SteppIR 80m Dipole Assembly Manual

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

80m Dipole

for the

Dream Beam 36

Assembly Manual

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

1

Inventory

check

QTY Part # Description

2 N/A 25’ Ultra Flex wire with inductance coil
1 60-0112

10-32 SS set screw
2 60-0075 5/16” X 3 1/4” SS hex bolt
2 10-1601-02 1 3/4” Solid Saddles
2 60-0046 5/16” Nylock Nuts
2 60-0028 1/4” X 2 1/4” SS hex bolt
2 60-0034 3/8” SS washer
2 60-0116 1/4” Regular nut
2 60-0030 1/4” Nylock nut

2 60-0094 3/16” SS Quick Link
2 60-0107 3/16” SS eyebolt with nut and washers

2 60-0111 10-24 Nylock nut for eye bolts
1 60-0117 Cable clip with adhesive back

2 10-1613-01 1” Aluminum spacers
1 10-1029-01 Connector Protector

80m coil Hardware kit Bag 1(Located in Antenna Box)

72-0028-01

80m coil Hardware kit Bag 2(Located in Antenna Box)

72-0028-11

Inventory

check

QTY Part # Description

2 10-1607-01 Truss attachment plate
2 N/A 25’ 3/16” Dacron rope
1 N/A 6’ RG 213 Jumper COAX cable
1 21-5001-01 30” 4 conductor control cable
1 09-0001 Electrical tape 66’ X 3/4”

1 20-6020-4

4 position terminal strip ( only used if Connector Box Option

was not purchased )

80m Dipole Parts

Inventory

check

QTY Part # Description

1 N/A 80m Dipole box with Lid (located in Antenna Box)
2 10-1054-01 30m/40m truss support (Located in Antenna Sweep Box)

2/05/2009 : Rev 3

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

STARTING ASSEMBLY

Notes:

The 80m dipole option is a wire dipole that runs above and parallel to the boom and then
connects to the reflector element center on one side of the dipole and to the director 2 on the
other. This forms an “H” shaped dipole shown below, where the two passive elements act as
large capacity hats that are tunable via the controller. The capacity loading is very efficient so
the DB 36 dipole is only -.7 dB below a full-sized dipole. The dipole wires connected to the
passive elements have no effect whatsoever on the performance of the antenna on other fre­quencies because the wires are connected at the zero current point in the center of the ele­ment.

Use the same starting notes that were given in the Dream Beam 36 manual. This
option should only be installed with the antenna down on the ground.

This Option is an add on to the DB 36 and can be installed after or during the buiding process
of the DB 36. Some hardware for installing the 80m Dipole will be used from the DB 36. Also
with the purchase of the 80m Dipole it includes 2 X 30m/40m truss option. Hardware from
both the truss kits and 80m dipole will be needed to complete the assembly.

Figure 11 on page 12 shows the complete layout of the 80m Dipole mounted on the DB 36.
Studing this Figure before assembling will help in understanding how the dipole is mounted
on the DB 36.

Refer to the 30m/40m truss manual for mounting the truss and truss support that will be
needed for the 80m dipole assembly.

2

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

3

MOUNTING 80M DIPOLE ANTENNA SWITCH

Locate 80m dipole antenna switch (located in Antenna box)

QTY 1 80m Dipole box with Lid (DO NOT MOUNT LID YET)

Locate 80m coil Hardware Kit Bag 1 72-0028-01 (located in Antenna box)

Follow Figure 1 for mounting the antenna switch.
Secure the SS Quick Links to the mounting plate of the antenna switch.
DO NOT attach the lid of the antenna switch, it will make wiring difficult and is almost impos­sible to take off once attached.
Make sure to mount the antenna switch so that the top of the saddles are 22 1/4” above the
top of the boom.

Figure 1

Mounting 80m Dipole Switch

DRIVEN RETURN

ELEMENT

DRIVEN ELEMENT

HOUSING

6M PASSIVE ELEMENT

BOOM TRUSS

BOOM TRUSS

QTY 2: 5/16” X 3 1/4” SS hex bolt

60-0075

22 1/4”

QTY 2: 3/16” SS Quick Link

60-0094

80m Dipole Antenna Switch

Connector Box Option

QTY 2: 5/16” Nylock nut

60-0046

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

MOUNTING DIPOLE ATTACHMENT POST / TRUSS SUPPORT

Locate the following parts for this assembly (located in Antenna Sweep box)

QTY 2 10-1054-01 30m/40m truss support

Locate 80m coil Hardware Kit Bag 1 72-0028-01 (located in Antenna box)
Locate 80m coil Hardware Kit Bag 2 72-0028-11 (located in Antenna box)

Notes:

Refer to your truss manual for assembling the truss support to the DB 36 boom. The
hardware will be in the truss hardware kit.
Once the truss supports are mounted to the boom, as shown in Figure 2 below and Figure 3
on the next page, the dipole mounting posts must be mounted.
Also mount the Truss Attachment Plates to the outside of the boom. These will be used to
anchor the 80m dipole rope. Use the existing mounting bolts on the EHU/ ERT for securing
the Truss attachment Plate

