SteppIR BigIR User manual

13406 SE 32nd St. Bellevue, WA 98005 | consumer.steppir.com | 425.453.1910 | [e-mail]
BigIR Antenna
Assembly Manual
REV 5.1 09/30/2021

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SteppIR - Why Compromise? 3
Preparing For Assembly 4
Antenna Specifications 5
Antenna Overview 6
Parts Checklist 7
EHU Overview 10
Section 1: Wiring and EHU/Coil assembly 11
Section 2: EHU/Coil wiring test 21
Section 3: Prepare the telescoping pole 22
Section 4: Prepare the CPVC liner 24
Section 5: Prepare the EST Extension assembly 25
Section 6: Mounting the BigIR 29
Counterpoise/Radial system overview - Ground mounted or elevated? 32
How to tune your vertical (mandatory) 37
Product warranty claim 40
TABLE OF CONTENTS

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The SteppIR antenna was originally conceived to solve the problem of covering the six ham bands (20m,
17m, 15m, 12m, 10m and 6m) on one tower without the performance sacrifices caused by interaction be-
tween all of the required antennas.
Yagis are available that cover 20 meters through 10 meters by using interlaced elements or traps, but do so
at the expense of significant performance reduction in gain and front to back ratios. With the addition of the
WARC bands on 17m and 12m, the use of interlaced elements and traps has clearly been an exercise in di-
minishing returns.
Obviously, an antenna that is precisely adjustable in length while in the air would solve the frequency prob-
lem, and in addition would have vastly improved performance over existing fixed length yagis. The ability to
tune the antenna to a specific frequency, without regard for bandwidth, results in excellent gain and front to
back at every frequency.
The SteppIR design was made possible by the convergence of determination and high tech materials. The
availability of new lightweight glass fiber composites, Teflon blended thermoplastics, high conductivity copper-
beryllium and extremely reliable stepper motors has allowed the SteppIR to be a commercially feasible prod-
uct.
The current and future SteppIR products should produce the most potent single tower antenna systems ever
seen in Amateur Radio! We thank you for using our SteppIR antenna for your ham radio endeavors.
Warm Regards,
John Mertel
John Mertel, WA7IR
President/CEO
STEPPIR—WHY COMPROMISE?

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• Before beginning assembly of this antenna, please read the manual in it’s entirety to familiarize yourself
with the task at hand. Doing so will eliminate potential confusion.
• Be sure to do an inventory of your parts as soon as possible after receipt of the antenna, and well before
your intended installation date — this way we can get you the parts required before it’s too late.
• Be sure to check the insides of the aluminum tubing and the telescoping poles when unpacking your box-
es. In certain situations we put items inside these pieces to reduce the amount of boxes used for shipping,
which in turn reduces your shipping costs.
• A large, cleared flat area is recommended for assembly of the antenna. Typically, an area 40 ft x 25 ft
would be ideal.
IMPORTANT NOTES!
Be sure to use the anti-seize compound supplied to prevent the galling of the stainless steel fasten-
ers. If you do not use the anti-seize, count on issues with the stainless steel hardware galling. Heat
is one of the primary culprits with galling, so if you use a ratchet, steady speed as you tighten will
help minimize galling. We have found that when the anti-seize is applied to the bolt portion of the
hardware, it will eliminate any galling issues. Rubber or nitrile gloves are recommended when ap-
plying the anti -seize to the stainless steel fasteners or the aluminum boom sections.
Never attempt to wire or change wiring on the antenna when the controller is connected to the con-
trol cable, even if it is turned off! This is the number one cause of installation failures for our prod-
ucts. Even with power off, damage can occur. When the power is “off” on your controller, there is
still a very small amount of power feeding to the stepper motors, to effectively “lock” them in place.
This leads to less need for calibration of the antenna.
PREPARING FOR ASSEMBLY

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Antenna
Longest element 34ft (10.5m)
Weight 15lbs (6.8kg)
Wind load 1.9 sq. ft./0.17 sq. m.
Wind rating 100mph w/two guys
Adjustable elements 1-2
Power rating 3.0 KW (1000W limit on 60/80m
bands)
Feed points 1
Frequency coverage 3.4-55 MHz with loading coil, 7.0-
54MHz without
Control cable 2 x 4 conductor with coil, 1x without
ANTENNA SPECIFICATIONS

