SteppIR Dream Beam 11 User manual
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Dream Beam 11
Assembly Manual
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iinngg aa SStteeppppIIRR pprroodduucctt!! WWee ggrreeaattll
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SSiinncceerreell,,
The SteppIR Team
DB11 Yagi Manual, 71-0018
Rev 3 (03/22/2011)
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iii
DB11 Specifications................................................................................................
Component checklist...................................................................................................
Antenna kit contents.............................................................................................
EHU wiring instructions........................................................................................
Tools needed for assembly.........................................................................................
Boom assembly procedure..................................................................................
Element housing unit (EHU) spacing.........................................................................
EHU assembly procedure......................................................................................
Wiring the control cable to the antenna switch........................................................
Mounting the coax antenna switch to boom.............................................................
Wiring the coax to the antenna switch................................................................
Mounting the terminal housing to boom...................................................................
Securing coax and control cable to the boom....................................................
Procedure for wiring element housings (EHU’s)......................................................
Preparing the telescoping poles..........................................................................
Installing the DB25 splice for hook up to the SDA 100 controller....................
Final antenna testing.............................................................................................2
1
2
3-4
5
6
7
8
9
10
11
12
13
14
15-16
17-19
20-21
22-23
TEPPIR ANTENNA LIMITED PRODUCT WARRANTY
Our products have a limited warranty against manufacturers defects in materials or construction for two (2) years from
date of shipment. Do not modify this product or change physical construction without the written consent of
Fluidmotion Inc, dba teppIR Antennas.
This limited warranty is automatically void if the following occurs: improper installation, unauthorized modification and
physical abuse, or damage from severe weather that is beyond the product design specifications.
SteppIR Antenna’s responsibi ity is strict y imited to repair or rep acement of defective components, at
SteppIR Antennas discretion. SteppIR Antennas wi not be he d responsib e for any insta ation or
remova costs, costs of any anci ary equipment damage or any other costs incurred as a resu t of the fai -
ure of our products.
In the event of a product failure, a return authorization is required for warranty repairs. This can be obtained at
www.steppir.com. hipping instructions will be issued to the buyer for defective components, and shipping charges to
the factory will be paid for by the buyer. teppIR will pay for standard shipping back to the buyer. The manufacturer
assumes no further liability beyond repair or replacement of the product.
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1
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EHU Wiring In truction
Follow the directions below for wiring each of your DB11 element housing units (EHU) from the
respective EHU to either the terminal housing, or the connector junction box, if you have purchased
this option.
NOTE:
This assembly sheet only shows you the correct way to assembly and wire the EHU to the boom. It
DOES NOT take into account the orientation of the EHU on the boom.
Follow figure 1 for wiring and routing cable in the wire tray on the lip of the EHU.
Depending on EHU type there will be 4 conductor or 6 conductor wire. Follow the wiring code that is printed on the
circuit board inside the EHU as shown in note A.
Be sure to unplug the top portion of the connector when wiring, as you cannot see the correct wiring code until the
upper plug is removed. The correct wiring code is printed closest to the terminal block and reads left to right:
Bk, R ,G, W, Blu, Br.
Trim the shield wire so that it is not exposed inside the EHU.
Figure 1 Wiring EHU
Wiring connector
board
eel
Location for
COAX seal
NOTE:
Wire the cable to the correct terminal on the wiring con-
nector board. Follow the color code on the circuit board
as shown in figure 1A. Route the wire into the wire tray.
Place a .25” piece of the provided coax-seal over the
cable and form it so that its flush with the wire tray. Do
this in the 3 locations shown below. (This will keep the
cable in place and prevent water from leaking into the
EHU.)
SteppI Use only, do not use this line for wiring!
Fig 1A
Fig. 1
Wire tray
5
Trim about 1 inch of the jacket and foil sheild ( including drain wire) off the end of the cable.
