MonstIR
INSTALLATION INSTRUCTIONS
SteppIR Antennas
2112 - 116th Ave NE, Suite 2-5 - Bellevue, WA 98004
Tel: 425-453-1910 Fax: 425-462-4415
Tech Support: 425-891-6134
www.steppir.com
Revision 08/04/08
SteppIR Antennas — MonstIR
Abbreviations
EHT Element Housing Tube
EHU Element Housing Unit
EST Element Support Tube (pole)
FCC Flexible Connection Coupler (rubber)
EHT
2
FCC
EHU
EST
SteppIR Antenna Information Web Sites (as of 4/09/07)
http://steppir.com/
http://groups.yahoo.com/group/steppir/
SteppIR Antennas — MonstIR
3
SteppIR - Why Compromise?
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 between 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 diminishing returns.
Obviously, an antenna that is precisely adjustable in length while in the air would
solve the frequency problem, 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 product.
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,
Mike Mertel
Michael (Mike) Mertel - K7IR
President
SteppIR Antennas — MonstIR
4
SteppIR Design
Currently, most multi-band antennas use traps, log cells or interlaced elements as a means to cover several frequency bands. All of these methods have one thing in common–they significantly compromise
performance. The SteppIR™ antenna system is our answer to the problem. Yagi antennas must be
made a specific length to operate optimally on a given frequency.
So, instead of trying to “trick” the antenna into thinking it is a different length, or simply adding more
elements that may destructively interact, why not just change the antenna length? Optimal performance is then possible on all frequencies with a lightweight, compact antenna. Also, since the SteppIR
can control the element lengths, a long boom is not needed to achieve near optimum gain and front to
back ratios on 20 - 10 meters.
Each antenna element consists of two spools of flat copper-beryllium tape conductor (.54” Wide
x .008” Thick) mounted in the element housing unit. The copper-beryllium tape is perforated to allow
a stepper motor to drive them simultaneously with sprockets. Stepper motors are well known for their
ability to index very accurately, thus giving very precise control of each element length. In addition,
the motors are brushless and provide extremely long service life.
The copper-beryllium tape is driven out into a hollow fiberglass elements support tube (see below),
forming an element of any desired length up to the limit of each specific antenna model (a vertical uses
only one side). The fiberglass elements support tubes (poles) are telescoping, lightweight and very durable. When fully collapsed, each one measures approximately 57” in length. Depending on the
model, there may be additional extensions added to increase the overall element length.
The ability to completely retract the copper-beryllium antenna elements, coupled with the collapsible
fiberglass poles makes the entire system easy to disassemble and transport.
The antenna is connected to a microprocess
that offers numerous functions including dedicated buttons for each ham band, continuous
frequency selection from 80m to 6m (depending on the model). There are also 17 ham and 6