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ANTENNA OVERVIEW
The BigIR is a vertical antenna that can be adjusted for resonance on the 40, 30, 20, 17, 15, 12, 10
and 6 meter ham bands, including frequencies in between. With the addition of the 80 meter coil accessory,
the BigIR/80 will also provide coverage on 80 and 60 meters, including frequencies in between.
The antenna comprises two primary subsystems:
1. The Element Housing Unit (EHU) contains the stepper motor, copper-beryllium tape and wiring interface.
The optional 80m coil attaches to this unit as well.
2. The Element Support Tubes (EST) provides guidance and protection of the copper-beryllium tape as it
extends or retracts.
With the EST subsystem affixed to the EHU subsystem, the antenna is complete (except for mounting and
radials).
Once the EHU and EST are coupled, under control of the controller unit, the element can be extended
or retracted within the EST. The EST consists of an outer portion of light-weight fiber composites and an in-
ner element-guidance portion of Chlorinated Poly Vinyl Chloride (CPVC). The CPVC portion is where the
tape extends and retracts, and the outer EST portion provides physical support and weather protection for
the inner portion. At the topmost end of the EST, a special rain cap ensures that air can move in and out of
the EST as the tape is retracted or extended, and that rain and moisture is prevented from entering the EST.
If the 80 meter coil accessory has been purchased, it attaches to the EHU and provides a tapped in-
ductor at the EHU feed point allowing the antenna to be made resonant on 80 and 60 meters. The antenna
with that option is designated the BigIR/80. Both the EHU and 80 meter coil accessory are controlled by the
in-station controller unit and each has its own 4-conductor control cable that interfaces with the in-station
control unit.
Once the antenna is mounted and radials have been put installed, the user controls the extension and
retraction of the radiator (copper-beryllium tape) by selecting the appropriate controls on the in-station con-
troller. The controller also provides operational modes whereby adjustments to tape-length memory points
can be made to fine tune for best SWR match. The in-station controller can communicate with a transceiver
such that a change in frequency prompts the controller to adjust the tape length automatically, provided you
have the correct interface cable. In addition, the tuning relay accessory can prevent trans-
mitting power to the antenna while it is tuning via the “PTT” port in the back of the controller.
Controller Control cable BigIR

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It is important that you do an inventory of the items that were shipped to you. Nothing is worse than dis-
covering a day before a planned installation that there are missing parts! We do our very best to ensure 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 available options — you will need
to check these items off only if you purchased them.
What Comes in the Box
✓QTY PART # DESCRIPTION
170-3410-01 EHU, BigIR Assembly
110-1501-22 Cover for Black EHU, No drain hole
170-3000-01 33 Volt supply with cord
121-6040 Splitter, 6" 3-1/2mm, Stereo Male to Two RCA Female
1N/A Orange Flash Drive containing manuals
172-0044-04 Kit, BigIR Mark IV Hardware/Heat Shrink
172-0044-11 Kit, BigIR EHU Wind Reinforcing Kit/ Mark IV Hardware
272-0046-01 Kit, BigIR MK III/IV Guy
170-6010-01 Adapter, 25pin Dsub Field Splice
110-1013-02 Telescoping Pole, 18 foot 4 section
170-2019-01 BigIR EST extension with aluminum coupler - Lower
170-2020-01 BigIR EST extension with aluminum coupler and ring - Upper
170-2021-01 CPVC Liner for BigIR, 89"x3/4", with coupler
170-2022-01 CPVC Liner for BigIR, 89" x 3/4", w/o coupler
110-1109-21 Antenna Support, 1-1/2, Vertical
109729 SDA 100 Controller w/ TX Interface and SDA All Relay Board
or
09760 OptimizIR Controller
21-601_-01 Transceiver Interface Cable
06021 80M Base loading Coil for the BigIR
21-5001-01 Control cable, 4 conductor
21-7008-01 Balun 1:1 SO239 Connector, External Vertical or Dipole
20-8052-41 Filter, suppressor unit, 8 position, 65v
21-6002-09 Kit, Ground Mounted Vertical Radials, 4 wire, 9', (20-6m)
21-6002-16 Kit, Ground Mounted Vertical Radials, 4 wire, 16', (40-6m)
21-6002-40 Kit, Ground Mounted Vertical Radials Kit, 4 wire, 40', (80-6m)
PARTS CHECKLIST