RECOMME DED TOOLS FOR ASSEMBLI G THE A TE A:
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6
STARTI G ASSEMBLY
In the hardware kits we have provided extra hardware. This is a precaution in case fasteners are
lost or damaged during assembly.
A large, cleared flat area is ideal for assembly of an antenna of this size and complexity. Typically,
an area 16ft x 24ft would be ideal. We recommend using sawhorses or sturdy tables when installing
the boom. By having the boom elevated, it is easier to ensure that the elements are level.
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 disassemble as needed for transportation
to the tower area.
Use of a level for adjusting the Element Housing Units (EHU’s) is highly recommended. This is a
surprisingly accurate and consistent method. Simply place the level on the mast plate, and adjust
each element accordingly.
12” Level
25’ Tape Measure
5/16”, 7/16”, 1/2”, 9/16”, 3/8” sockets
and wrench
(deep well works best)
Screwdriver
#1 Flat head
#1 Phillips
#2 Phillips
Volt-ohm meter
Razor Knife
3/32 allen wrench
2 work benches for assembling antenna (saw
horses or clamping work benches work the
best)
5/16” nut driver
(or drill works well with driver bit)
Pliers
Hammer
Wire Cutters and strippers
Torque wrench (capable of 5-20 ft lbs) (6.8-
27.1 m)
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7
BOOM ASSEMBLY PROCEDURE
Locate boom pieces in the Antenna Boom Box
QTY 1 1 3/4” x 62”
QTY 1 1 3/4” x 72”
QTY 1 1 1/2” x 8” center splice
Apply a thin film of anti seize or a spray-on lubricant (i.e. WD-40, Dry Lube) to the male engage-
ment area of the boom sections.
Secure the 60-0062 1/4” bolts, nuts and washers onto the boom. Each boom bolt will require qty
4 of the 60-0041 washer, used as spacers.
Repeat this for each section until the boom is completely assembled as shown in figure 2.
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Figure 2
Boom Assembly
OTES: Our boom pieces are drilled using a precision drill press. This ensures that all of the bolts
are snug when assembled. With the DB series antennas, if a boom piece is ever damaged, we can
now replace the individual boom piece, as opposed to the entire boom.
Always apply anti-sieze lubricant to stainless steel hardware. This will prevent galling, which
destroys the bolts and can be a real problem getting apart. Each bolt has a specific length for the
aluminum boom piece it is holding together. The bolts will be a little bit long, so we provide you with
5 stainless steel washers per bolt to make up the difference. It is critical you use these washers, so
that only the shank of the bolt is engaging the aluminum tubing
QTY 4: 60-0062
1/4”x2-3/4” BOLT
QTY 16: 60-0041
1/4” WASHER
QTY 4: 60-0030
1/4” NYLOCK NUT
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ELEME T HOUSI G U IT SPACI G
Locate the three Element Housing Units (EHU) with gaskets, in the Antenna Box
QTY 1 Driven EHU 20m (This is the only EHU that uses 4 conductor wire)
QTY 2 Director / Reflector EHU DB11 (both are identical and use 6 conductor wire)
Refer to figure 4 on page 9 for the hardware required to connect the EHU’s to the boom.
8
BOOM Figure 3
CTR CTR CTR CTR CTR CTR
Forward
OTES:
Spacing of the elements in relation to each other is critical. Take great care to ensure that the ele-
ments are mounted as shown in figure 3 below. All dimensions are taken from the center of the ele-
ment, which is the center-point of fiberglass tube that houses the copper beryllium strip, both at the
EHU and at the return EST. Refer to the CTR marks below showing actual radiating element for
eachof the 3 EHU’s and return EST’s.
30.0” 30.0” 30.0”
6.06”
68.75”
0.65”
96.0”
48.0”
72.0” 62.0”
REF DVR DIR
9
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ELEME T HOUSI G ASSEMBLY PROCEDURE
Figure 4
Attach the appropriate EHU to the mounting plate and return mounting bracket. Then attach the
mounting plates to the boom. See figure 4.
