mounted to the ends of the fiberglass tele-
scoping poles the two resultant assemblies are ready for final preparation and installation to
the element housing tube and the return bracket tube (Drawing 13).
SteppIR Antennas 40m - 30m Dipole Kit 20
Picture 28
This Side Molded
to Hold a Nut
# 4 x 5/8 Screws
(4) # 6 Screws
Picture 29
Not Used
# 4 x 3/4 Screws
Drawing 13
Reinforcing Rings
EHT
ERT
EHU