SteppIR HFT540C User manual

HFT540C
Assembly Manual
REV 2.0.4 7/2/2021
13406 SE 32nd St. Bellevue, WA 98005 | www.steppir.com | 425.453.1910 | [e-mail]

PRE-INSTALL NOTES
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•Taking inventory of the parts received and comparing with the Bill of Materials (BOM) is recom-
mended. That way if any parts are missing they can be delivered quickly to minimize delays.
•We recommend reading the entire manual at least once before beginning assembly, this will give
you an overview of the assembly.
•The antenna assembly is divided into sub-assemblies which can be performed simultaneously.
Working on multiple sub-assemblies in parallel can speed up the assembly time.
•Critical bolt torques are listed on the appropriate assembly step. Make sure to tighten from the
nut with a torque wrench and use anti-seize or threadlock where applicable.
Recommended Tools/Materials:
•Sawhorses (at least 2)
•Heat Gun
•Speed Square
•Level
•Torque Wrench
•Safety Wire Twist Pliers (provided)
•Paint Pen
•Acetone
•Loctite 243 (provided)
•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)

INVENTORY CHECKLIST
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Saddle Box
Item
Part Number
Quantity
Boom Truss Attachment square saddle
10-1601-81
2
Saddle, 1.75"
10-1601-03
8
Saddle, 2.25"
10-1601-32
16
Saddle, 2.5"
10-1601-41
12
Saddle, 2"
10-1601-22
8
Saddle, 3"
10-1601-61
32
Square Saddle
10-1601-71
10
Backing Plate - Angle
10-1601-91
10
Hardware Box
Item
Part Number
Quantity
Hex Bolt, 1/2" x 2.5"
60-7000
3
Hex Bolt, 1/4-20 x 1.75"
60-0078
18
Hex Bolt, 1/4-20 x 3"
60-0029
18
Hex Bolt, 3/8 x 6.5" SS
60-7001
9
Hex Bolt, 3/8 x 7" SS
60-7002
8
Hex Bolt, 5/16-18 x .75"
60-7003
71
Hex Bolt, 5/16-18 x 2.75"
60-0093
3
Hex Bolt, 5/16-18 x 4.5"
60-0115
23
Hex Bolt, 5/16-18 x 4"
60-0066
14
Hex Bolt, 5/16-18 x 5.5"
60-0204
6
Hex Bolt, 5/16-18 x 5"
60-0141
9
Hex Bolt, 5/16-18 x 6"
60-7004
5
Hex Bolt, 5/16-18 x 7.5"
60-7005
28
Hex Bolt, 5/16-18 x 7"
60-0215
32
Hose Clamp, #16, SS
60-6000-15
10
Hose Clamp, #24, SS
60-6000-20
4
Hose Clamp, #48, SS
60-6000-35
13
Lock Washer, 10-32, Split, S/S
60-0175
37
Nut, 1/2", Nylock
60-7006
5
Nut, 1/4-20, Nylock
60-0030
37
Nut, 10-32, Nylock
60-0019
3
Nut, 3/8", Nylock
60-0050
16
Nut, 5/16, Nylock
60-0046
117
Pan Screw, 10-32 x .625"
60-0113
3
Pan Screw, 10-32 x .75" w/locking strip
60-0101
3
Pan Screw, 10-32 x 1" w/locking strip
60-0101-01
17
Pan Screw, 10-32 x 1.25" w/locking strip
60-0101-02
14