Use a level to check the EHU and Return mounting bracket before tightening the aluminum sad-
dles to the boom. When the plate is level tighten the saddle bolts to 20 ft/lbs (27.09Nm).
QTY 10: 60-0017
#10 x 3/4 Panhead
QTY 10: 60-0018
#10 flat washer
EHU:
DIR, REF: 70-3407-01
DVR: 70-3401-01
10-1502-01
30/40 EHU gasket
QTY 4: 60-0075
5/16 x 3 -1/4” Bolt
70-2030-01 Element
Mounting plate with
center gasket.
QTY 6: 10-1601-03
1 - 3/4” Alumn Saddle
QTY 10: 10-0019
#10 Nylock Nut
1-3/4 boom
QTY 6: 60-0046
5/16 Nylock Nut
QTY 2: 60-0075
5/16 x 3 -1/4” Bolt
QTY 8: 60-138
1/4 x 5/8” Bolt
10-1151-11
Return Bracket
QTY 2:
10-1152-11
Return Clamp
QTY 8: 60-0030
1/4” Nylock Nut
10
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WIRI G THE CO TROL CABLE FOR THE A TE A SWITCH
Locate the following kits:
QTY 1 72-0053-01 Antenna Cable Kit
QTY 1 70-3001-01 COAX Switch Assy
Refer to figure 6 for assembly hardware required for this step.
Follow figure 5 for wiring the control cable to the Coax Antenna Switch
Once wired correctly, the cable must be pulled through the drain hold on the lid of the Coax
Antenna Switch.
The loose end of the control cable will be wired to the terminal housing or connector junction box,
if this option was purchased. This procedure will be completed in a later step of the assembly
process. For now, let the control cable hang unattched while the coax antenna switch is mount-
ed to the antenna.
DO NOT secure the lid and gasket to the enclosure until the final testing has been completed.
Figure 5 Control Wiring for Coax Antenna Switch
Inside view of Coax Antenna Switch
Control Cable
(Other end will be wired to
the terminal housing or con-
nector box)
11
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Figure 6
MOU TI G COAX A TE A SWITCH
First attach the Coax Switch Bracket to the Antenna Switch Housing Lid.
Leave the Antenna Switch PCB exposed, so testing can be completed before the lid and gasket are
permanently secured to the antenna.
Attach the assembly to the boom, without the lid and gasket (as shown in figure 6.
OTES:
DO NOT mount the Antenna Switch housing and
gasket. These will be mounted once all testing of
the antenna is complete. QTY 2: Aluminum saddle
10-1601-03
Antenna Switch Housing
(DO NOT mount until all testing
is complete)
Antenna Switch housing gasket
(cut to length)
(DO NOT mount until all testing
is complete)
Antenna Switch board mounted
to housing lid
QTY 4: Flat head screw
(located in small zip lock bag)
QTY 2: #10 X 5/8” SS pan head
60-0113
QTY 12: 5/16” Nylock nut
60-0046
QTY 1: COAX Switch bracket
10-1619-01
QTY 2: 60-0075
5/16”x3-1/4” SS hex bolt
Coax Antenna Switch Assembly
QTY 2: 60-0019
#10-32 Nylock nut
DIRECTOR
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12
WIRI G THE COAX CABLE TO THE A TE A SWITCH
The coax cables have been made specifically for each individual element.
Follow figure 7 and figure 8 below for connecting the coax to the antenna switch box.
Tighten all coax connectors with pliers to ensure a good connection.
Weather-proofing should be done when all testing and assembly have been completed.
Figure 7 Wiring Coax to Elements
REFLECTOR DRIVEN DIRECTOR
DB11
Coax Antenna Switch
Figure 8 Wiring Coax Antenna Switch
For details on wiring the Coax Antenna
Switch refer to Figure 7 below. The lid
of the Coax Antenna Switch should not
be attached yet.
Reflector EHU
Feed from shack
Control cable that will be
wired into the terminal
housing or connector box.