Figure 2

Installing Attachment Post and Plate

4

DIRECTOR 2 ELEMENT HOUSING

QTY 1: Truss

Attachment Plate

10-1607-01

DIRECTOR 2 RETURN SIDE

Bolts form DB 36 assembly

Nuts form DB 36

assembly

QTY 1: 1/4” Nylock nut

60-0030

QTY 1: 1/4” Regular nut

60-0116

QTY 1: 1” Aluminum Spacer

10-1613-01

QTY 1: 3/8” SS washer

60-0034

QTY 1: 1/4” X 2 1/4” hex bolt

60-0028 (Dipole Attachment Post)

QTY 1: 30m/40m Truss support

10-1054-01

15”

Hardware from the

truss option

Hardware from the

truss option

Element Return

Tube (ERT)

Element Support

Tube (EST)

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

5

Figure 3

Installing Attachment Post and Plate

REFLECTOR 2 ELEMENT HOUSING

QTY 1: Truss

Attachment Plate

10-1607-01

REFLECTOR 2 RETURN SIDE

Bolts form DB 36

assembly

QTY 1: 1/4” Nylock nut

60-0030

QTY 1: 1/4” Regular nut

60-0116

QTY 1: 1” Aluminum Spacer

10-1613-01

QTY 1: 3/8” SS washer

60-0034

QTY 1: 1/4” X 2 1/4” hex bolt

60-0028 (Dipole Attachment Post)

QTY 1: 30m/40m Truss support

10-1054-01

15”

Hardware from the

truss option

Hardware from the

truss option

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

DACRON ROPE INSTALLATION

Locate 80m coil Hardware Kit Bag 1 72-0028-01 (located in Antenna box)
Locate 80m coil Hardware Kit Bag 2 72-0028-11 (located in Antenna box)

Notes:

All rope terminations must be done with three half hitches and covered with electrical tape.
Melt the ends of the Dacron rope to prevent fraying.

For mounting the Dacron rope to the DB 36 work from either end of the boom to the
mast. Before securing the first end of the rope to the boom, you must first mount the induc­tance coil to the Dacron rope. This process is only possible while the rope is loose.

First mount the tension eye bolt to the truss mounting plate as shown in Figure 4A. Secure it
loosely by engaging 2-3 threads.
Slide the Dacron rope through the mounting holes in the inductance coil so that it will be posi­tioned as shown in Figure 4B.
Tie the short end of the Dacron rope to the Tension Eye Bolt using three half hitches.
Pull the rope very tight and wrap one turn around the Attachment Post. While continuing to
hold the tension tight run the rope all the way to the antenna switch and tie it to the Quick
Link as shown in Figure 6

Figure 4A and Figure 4B

Mounting the 80m Dipole for the Director 2 Element

6

4A

3/16” washer that

comes with eye bolt

4B

QTY 1: 3/16” SS Tensioning
eye bolt w/ nut and washers

60-0107

3/16” washer that

comes with eye bolt

QTY 1: 10-24 Nylock nut

60-0111

Wrap the Dacron rope
around the attachment

post once

Tape

Tape

15”

4” spacing for con-

ductor wire from

truss support

Secure lug to brass terminal

on the back the side of the

housing. Weather proof with

Coax-Seal or equivalent

Wrap 3 times per ft

Keep plenty of threads

to allow for tighting

Dacron Rope

Rope must be

between the spacer

and washer

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

7

First mount the tension eye bolt to the truss mounting plate as shown in Figure 5A. Secure it
loosely by engaging 2-3 threads.
Thread the dacron rope through the inductance coil before securing the rope to the thimble
on the boom truss.
Run the rope up and over the attachment post then down through the tensioning eye bolt. Once
through the eye bolt the Dacron rope must be ran back up to the attachment post. Wrap the Dacron
rope completely around the attachment post and then continue on to the antenna switch while
keeping tension on the rope. Secure the rope to the Quick Link using three half hitches

Figure 5A and Figure 5B

Mounting the 80m Dipole for the Reflector Element

5A

3/16” washer that

comes with eye bolt

QTY 1: 3/16” SS Tensioning
eye bolt w/ nut and washers

60-0107

3/16” washer that

comes with eye bolt

QTY 1: 10-24 Nylock nut

60-0111

5B

Wrap Dacron rope

around bolt once

Tape

Tape

15”

4” spacing for con-

ductor wire from

truss support

Secure lug to brass

terminal and weather

proof with COAX seal

Wrap 3 times per ft

Keep plenty of threads

to allow for tighting

Dacron Rope

Wrap once completely

around the attachment post

Rope must be

between the spacer

and washer

Tie the Dacron rope to the
thimble on the boom truss

with 3 half hitches and

cover with electrical tape

This portion of the Dacron

rope simply lays over the
bolt, between the washer

and standoff

BOOM TRUSS

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

Figure 6

Securing the rope to the Antenna Switch

Notes:

Pull the rope tight to the quick links and terminate using three half hitches and cover with
electrical tape. To completely tighten the rope go to either ends of the boom and tighten
down the eye bolts completely. Tighten the regular nut to the truss plate to lock the eye bolt in
place.