non-ham band memories and you can select a 180° direction reversal* or bi-directional*
mode and it will adjust in just about 3 seconds (* Yagi only).
Copper-Beryllium Tape
or-based controller (via 22 gauge conductor cable)
Element Support Tube
Stepper Drive Motor
Boom
Copper Beryllium Tape
Element Housing Unit
SteppIR Antennas — MonstIR
5
JÜRG DR. REGLI (HB9BIN)
SWITZERLAND
SteppIR Antennas — MonstIR
6
Table of Contents
Topic
Abbreviations
Why Compromise
SteppIR Design
Table of Contents
Parts List 7
Word of Caution 12
Installing Boom to Mast 13
Boom Assembly 15
Element Bracket Assembly 18
Install the Boom Truss 22
Page
2
3
4
6
Element Truss Assembly 25
Assemble 70’ Elements 26
Wiring Elements 30
Prepare the Telescoping Fiberglass Element Support Tubes (EST) 35
Installing the Fiberglass Element Support Tubes (EST) 38
Installing Element Trusses 39
6m Passive Element Installation (Optional) 40
SteppIR Performance Topics 42
SteppIR Warranty 45
HB9BIN Assembly Crew
SteppIR Antennas — MonstIR
7
ITEM QTY SIZE
BOX 1
BOX 2
BOX 3
BOX 4
BOX 5
BOX 6
BOX 7
BOX 8 +
1 36x19x12 ELEMENT BOX
1 19x19x6 MASTER PLATE BOX
1 60x3x6 TELESCOPING POLE BOX
1 81x11x7 BOOM BOX
1 108x6x4 FIBERGLASS POLE BOX
1 108x6x4 FIBERGLASS POLE BOX
1 60x3x6 OPTIONAL 6M PASSIVE BOX
? ? ANYTHING ADDITIONAL
DESCRIPTION
PART
ITEM QTY
IN BOX 1
1
1 72-0009-03 GLUE KIT (CPVC - PRIMER / GLUE)
1
2
1
2
1
NUMBER
BRACKET ASSEMBLY
3 10-1405-01 ELEMENT SUPPORT PLATE (FOR 40m ELEMENTS)
3 70-1414-11 TRUSS ASSY, ELEMENT SUPPORT (“A” FRAME)
3 10-1416-L TRUSS ASSY, ELEMENT CENTER SUPPORT (LEFT)
3 10-1416-R TRUSS ASSY, ELEMENT CENTER SUPPORT (RIGHT)
MAST PLATE ASSEMBLY
2 10-1021-31 15” x 15” MAST PLATE
4 60-0027 1/4-20 x 1” SS BOLT
4 60-0030 1/4-20 SS NYLOK NUT
MonstIR INSTALLATION MANUAL
OPERATORS MANUAL
SteppIR STICKERS
40M ELEMENT HOUSING UNIT (DRIVEN)
40M ELEMENT HOUSING UNIT (PASSIVE)
16 CONDUCTOR CONTROL CABLE
DESCRIPTION
BOOM TRUSS MAST — ASSEMBLED & STRETCH-WRAPPED
1 10-1430-01 BOOM TRUSS MAST (1-3/4 x 32”)
1 60-0065 5/16-18 x 3-1/2" SS BOLT
4 60-0034 5/16" WASHER
1 60-0046 5/16-18 SS NYLOK NUT
2 60-0070 3/8-16 x 6” GALVANIZED TURNBUCKLE (BOOM TRUSS)
SteppIR Antennas — MonstIR
8
PART
ITEM QTY
IN BOX 1
NUMBER
DESCRIPTION
MAST PLATE ASSEMBLY
BAG 1 72-0010-01
1 60-0085 3/8-24 x 3” SS THREADED BOLT
3 60-0050 3/8-24 SS NYLOK NUT
4 60-0034 3/8" SS WASHER
BAG 2 72-0010-02
2 60-0007 2-3/4" U-BOLT & SADDLE
4 60-0050 3/8-24 SS NYLOK NUT
BAG 3 72-0010-03
2 1-3/4” U-BOLT (3-5/8” LONG REACH)
2 1-3/4" U-BOLT SADDLE
4 60-0046 5/16" SS NYLOK NUT
BAG 4 72-0010-04
16 60-0045-14 1/4” WIRE CLIP (FOR PHILLYSTRAN - BOOM TRUSS)
4 60-0073 5/16” THIMBLE
4 60-0044-20 1/4” PLASTIC END CAPS (FOR PHILLYSTRAN)
BAG 5 72-0010-05
1 10-1102-21 CONTROL WIRING TERMINAL PROTECTIVE HOUSING
2 60-6000-40 HOSE CLAMP (4”)
2 20-6016-8 8 - POSITION TERMINAL STRIP
1 20-6016-1 1 - POSITION TERMINAL STRIP
2 10-1029-01 CONNECTOR PROTECTOR (CREAM - IN BLUE POUCH)
BAG 6 72-0010-06
4 10-1421-01 2" SADDLE (SOLID) - WITH CENTER HOLE
4 60-0072 #10-32 x 1” SS PAN-HEAD SCREW
4 60-0019 #10-32 SS NYLOK NUT
4
2" U-BOLT ONLY (4” LONG REACH)
8 60-0046 5/16-18 SS NYLOK NUT
IN BOX 1