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PARTS CHECKLIST
72-0044-04
Kit, BigIR Mark IV Hardware/Heat Shrink
✓QTY PART # DESCRIPTION
260-1006-22 QUICK DISCONNECT, 1-1/2" to 1-1/4", Fernco
160-6000-20 Hose Clamp, 1.16" to 2" ID, Used for BigIR, S/S
310-1104-11 O-Ring, 1-3/4" x 2", EP DM
172-0009-03 Kit, Glue
110-1029-01 Connector Protector Cat, 0.14 oz, (silicon goop for terminals)
310-1059-01 Polyolefin Heat Shrink 1-1/2” x 3”
310-1059-11 Polyolefin Heat Shrink 2.05” x 4”
110-1105-11 Vertical Pole Rain Cap
PARTS CHECKLIST
72-0044-11
Kit, BigIR EHU Wind Reinforcing Kit/ Mark IV Hardware
✓QTY PART # DESCRIPTION
8” 09-1022 Coax Seal, 12' x 1/2"
110-1021-54 Reinforcing Plate, for High wind kit EHU, 10-7/16" x 4-1/4" x 1/4"
110-1028-01 Anti-seize single packets, TMP-1
210-1601-03 Saddle, 1-3/4" x 3/4"
210-1601-22 Saddle, 2" x 3/4"
410-1613-11 AL Spacer, 1/4" X 5/16" ID X 3/4" OD
460-0017 Screw, 10-32 x 3/4", Panhead, S/S
160-0017-10 Screw, 10-32 x 7/8", Flathead, Phillips
15 60-0018 Washer, 10-32, Flat, S/S
10 60-0019 Nut, 10-32, Nylock, S/S
10 60-0033 Washer, 5/16", Flat, S/S
460-0046 Nut, 5/16" -18, Nylock, S/S
260-0066 Bolt, 5/16" x 4", S/S
560-0071 Screw, 10-32 x 1", Panhead, Phillips, S/S
260-0114 Bolt, 5/16" x 3-3/4", Hex Head, S/S

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PARTS CHECKLISTPARTS CHECKLIST
72-0046-01
Kit, BigIR MK III/IV Guy
✓QTY PART # DESCRIPTION
210-1429-21 Element Truss Guy Clamp, BigIR
460-0027 Bolt, 1/4"-20 x 1", S/S
460-0030 Nut, 1/4"-20, Nylock, S/S
260-0094 Quick Link, 3/16", S/S
06021
80M Base loading Coil for the BigIR
✓QTY PART # DESCRIPTION
170-2101-01 Coil, 80m, BigIR
172-0044-20 Kit, BigIR Mark IV 80m Coil Hardware
72-0044-20
Kit, BigIR Mark IV 80m Coil Hardware
✓QTY PART # DESCRIPTION
460-0095 Screw, 10-32 x 2", Panhead, Phillips, S/S
460-0019 Nut, 10-32, Nylock, S/S
460-0018 Washer, 10-32, Flat, S/S
460-1004-01 Spacer, 1/2", Nylon
210-1613-11 AL Spacer, 1/4" X 5/16" ID X 3/4" OD
420-6043-01 Ring Terminal, 18-22 AWG, #6 stud
430-5008 Heat Shrink, 1/8", Waterproof

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Figure 1 provides an overview of a SteppIR EHU (the specific model shown is a 20m driven).
EHU terminal header
Spool with copper tape
Element Support Tube (EST)
Balun (yagi driven EHU only)
SO-239 (driven EHU only)
Sprocket/Stepper motor Platen
Control cable routing tray
EHU OVERVIEW
Figure 1