INVENTORY CHECKLIST
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Hardware Box—Continued
Item
Part Number
Quantity
Spacer, #10 x 0.5 OD x 0.25 tall Aluminum
10-1613-12
9
Spacer, #10 x 0.5 OD x 0.50 tall Aluminum
10-1613-13
13
Spacer, 5/16" ID x 1" tall, Aluminum
10-1613-01
14
Spacer, 5/16" ID x 1/4" tall, Aluminum
10-1613-11
51
Spacer, 3/8" ID x 3/4" tall, Aluminum
10-1613-21
28
Set Screw, 10-32 x 0.25", Cup Point
60-0112
23
Shackle, 1/2", S/S
60-7007
2
Shackle, 7/16", S/S
60-7008
4
Shackle, Twisted,15/32, SS
60-7009
4
Thimble, 3/16, Heavy-Duty, SS
60-7048
35
Thimble, 1/2 - heavy duty SS
60-7010
8
Turnbuckle, 1/2" x 8", SS
60-7011
5
Turnbuckle, 1/4" x 4", Eye to Eye, S/S
60-0083
9
Turnbuckle, 5/16" x 8", Eye to Eye, S/S
60-0159
9
Washer, #10
60-0018
25
Washer, 0.5" ID x 1.5" OD
60-7012
14
Washer, 1/4
60-0041
37
Washer, 5/16"
60-0033
350
Wire Clip, 3/16 - S/S
60-7013
52
Eyebolt, 1/2" x 4"
60-7014
2
Double cable clamp, 3/16"
60-7015
18
Boom Box
Item
Part Number
Quantity
4" Square Boom Section - 10ft
10-1200-01
1
4" Square Boom Section - 9ft
10-1200-11
2
4" Square Boom Section - 6ft
10-1200-21
2
Element Truss Mast, 2.25" x 48"
10-1618-51
4
Boom Truss Boom, 2.5" OD x 36"
10-1618-61
1
Boom Truss Mast, 2.5" OD x 48"
10-1618-71
1
Boom Splice
10-1203-41
8
Element Mounting Plate - Lower
10-1605-31
5
Element Mounting Plate - Upper
10-1605-41
4
Guy Line Grip, (PLP-2739)
60-7016
10

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INVENTORY CHECKLIST
Pole Box
Item
Part Number
Quantity
Fiberglass Extension, 1.75in OD x 7.5ft
70-2030-01
2
Fiberglass Extension, Tapered, 17.5ft
70-2031-01
6
CPVC 3/4 x 89" w/coupler
70-2021-01
6
CPVC 3/4 x 89" w/out coupler
70-2022-01
8
CPVC Assembly with 1.35" foam ring + washer hose w/out coupler
70-2025-43
2
CPVC Assembly with 1.5" foam ring + washer hose + coupler
70-2025-33
2
CPVC Assembly with 2" foam ring + washer hose
70-2025-53
6
Telescoping Fiberglass Pole
10-1013-02
10
Cable Box
Item
Part Number
Quantity
Control Cable - 4c
21-5001-01
50
Control Cable - 6c
21-5013
30
Dacron, 3/16"
21-7002-01
255
Phillystran, 4000i
21-8004
80
Phillystran 2100i
21-8002
165
Coax jumper, 11' 6", PL259/RG213
21-6301-96
1
Coax jumper, 4', PL259/RG213
21-6301-30
1
Coax jumper, 8', PL259/RG213
21-6301-80
1
Controller Box
Item
Part Number
Quantity
OptimizIR Controller (with whitescreen fix)
70-4005-01
1
Stereo Splitter
21-6040
1
DB25 Field Splice
70-6010-01
1
DB42 100W Power Supply
70-3000-11
1
EHUs
Item
Part Number
Quantity
HFT540C 20m Driven w/Normal Passive Relay
70-3413-01
1
HFT540C 40/30 Passive
70-3414-01
2
HFT540C 40m Driven w/Normal Driven Relay
70-3415-01
1
HFT540C 40m Driven w/Normal Passive Relay
70-3412-01
1
EHU Lid (packaged with EHUs)
10-1501-23
5
EHU Lid Hardware Kit (packaged with EHUs)
72-0054-01
5