1 60-0035-10 3/8” x 151" PHILLYSTRAN (FOR BOOM TRUSS)
1 60-0035-10 3/8” x 164” PHILLYSTRAN (FOR BOOM TRUSS)
SteppIR Antennas — MonstIR
PART
ITEM QTY
IN BOX 1
NUMBER
POLE ASSEMBLY HARDWARE
BAG 1 72-0012-01
6 10-1114-01 COUPLER (3/4" CPVC)
BAG 2 72-0012-02
12 10-1429-21 ELEMENT TRUSS CLAMP HALF
24 60-0027 1/4-20 x 1” SS BOLT
24 60-0030 1/4-20 SS NYLOK NUT
BAG 3 72-0012-03
6 60-0004-01 2" U-BOLT (3.5” LONG REACH) w/ SADDLE
12 60-0046 5/16-18 SS NYLOK NUT
BAG 4 72-0012-04
6 60-1006-01 QUICK DISCONNECT BOOT (1.5" TO 1.25") (FERNCO)
BAG 5 72-0012-05
2 60-1006-01 QUICK DISCONNECT BOOT (1.5" TO 1.25") (FERNCO)
6 60-1006-21 QUICK DISCONNECT BOOT (1.5" TO 1.25") (MISSION)
BAG 6 72-0012-06
2 09-0003 SILICONE TAPE (20-FT ROLL)
1 09-0004 SILICONE TAPE (10 FT ROLL)
2 09-0001 ELECTRICAL TAPE (3/4” x 66’ ROLL)
6 60-0008 #2 x .25 COUPLER SCREW (INSTALLS AT THE HOUSING)
BOOM ASSEMBLY HARDWARE
72-0015-03 BOOM TRUSS MAST ASSEMBLY
BAG 3 60-0037 5/16-18 x 4-3/8” GALVANIZED EYEBOLT
1 ANTI-SEIZE (IN SYRINGE)
3 60-0067 3/8-16 x 4-1/4” SS BOLT
3 60-0050 3/8-16 NYLOK NUT
60 60-0041 1/4” FLAT WASHER
9 60-0091 1/4-20 x 3-3/4” SS BOLT
6 60-0100 1/4-20 x 3-1/2” SS BOLT
15 60-0030 1/4-20 SS NYLOK NUT
3 60-0046 5/16-18 NYLOK NUT
6 60-0034 3/8” FLAT WASHER
DESCRIPTION
9
SteppIR Antennas — MonstIR
PART
ITEM QTY
IN BOX 2
BRACKET HARDWARE
BAG 1 72-0011-01
12 10-1406-11 2-1/8” SADDLE (MACHINED SOLID-SHORT)
12 60-0067 3/8-16 x 4-1/4” SS BOLT
12 60-0050 3/8-16 SS NYLOK NUT
BAG 2 72-0011-02
12 10-1406-21 2-1/8” SADDLE (MACHINED SOLID-TALL)
12 60-0067 3/8-16 x 4-1/4” SS BOLT
12 60-0050 3/8-16 SS NYLOK NUT
BAG 3 72-0011-03
18 60-0068 1/4-20 x 1” SS FLATHEAD PHILLIPS SCREW
3 60-0053 1/4-20 x 2.5” SS BOLT
6 60-0078 1/4-20 x 1.75” SS BOLT
27 60-0030 1/4-20 SS NYLOK NUT
12 60-0034 1/4” SS WASHER
BAG 4 72-0011-04
6 60-0083 1/4-20 x 4” SS TURNBUCKLE (FOR ELEMENT TRUSS)
BAG 5 72-0011-05
6 60-0035 3/16” x 14’ PHILLYSTRAN (FOR ELEMENT TRUSS)
BAG 6 72-0011-06
48 60-0045 3/16” WIRE CLIP (FOR PHILLYSTRAN - ELEMENT TRUSS)
12 60-0048 3/16” THIMBLE
12 60-0044 3/16” PLASTIC END CAP (FOR PHILLYSTRAN)
BAG 7 72-0011-07
8 60-0061 #10-32 x 7/8” PAN-HEAD PHILLIPS SCREW
18 60-0072 #10-32 x 1-1/4” PAN-HEAD PHILLIPS SCREW
16 60-0017 #10-32 x 3/4” PAN-HEAD PHILLIPS SCREW
26 60-0018 #10 SS WASHER
42 60-0019 #10-32 SS NYLOK NUT
IN BOX 3
1
1
1
1
8 10-1013-01 TELESCOPING POLE (18 FOOT - 4 SEGMENT - FIBERGLASS)
NUMBER
10
DESCRIPTION
20M ELEMENT HOUSING UNIT (PASSIVE)
CONTROLLER
POWER SUPPLY (FOR CONTROLLER)
“T” SHIRT (FOR YOU)
SteppIR Antennas — MonstIR
PART
ITEM QTY
IN BOX 4
BOOM ASSEMBLY
NOTE:
2 10-1425-01 2.75" x 72” SECTION
2 10-1426-01 2.5" x 72” SECTION (END)
1 10-1426-11 2.5" x 72” SECTION
1 10-1426-21 2.5" x 63” SECTION
2 10-1428-01 2.25" SPLICE
1 10-1427-01 2.5" SPLICE (CENTER)
1 10-1017-51 BRACKET (FOR 20m PASSIVE)
3 10-1404-01 BRACKET (FOR TRUSS ASSEMBLY)
9 60-0067 3/8-16x4 1/4” SS BOLT
9 60-0050 3/8-16” SS NYLOK NUT
6 60-0029 1/4-20 x 3” SS BOLT
12 60-0063 1/4-20 x 3-1/4” SS BOLT
2 60-0032 1/4-20 x 3-1/2” SS BOLT (20m BRACKET)
11 60-0030 1/4-20” SS NYLOK NUT
2 10-1430 2.5-MIR BOOM COUNTERWEIGHT
5 60-0091 1/4-20x 3/4” SS BOLT
36 60-0041 1/4” FLAT WASHER