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Figure 1.10 Figure 1.11 Figure 1.12
Section 1.1: Wiring the EHU
1. Trim approximately 1.5 inches of the outer jacket of the control cable.
2. Remove the outer foil shield, the support thread, and cut the shield wire off.
3. Attach electrical tape at the end of the trimmed control cable jacket so that there is no chance for a short.
4. Remove 0.25 inches of the insulation from each of the individual 22 AWG wires, leaving bare copper. Tin-
ning of the copper wire ends with solder is NOT recommended by the connector manufacturer. Figure
1.10 shows the control cable should look like when you are finished with the trimming.
5. Dip each of the copper wires into connector protector before inserting into the terminal plug. Figure 1.11
shows what the connector protector will look like.
6. The terminal header assembly consists of the terminal header and the terminal plug as shown in. The
plug is shipped loosely attached to the header. Remove this plug when wiring and firmly plug back in
when completed (use dielectric grease on this terminal plug to prevent moisture ingress/corrosion).
7. Follow the wire sequence in figure 1.13. Be careful to ensure that there are no bare wires protruding out
from the terminal clamps, to avoid potential shorts. Also make sure you are clamping down on bare wire,
and not the insulation of the wire The wiring sequence for the EHU is also imprinted on the PCB that the
terminal header is mounted on (located inside the EHU), as shown in figure 1.12. Pay no attention to the
second row of imprinted text, these pins are for use in the manufacturing of the board itself and are of no
use to you. Figure 1.12 shows a blue line crossing out the text in question. The orange circle shows the
correct wiring sequence.
1.5”
0.25
BLACK RED GREEN WHITE
4 Pin Header Wiring Sequence
WIRING/EHU/COIL ASSEMBLY
Figure 1.13

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Figure 1.15 Figure 1.17 Figure 1.16
Figure 1.18 Figure 1.19
8. Check to be sure the terminal plug is firmly inserted into the terminal header.
9. Cut three 1-inch strips of coax seal for each EHU as shown in figure 1.15, and place them at each end of
the wire tray of the EHU, as well as one in the center (figure 1.16) . This trough acts as a strain relief so
that the cable will not be pulled out of the EHU. The remainder can be used to seal the driven element/
loading coil SO239 connector and 4 conductor control cable.
10. Lay the control cable wire inside the wire tray of the EHU as shown in figure 1.17. It is a good idea to
leave a small amount of slack between the plug and the point which the tray starts as shown in the circled
region of figure 1.17.
11. Wrap the coax seal around the control cable as shown in figure 1.18. This will help keep water from en-
tering into the EHU. Repeat this process to the remaining areas of the wire tray as shown in figure 1.19.
12. When finished, the EHU will be secured to the high wind reinforcing kit and optional loading coil.
WIRING

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Section 1.2: EHU assembly
ASSEMBLY
Key QTY Part Number Description
A1- EHU, BigIR (with control cable & coax seal)
B110-1501-22 Cover for EHU, no drain hole
C110-1502-12 EHU Gasket
D460-0017 Pan Screw, 10-32 x 3/4”
E160-0017-10 Flat Head Screw, 10-32
F560-0019 Nut, 10-32, Nylock
G460-0018 Washer, 10-32, Flat
A
BC
D
E
F
G
Use anti-seize on
all SS hardware!
Do not install if
using 80m coil

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Section 1.3: High wind kit assembly
ASSEMBLY
Key QTY Part Number Description
A210-1601-03 Saddle, 1-3/4" x 3/4”
B210-1601-22 Saddle, 2" x 3/4”
C110-1021-54 Reinforcing Plate, for High wind kit EHU
D260-0066 Bolt, 5/16" x 4", S/S
E260-0114 Bolt, 5/16" x 3-3/4", S/S
F10 60-0033 Washer, 5/16", Flat, S/S
G410-1613-11 AL Spacer, 1/4" X 5/16" ID X 3/4" OD
H460-0046 Nut, 5/16" -18, Nylock, S/S
I560-0071 Screw, 10-32 x 1", Panhead, Phillips, S/S
J560-0018 Washer, 10-32, Flat
K560-0019 Nut, 10-32, Nylock
A
B
C
D
E
F
G
H
I
J
K
Use anti-seize on
all SS hardware!
Leave 2” saddles loose until EST
extension assembly is installed
Do not install if
using 80m coil