Once the dacron rope has been secured to the Quick Links at the antenna switch finish wrap­ping the 80m dipole conductor around the dacron rope. Wrap the conductor approximately 3
times around the dacron rope per foot. This will prevent any sagging of the conductor.

Make sure to tighten the brass nut on the Element Housing Units and weather proof with
Coax-Seal or equivalent.

The next step will be to connect the conductors to the antenna switch box.

8

Pull Dacron rope tight and secure to the Quick Links

(60-0094) with 3 half hitches and cover with electri-

cal tape. Cut the extra rope and use a lighter to melt

the ends of the rope to prevent from fraying.

Note:

Once the Dacron rope is secured to
the Quick Links (60-0094), go to either
ends of the boom and tighten the ten­sioning eye bolts as tight as they will
go.

BOOM TRUSS

BOOM TRUSS

DRIVEN ELEMENT

HOUSING

6M PASSIVE ELEMENT

Dacron rope from truss support

Dacron rope from truss support

DIR 1

DIR 2

REF

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

9

CONNECTING DIPOLE CONDUCTOR TO ANTENNA SWITCH

Locate 80m coil Hardware Kit Bag 2 72-0028-11 (located in Antenna box)

Notes:

The figures are showing the Dream Beam 36 with the 80m dipole option along with the
connector box option. If the connector box option was not purchased then the antenna
came with the terminal housing tube. This tube can be mounted in a variety of places and
will work fine with the provided 80m dipole option

Always use the provided Connector Protector when securing wires, this will prevent corrosion.

Refer to Figure 7 for correct installation of the 80m dipole conductor.
Insert the Blue Ultra Flex wire through the grommets on the side of the 80m Dipole switch.
The conductor on the Director 2 side of the dipole will be inserted into the top grommet. The
conductor on the Reflector side of the dipole will be inserted into the bottom grommet.
Refer to Figure 8 for wiring the 80m dipole if you do not have the connector box option.
Refer to Figure 9 for wiring the 80m dipole if you have the connector box option.

Figure 7

80m Dipole Conductor Configuration

Mount the cable clip

to the top of the 80m

dipole lid

Tape

Coax jumper RG213 plugs into the “OUT”

on the antenna switch. The Coax from

the tower plugs into the “IN” on the anten-

na switch.

30” 4 conductor cable

from the connector

box the the Antenna

switch.

Wind conductor towards

the antenna switch

Wind conductor towards

the antenna switch

Table cable to

mast

Notes:

Refer to Figure 10 for wiring
antenna switch

Tape

Tape

REF

DIR 2

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

Figure 8

Wiring Diagram for non connector box instullations

Figure 9

Wiring Diagram for connector box instullations

10

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

11

CONNECTING COAX JUMPER

Locate the 6 ft Coax jumper from 80m coil Hardware Kit Bag 2 72-0028-11

Notes:

Make sure to tighten all COAX connectors very snug and weather proof with either electrical
tape or Coax-seal or equvalent.

Tape down all cables to prevent sagging. DO NOT kink or curve the cable to a radius pf less
than 3”. Allow for natural bends and secure cables to the boom or mast of the antenna.

Plug the 6 ft COAX jumper from the driven element on the DB 36 to the “OUT” plug on the
80m dipole Antenna Switch.
Plug the COAX cable coming up the tower in the “IN” plug on the 80m dipole antenna switch.
Refer to Figure 10 for correct installation.
Once wiring has been completed inside the 80m dipole antenna switch secure the lid to the
antenna switch housing. The lid should close in a downward motion if installation has been
done correctly. Refer to Figure 7 for applying the cable clip onto the lid of the antenna switch.

Figure 10

Wiring Diagram for 80m Dipole switch, Front & Back

FRONT

30” 4 conductor
cable will go to the
connector box option
or terminal housing.
2 conductors from
the cable will not be
used.

Coax jumper that was
provided will go out to
Driven Element housing.

Coax line coming in
from tower and shack

BACK

Director 2 Element Housing

Reflector Element Housing

Notes:

The Blue Ultra Flex wire will need to be trimmed
before wiring to the 80m Dipole Antenna switch.
Figure 7 shows the correct layout of the conductor
at the antenna switch. The wires MUST be wired as
shown or the dipole will not work properly.

Tighten all COAX connectors with pliers to assure
good connection.

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]

12

Figure 11

80m Dipole Full Layout

80m Dipole Full Layout

Reflector Driven Director 1 Director 2

80m Dipole

Truss Support

Inductance Coil

80m Dipole

Switch

Connector Box

Option

Truss Support

Truss Support

Inductance Coil

80m Dipole

Boom Truss

Boom Truss

2112 116TH AVE NE SUITE 1-5, BELLEVUE WA, 98004 WWW.STEPPIR.COM TEL: [phone] FAX: [phone]