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INVENTORY CHECKLIST—CONTINUED
Miscellaneous Box
Item
Part Number
Quantity
Vinyl Cap, 1.5" x 1.5", Black, with hole
60-7024
2
Vinyl Cap, 1.75" x 1.5", Black, with hole
60-7025
2
Vinyl Cap, 2.5" x 1.5", Black, with hole
60-7026
6
Zip Tie, Black, UV
09-2019
10
Vinyl Cap, 2.25" x 1.5", Black, w/o hole
60-7021
4
Vinyl Cap, 2.5" x 1.5", Black, w/o hole
60-7022
3
Plug for Square Tube, 4", Black
60-7023
2
Polyolefin Heat Shrink, 1.5" x 3"
10-1059-01
33
Resin Clamp, 1.75" (set)
60-7020
8
Resin Clamp, 1" (set)
60-7019
8
Phillystran Rubber Cap (2100i)
60-0044
17
Phillystran Rubber Cap (for 4000i)
60-7018
9
Foam Plug
70-1007-01
10
Mixing Nozzle, 1:1, 2:1
60-7029
1
Urethane Adhesive, 3M Scotch-Weld DP620NS
60-7028
1
Glue Gun, 50ml , 1:1 / 1:2
60-7027
1
Glue kit
72-0009-03
3
Threadlocker, No. 42, 10 ML Medium Strength
60-7030
1
6 In. Safety Wire Twisting Pliers
60-7031
1
Electrical Tape, 3M Super 88
09-0005
1
Electrical Tape, MERCO
09-0001
1
Coax Seal (sold per inch)
09-1022
40
0.032" S/S lock wire (full roll)
60-7017
1
Anti-seize, TM-1
10-1028-21
2
Element Truss Attachment Plate - 2in
10-1607-21
8
Element Truss Attachment Plate - 4in
10-1607-31
8
Coax Switch and Connector Junction Box Dual Mounting Bracket
10-1619-11
1
Coax Switch
70-3001-01
1
Connector Junction Box, DB42
70-2038
1
Rubber Quick-Disconnect Boot
60-1006-22
10
Boom Plate, 8"
10-1021-43
1
HFT540C Mast Plate
10-1021-51
1
Stress Relief Sleeve, 1.5" ID x 1.75" OD
10-1630-51
4
Stress Relief Sleeve, 1.75" ID x 2" OD
10-1630-11
4
Stress Relief Sleeve, 2.5" ID x 3" OD
10-1630-41
12
Options
Item
Part Number
Quantity
Filter, suppressor unit, 8 position, 50v
20-8052-41
1
Filter, suppressor unit, 16 position, 50v
20-8052-51
1
Control Cable, 24c (customer specifies length)
1

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)
ANTENNA OVERVIEW—ELEMENT FUNCTIONS
FORWARD DIRECTION
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ANTENNA OVERVIEW—DIMENSIONS
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40 ft
71.5 ft

GLUING THE FIBERGLASS POLES
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The glue will take 48 hours to fully cure so be sure to do this step first!
•The 17.5ft fiberglass extension pole is shipped in 2 parts which must be glued together. This is to allow the antenna
to be shipped without requiring crating.
Gluing Procedure:
You will need:
•(6x) 1.75” OD Fiberglass Poles, gray with sanded base
•(1x) 3M Glue Gun, Glue, and Mixing nozzle
•(6x) 70ft Fiberglass Extension (Gray pole)
•Acetone or Isopropyl alcohol
Step 1: Degrease 6 inches of the interior and exterior mating surfaces with acetone/alcohol to remove dust/dirt.
Step 2: Use applicator gun to apply glue to the sanded outer diameter of the 1.75” pole as well as sanded inner diameter
of the 2.0” OD pole.
Step 3: Insert the smaller pole into the larger pole. Twist a few times to spread the glue around and then back the pole
out. Remove excess glue from the inside of the smaller pole.
Step 4: Add more glue if necessary and repeat until the mating surfaces are covered in glue evenly and there are no
blockages caused by excess glue. Work quickly as the work time of the glue is 20 minutes.
Step 5: Once the glue is evenly distributed, insert the pole 6” into its final position.
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