12 60-0100 1/4-20x3 1/2” SS BOLT
9 60-0102 3/8-16x3/4 TYPE FTCS BLACK OXIDE BOLT
18 60-0034 3/8 FLAT WASHER
IN BOX 5&6 ==> ** BOX 5 & 6 HAVE IDENTICAL CONTENTS **
2 in. FIBERGLASS TUBE ASSEMBLY
6 10-1408-02 FIBERGLASS ELEMENT SUPPORT TUBE
6 10-1407-11 ELEMENT PROTECTION SLEEVE (2.1” x 3.75” ALUMINUM)
6 10-1407-21 ELEMENT PROTECTION SLEEVE (2.1” x 2” ALUMINUM)
6 10-1409-01 SPLICE (2” TO 1.75”)
1.75” FIBERGLASS TUBE ASSEMBLY
IN BOX 7
1 6-METER PASSIVE KIT - SHORT (104.5”) (OPTIONAL)
6 10-1411-01 1.75” x 99” FIBERGLASS ELEMENT SUPPORT TUBE
6 10-1410-01 SPLICE (1.75” TO 2”)
6 10-1034-21 EST RING (.4”)
6 10-1412-02 ELEMENT GUIDE INNER (3/4” x 105.5” CPVC W/COUPLER)
6 10-1413-01 ELEMENT GUIDE CHAMFERED (3/4” x 102” CPVC)
1 6-METER PASSIVE KIT - LONG (112.0”) (OPTIONAL)
NUMBER
72-0024-05 BOOM ASSEMBLY (6 PRE-ASSEMBLED SUB-SECTIONS)
MOST HARDWARE BELOW IN PRE-ASSEMBLED SUB-ASSEMBLIES
DESCRIPTION
11
SteppIR Antennas — MonstIR
12
Word of Caution
Be Careful to avoid making contact with power lines or
other potential hazards when constructing, moving and
installing the antenna, as you could be seriously injured or
even killed if a metal object comes in contact with high
voltage.
Assembling the Antenna
It is highly recommended that you read these assembly instructions in their entirety before
assembling the antenna. Doing so will provide you an overall idea of what needs to be done
and helps avoid making time-consuming mistakes. Building your SteppIR is a
straightforward process. It entails:
● Lubricate all fasteners ¼” or larger with anti-seize grease (in syringe)
● Determine how you will raise the antenna.
● Assembling the boom-to-mast plate and mounting it to a temporary mast.
● Assembling the boom.
● Attach the boom to the boom-to-mast plate.
● Assemble three large element brackets.
● Attach four element housings and routing control lines.
Methods to Raise the Antenna
The MonstIR is to be raised with the boom to mast plate attached. To facilitate easy
attachment to the mast on the tower the 2” u-bolt saddles are bolted to the mast plate so all
you have to do is slip on the four u-bolts and install the nylock nuts. The boom truss is
supported by a provided 1 ¾” O.D. x 32” aluminum tube that is attached with u-bolts to the
mast plate. This allows you to mount the antenna at the very top of your mast and raise the
antenna completely assembled. There are many ways to raise an antenna so this is just a
suggestion, however we have found it to work very well. So if you like our method, follow
the instructions as they appear.
SteppIR Antennas — MonstIR
Installing Boom to Mast
● Erect a temporary mast that is about 4 feet tall to build the antenna on.
Picture 1
ways to tempo- rarily mount the mast
during assem- bly. We strongly recommend against building it laying flat on the ground. You will ding
up the element housings and you won’t
be able to ad- just the trusses correctly. The mast must be strong
enough to hold the 260 lb antenna
safely, even when it is slightly unbalanced. You could use one leg of
your tower if you have adequate
room around it or bury a 2” pipe about
3 feet into the ground and pack soil tightly around it.