Driven EHU
Director EHU
Bottom View of Coax Antenna Switch
otes: Take care not to bend the cable over any sharp corners of the boom assembly, or particu-
larly, the top plate on the antenna tower, or the cable could be damaged. Do not bend the cable in a
smaller diameter than 10 inches. Do not clamp anything over the cable that could possibly pinch, or
damage it. A short-circuit of the cable may cause damage to the electronic controller.
OUT 2
OUT 1 OUT 3
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MOU TI G TERMI AL HOUSI G
Locate the following kit for assembling Terminal Housing:
QTY 1 72-0022-11 Terminal Housing Kit
OTES: If you purchased the optional Connector unction Box option for your antenna, the terminal
housing kit will not be included. Refer to the separate connector junction box instruction manual for
installation.
The terminal housing can be installed anywhere along the middle of the boom. Location is not criti-
cal, as long as all the element control cables can reach the terminal housing. We recommend you
mount the terminal housing as close to the mast plate as possible. Refer to figure 9 below for
mounting.
Unscrew the SS hose clamp 056 (60-6000-40) so that it can be fitted around the boom.
Use the SS hose clamp to secure the terminal housing to the boom or mast. The housing
can be horizontal or vertical.
Regardless of the mounting orientation make sure that the hole in the end cap of the terminal
housing will be facing downward when you attach it. This it to allow the housing to drain and
prevent water from collecting inside the housing.
DO OT SEAL THE TERMI AL HOUSI G
IT EEDS TO BREATHE OUT OF THE BOTTOM DRAI HOLE
Figure 9 Terminal Housing Assembly
OTES:
With the hose clamp unscrewed, it can be fitted
around the boom to use for securing the termi-
nal housing.
Make sure upon completion that the drain hole
in the terminal housing cap is facing downward
to allow water to escape the terminal housing.
The location shown for the terminal housing is a
recommendation, only. It can be mounted in
many different locations depending on your pref-
erence.
Terminal Housing
Terminal Housing cap
with drain hole facing down
Location for SS hose clamp
Wire terminals will be folded
and slid inside the terminal
housing once wiring and
testing is complete.
13
QTY 1: 10-1021042
Mast Plate
QTY 8: 60-0065
5/16”x3-1/2” SS Bolt
Mounting holes (4) for 2”
saddles to secure antenna
to the mast
!
"!
BOOM
MA T
GOE
HERE
BOOM-TO-MA T DETAIL
MA T PLATE
14
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SECURI G THE COAX A D ELEME T CO TROL CABLE TO THE BOOM
OTES: Take care not to bend the coax or control cable over any sharp corners of the boom
assembly, or particularly, the top plate on the antenna tower, or the coax/control cable could be
damaged. Do not clamp anything over the coax/control cable that could possibly pinch, or damage
it.
When taping the cable to the boom, start on the ends of the boom and work towards the mast plate.
This will allow you to trim the cable to the exact length if desired.
We recommend labeling all the wires at the terminal housing location. Knowing which wire goes to
each EHU could be very handy in the event of any control cable issues at a later date, when the
antenna is in the air!
Secure the coax and control cables from the EHU’s to the boom.
Use the outdoor electrical tape (09-0001) to secure the cable to the boom
Only two wraps of the tape are needed to hold the cable to the boom.
Tape the control cable and coax cable to the boom approximately every two feet.
Once both cables have been secured to the terminal housing or connector junction box, the con-
trol cable can be trimmed to length or coiled up and out of the way.
The actual wiring of the control cable will be addressed on the next page.
Below is a pic ure of an ac ual DB11 when fully ins alled. This will give you a birds eye view of how he
an enna should look when comple ed. Shown here is he pro o ype 40m dipole curren ly in developmen .
This DB11 is ins alled a he S eppIR fac ory, home of he S eppIR Ama eur Radio Club - call sign WB7IR.