BOOM ASSEMBLY
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Apply the provided Loctite 243 to the Hex bolts before installing them. This is critically
important to prevent the bolts from loosening due to vibrations!
•Join the 5 boom sections together using the boom splices and secure them with the provided hex bolts and washers.
Be sure to use the proper length boom section, 10ft in the middle followed by 9ft and then 6ft on the ends.
•The orientation of the boom splice matters! The boom joints are pre-marked A, B, C, and D. Make sure these mark-
ings line up.
•Once installed, tighten the bolts to a final torque of 20 ft-lb
G
C
B
A
20 ft-lb
BE
F
C D
G
Key
QTY
Part Number
Description
A
1
10-1200-01
4" Square Boom Section - 10ft
B
2
10-1200-11
4" Square Boom Section - 9ft
C
2
10-1200-21
4" Square Boom Section - 6ft
D
8
10-1203-41
Boom Splice
E
64
60-7003
Hex Bolt, 5/16 x 3/4in
F
64
60-0033
Washer, 5/16
G
2
60-7023
Plug for Square Tube, Black

BOOM ASSEMBLY—CONTINUED
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•The picture below show an example boom joint. Note that we have marked the bolt heads that we torqued down with
a red paint pen to indicate that they have been fully tightened. The boom can be placed on sawhorses for easier ac-
cess. 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.

BOOM ASSEMBLY—MARKING THE BOOM
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•The location of the element plates, mounting plate, and truss attachments is critically important. Take care when
measuring and double check your measurements.
•Pick one end of the boom (it doesn’t matter which) to be the back of the antenna. Measuring from the back of the
antenna mark the boom with a permanent marker at the locations listed in the table below. Label the marks with the
indicated labels for future reference.
FRONT BACK
Description
Label
Distance (in)
Distance (cm)
Reflector Element Mounting Plate
REF
3
7.62
Truss Attachment
T1
53.75
136.5
Driven Element Mounting Plate
DVR
80
203.2
Director 1 Element Mounting Plate
D1
168
426.7
Mast Plate
MAST
210
533.4
Director 2 Element Mounting Plate
D2
286
726.4
Truss Attachment
T2
397.75
1010.3
Director 3 Element Mounting Plate
D3
463
1176

ELEMENT PLATE INSTALL—OVERVIEW
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•In the following steps, the element mounting plates will be installed on the boom. The orientation of these plates is
important because they are NOT symmetrical. There are two important things to note:
1. The mounting plate must be installed with the four threaded #10-32 holes facing UP.
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
Note the orientation of the element plates before installing them on the boom!

ELEMENT PLATE INSTALL—OVERVIEW
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•5 element plates will be installed on the boom. Use the markings on the booms to position the element plates cor-
rectly. 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)

ELEMENT PLATE INSTALL
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•Install the element plates following the drawing below. Use the markings on the boom to position the plates. Place
the plates on the side of the mark closer to the FRONT of the antenna
•Note the orientation of the mounting plate! The plate is NOT symmetrical and must be installed with the wid-
er spaced threaded holes closer to the center of the antenna.
•Use a speed square to position the element plate perpendicular to the boom as shown in the photo below.
•Tighten the hex bolts to 11 ft-lb with the torque wrench on the nut side.
C5X
C C
AC
11 ft-lb
MARKING ON
BOOM
B B
D
DD
D
Key
QTY
Part Number
Description
A
1
10-1605-31
Element Mounting Plate—Lower
B
2
10-1601-91
Backing Plate
C
4
60-0215
Hex Bolt, 5/16 x 7”
D
4
60-0046
Nut, 5/16, Nylock
Use anti-seize on
all SS hardware!