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Section 1.3: 80M Base Coil Installation (skip if 80m coil is not purchased)
ASSEMBLY
Key QTY Part Number Description
A460-0095 Screw, 10-32 x 2", Panhead, Phillips, S/S
B460-1004-01 Spacer, 1/2", Nylon
C210-1613-11 AL Spacer, 1/4" X 5/16" ID X 3/4" OD
D460-0018 Washer, 10-32, Flat
E460-0019 Nut, 10-32, Nylock
Use anti-seize on
all SS hardware!
A
B
C
D
E

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Section 1.3 (continued): 80M Base Coil Installation (skip if 80m coil is not pur-
chased)
ASSEMBLY
Use a dielectric grease on the center conductor and threads, and coax seal for
the exterior of the connection.
EHU ground lug

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Section 1.4: 80M Base Coil Wiring (skip if 80m coil is not purchased)
The 80m base loading coil is wired to a separate piece of 4 conductor control cable, that should be
labeled on both ends. A piece of tape is often an easy way to do this.
1. Strip approximately 2 inches of jacketing off of the end of the 4 conductor control cable closest to the coil,
being careful not to damage the insulation of the inner 22awg wires (figure 1.41). Trim off the foil shield,
support thread, and shield wire.
2. Strip 0.25 inches of insulation off of the 22awg wires, and place heat shrink over the wires (figure 1.42).
3. Using the provided ring terminals (PN 20-6043-01), crimp and solder them to the ends of the control cable
(figure 1.43).
4. You may now use the provided heat shrink (PN 30-5008) to weatherproof these connection points (figure
1.44).
5. A small piece of coax seal should be used to seal the outer insulation of the 4 conductor control cable as
well (figure 1.45).
WIRING
Figure 1.41 Figure 1.42 Figure 1.43
Figure 1.44 Figure 1.45 Figure 1.46

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Section 1.4 (continued): 80M Base Coil Wiring (skip if 80m coil is not pur-
chased)
WIRING
Important Notes:
• Do NOT jumper the radial grounds between the
EHU and coil, the EHU radial ground lug should be
completely disconnected from anything.
• Once the antenna is mounted and your radial set-
up is prepared, the radials can then be attached to
the ground lug on the coil, and coax seal can be
applied to all external electrical connections on the
EHU/coil.
Coil ground lug

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Figure 1.20 Figure 1.30 Figure 1.31
Section 1.5: Preparing the control cable
1. Strip the jacket and aluminum shielding off of the control cable as shown in figure 1.20, approximately
2.75” from end of control cable, being careful not to damage the individual wires.
2. Strip the plastic insulation off of each of the control cable wires, approximately 0.25” in length should be
bare wire.
Section 1.6: Connecting control cable to the DB25 Field Splice
1. Apply the provided dielectric grease to the exposed copper portion of each wire.
The terminals may be closed by default. If so, turn the terminal screw ccw ~10 turns to open it before
inserting the wires.
2. Connect each wire to the appropriate terminal and tighten using a flat head screwdriver.
3. Consult the table on the next page for the correct wiring sequence.
4. Position the control cable between the cable clamp halves as shown in figure 1.31. Electrical tape can be
wrapped around the cables to increase their thickness if necessary.
5. Tighten the two pan head screws until the cable is snug, but do not over-tighten.
6. Thread the two thumb screws into the connector face as shown in figure 5.23.
7. Plug the DB25 splice into the back of the controller, ensuring that it is fully seated, and twist the thumb-
screws to secure it. We have seen customers install these partially, resulting in fault codes on the control-
ler.
WIRING
2.75”
0.25”

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Section 1.7: BigIR Wiring Diagram
WIRING
25 PIN DSUB FIELD SPLICE
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
B
R
G
W
Red
Black
White
Green
Red
Black
White
Green
To Coil
Attach ring
terminals to
wire ends
To EHU
Shield
EHU
Coil
*Ensure that the shield wire for both the EHU and loading coil connect
to the “G” terminal on the DB25 connector, and trim them at the EHU/
coil so they are not connected to anything.