15
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Preliminary WIRI G A D MECHA ICAL EHU TESTI G
Refer to the SDA 100 manual for conducting the preliminary testing for the EHU’s
PROCEDURE FOR WIRI G THE ELEME T HOUSI GS
OTES: If you have purchased the connector junction box option you will need to use the provided
manual for wiring, as it is different than the instructions for the terminal housing kit.
Ensure all of the control cables are taped and secured to the boom.
If you have purchased the connector box option refer to the connector junction box manual
for correct wiring.
Apply a thin coat of connector protector to each of the exposed wires.
Follow figure 10 for correct wiring. Note that the shield wires are all connected together as
one single wire and use a single position terminal strip separate from the other terminal
blocks. Be careful not to over tighten the screws on the terminal blocks.
Perform all tests on the antenna to ensure wiring is correct, then complete the following pro-
cedures - these will generally be the last items done before putting the antenna on the tower.
Once the control cables from the EHU’s and control cable are correctly wired, fit the terminal
strip into the terminal housing that has been mounted in it’s respective location.
Make a couple of wraps of electrical tape around the control cable bundle where it will pass
through the notch in the threaded plug. This will help to protect the cable sheath from the
threads in the plastic tube.
Guide the control cable into the drain hole on the black screw on cap.
Tighten the cap onto the terminal housing, CAUTIO : Be careful not to cut or damage the
control cable as you tighten the terminal housing cap.
OTES:
This test is to ensure that the wiring of the EHU’s has been done correctly. It is critical that
the wiring be done exactly as shown in figure 9. Incorrect wiring can cause poor performance
and potentially damage the antenna or antenna controller.
Once all the EHU’s are correctly wired and each EHU is being properly adjusted by the elec-
tronic controller, the initial testing is completed.
Other tests will need to be conducted to ensure that the relays are working correctly inside
the EHU’s and also inside the Coax Antenna Switch. These tests will be done once the tele
scoping poles and sweeps have been assembled.
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16
Figure 10 DB 11 Wiring Diagram
Note:
Be sure to abe a the termina b ocks with the
corresponding EHU so that testing can be done
more easi y. Labe ing wi a so he p with any
future troub eshooting, shou d an issue arise.
Telescoping Poles: The telescoping poles come packed with all 4 sections together for shipping
purposes only. When installing, the pole sections will need to be separated, with the two larger sec-
tions comprising one single pole assembly, and the two smaller sections comprising another single
pole assembly. See drawing 70-2042-01 for further details on how to assemble the poles. The
pole sections are taped using 1.5” wide 3M Super 88 tape. This tape is wider than normal, to pre-
vent the telescoping pole joints from twisting in high winds. See figure 11 below for correct tape
lengths for each respective joint.
17
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Figure 11
AC
A
C
40in / 102cm
22in / 56cm
Note:
Measurements are taken when the tape is
unstretched and laying naturally.
Tape should be stretched to 50% when
being applied to the fiberglass poles.
The drawing is showing 3 joint sections of a
single pole, but you will only be concerned
with joints A and C, because the single pole
will be creating two separate pole assem-
blies as shown in drawing 70-2042-01.
Once the pole is extended and within the correct length the joints can be taped as follows.
Start the tape with one complete wrap of electrical tape around the telescoping pole section joint.
Make sure to smooth the tape as you wind it around the joint. To prevent any air bubbles and to
create better adhesion.
Wrap the tape past the joint by about 3 inches using a half-overlapping method. Wrap back down
to the smaller fiberglass pole section using the same technique so that you finish where you start-
ed.
Apply the last full wrap with no tension, to prevent from the tape coming undone and flagging over
time.
CAUTION: never tear the tape to terminate it, use a knife or scissors to cut the tape.
Rub the end of the tape firmly to ensure the tape is bonded and smooth out any air bubbles.
Repeat this for joints A and C on the telescoping pole.
Lengths for 1 1/2 inch PVC tape
PROCEDURE FOR TAPI G THE TELESCOPI G POLES
This manual suits for next models
1
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