MAST PLATE INSTALL
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B
C
E
30 ft-lb
D
MARKINGS ON
BOOM
D
B
B
D
D
B
B
A
D
D
B
C
C
E
E
C
Boom Truss Holes
C
C
Use anti-seize on
all SS hardware!
•Install the mast plate as shown below. Use the markings on the boom to position the mast plate.
•Note the four holes for the boom truss mast are closer to the front of the antenna.
•Note: If you are side-mounting the antenna on a tower, you may need to mount the mast plate on the opposite side
of the boom. This is okay as long as you make sure that the boom truss mast attachment holes are still closer to the
front of the antenna.
•Tighten the hex bolts down to 30 ft-lb with the torque wrench on the nut side.
Key
QTY
Part Number
Description
A
1
10-1021-51
HFT540 Mast Plate
B
6
10-1601-71
Square Saddle, 4”
C
6
60-7002
Hex Bolt, 3/8 x 7”
D
6
60-0050
Nut, 3/8, Nylock
E
3
60-0101-01
Pan Screw, #10-32 x 1” w/locking strip

MAST PLATE INSTALL—CONTINUED
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D
B
E
C
A
Use anti-seize on
all SS hardware!
•The antenna uses saddles that are designed to mount onto a 3” OD pipe.
•Use the 10-32 pan screws to hold the inner saddles in place while the antenna is mounted onto the mast. Then in-
stall the hex bolts and nuts. Do not tighten the hardware until the antenna is installed onto the mast.
•Remember to install and tighten the set screws after the antenna is mounted to the mast. This will help prevent the
antenna from twisting around the mast.
Key
QTY
Part Number
Description
A
8
10-1601-61
Saddle, 3”
B
8
60-0141
Hex Bolt, 5/16 x 5”
C
8
60-0046
Nut, 5/16, Nylock
D
3
60-0101-01
Pan Screw, #10-32 x 1” w/locking strip
E
4
60-0112
Set Screw, 10-32 x 1/4”

COAX SWITCH AND JUNCTION BOX ASSEMBLY
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H
H
C
F
F
E
E
B
G
A
G
E
D
E
D
View orientation
changed to more clear-
ly show the assembly!
•Apply blue Loctite to the 10-32 x .625” Pan Screws (H) before installing them in the threaded holes in the mounting
bracket.
•Be careful when tightening the hex bolts (D) as the mounting bracket will deform. Tighten just until the mounting
bracket square tube begins to bow inward.
•Note: you may need to shift the location of the coax switch and junction box assembly over one saddle if you chose
to mount the mast plate on the opposite side of the boom (relative to what is shown in this manual).
Key
QTY
Part Number
Description
A
1
10-1619-11
Coax Switch / Connector Junction Dual Mounting Bracket
B
1
70-2038
Connector Junction Box
C
1
70-3001-01
Coax Switch Box
D
2
60-0093
Hex Bolt, 5/16 x 2.75”
E
4
60-0033
Washer, 5/16
F
2
60-0046
Nut, 5/16, Nylock
G
2
60-0101-01
Pan Screw, #10-32 x .75”, w/locking strip
H
2
60-0113
Pan Screw, #10-32 x 0.625

COAX SWITCH WIRING
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•Locate the 4 conductor control cable and cut off a 3ft length. This cable will connect the coax switch box to the con-
nector junction box.
•Trim the cable jacket off (about 1.5” will suffice) and remove the foil. Be careful when removing the cable jacket—
too much pressure can cause damage to the other wires.
•Trim the reinforcing thread so that you end up with a cable end that looks like figure 10.05. Only three of the four
wires are used, along with the shield wire. The green wire needs to be trimmed as shown in figure 10.06.
•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

COAX SWITCH WIRING—CONTINUED
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FIG. 10.10
FIG. 10.11
•Figure 10.10 shows the wiring sequence for the coax switch. Be certain not to use terminal pin R4. This is the green
wire that was cut off in the earlier step.
•Always dip your bare copper wire ends into the provided connector protector before securing to the terminal connec-
tions. Insert wires as shown in figure 10.12.
•Form a knot in the control cable as shown in figure 10.13. This will serve nicely as a strain relief. Be careful not to
over-stress the control cable while forming your knot. Alternatively, a tie wrap works well.

SHIELD

BLACK

DO NOT USE

WHITE

RED
FIG. 10.12 FIG. 10.13
J5
⦸
COM
⦸
R4
⦸
R3
⦸
R2
⦸