The mast plate consists of two identical pieces, each 15” x 15” x .250” thick and
comes already bolted together. The mast plate has 33 pre-drilled holes. The four 2”
u-bolt holes are used to secure the antenna to the mast on your tower. The optional
pilot holes are there in the event you are using a 2-1/2” mast. If you are using a 2”
mast, these holes are left unused. The two 2¾” u-bolts are used for attaching the
boom to the mast plate. (Picture 2 & Picture 3)
• The Ez-eye is shown highlighted in Picture 3, near the middle of the mast plate.
This system serves two purposes;
• The primary purpose is to positively secure the boom to the mast plate prevent-
ing any rotation of the boom during high winds.
• The second is to allow precise leveling of the antenna before tightening the 2 ¾”
u-bolts that secure the boom.
See Picture 4 and Picture 4.1 for details on mounting the 3/8”x3” bolt, the three 3/8”
Nylok nuts, and the four 3/8” flat washers. Install just the 3/8”x3” bolt as shown before mounting the mast plate to the temporary mast.
Picture 1
shows one of many
13
SteppIR Antennas — MonstIR
• Locate: 4 - 2” aluminum saddles
4 - #6-32x1” machine screws
4 - #6-32 Nylok nuts
Mount the saddles as shown in Picture 2. Be aware that the mast saddles mount on the
opposite side from the boom.
2” U-Bolt Saddles
14
Picture 2
Attach the Boom-to-Mast Plate to the Temporary Mast
NOTE: Take the time now to make sure all of the 2” u-bolts will easily fit the mast plate
holes, bend as required, you will be glad when you are up on the tower!
Mount the assembled plate to your temporary mast, as shown in Picture 3, at a convenient
height for assembly purposes using the four 2” u-bolts. Pay attention to the orientation when
mounting it, as the plate is not symmetrical.
1-3/4” Truss Mast
EZeye
Adjust
2-3/4” Boom
U-bolts
Picture 3 2” Mast
SteppIR Antennas — MonstIR
15
Picture 4
Picture 4.1
Boom Assembly
The boom was completely assembled and drilled and marked at the factory to assure
precision element alignment. You may notice in some cases that on a given splice ( Picture
4 .5) the holes on each side of the splice are at 90 degrees with each other. This is as designed and not a mistake. The pre-drilled holes are quite snug and align almost perfectly.
The holes are purposely tight so no movement is allowed. Movement will cause work
hardening and that leads to boom failure. Therefore, DO NOT drill out the holes for more
clearance. Thread the bolt in as far as possible, then lightly tap with a hammer to seat the
bolt.
If the holes are visibly out of alignment when you are assembling the boom, you probably
have the boom pieces put together in the wrong order – or the boom sections that do not have
an element bracket on them may need to be rotated 180 degrees. Each boom piece has a
number permanently written, scribed or stamped on it. Match each number with the exact
same number of a corresponding boom piece. Picture 4.5 shows joint # 1 markings inside
the ring (they must line up). Figure 1 shows how each boom section is numbered.
Picture 4.5
SteppIR Antennas — MonstIR
Figure 1
JOINT NUMBER BOLT SIZE QUANTITY
1 ¼” x 20 x 3.5 “ 6
2 ¼” x 20 x 3.75” 3
3 ¼” x 20 x 3.75 “ 6
4 ¼ “x 20 x 3.75 “ 3
5 ¼” x 20 x 3.5 “ 6
TABLE 1
16
Figure 1.2
Counter-Weight
Bracket (1)
3/8-16 x 3/4 Type FTC Black Oxide Self Tapping Bolts
Standard Bracket (2)
Zip Ties
3/8-16 x 4-1/4 SS Bolts
3/8-16 x 4-1/4 SS Bolts
New Element Bracket Mounting
We have modified the hardware securing the (3) 40m element mounting brackets to the
boom on your new MonstIR antenna (Figure 1.2) as of August 2007.
Counter-Weight Bracket (1):
• Remove zip ties
• Make sure counter-weights clear the hole
• Position vertical truss supports
• Install the included bolt / no washer
• Put ’Connector Protector’ on the threads
• Tighten the nut securely
Standard Bracket (2):
• Position vertical truss supports
• Install the included bolt / no washer
• Put ’Connector Protector’ on the threads
• Tighten the nut securely
417
SteppIR Antennas — MonstIR
404
220
130
DVRReflector
90
35.00
184
103.0
Director 1
17
Director 2
MAST
6M option
DIR 3
112"
Turning Radius = 39.8 Feet
07/14/06 Revised for 112" 6m passive
28
69-6 fee t
6M option
DIR 4
104.5"
Figure 2
Refer to Table 1 for selecting proper bolt sizes for each respective connection. A socket
wrench is a better choice because the Nylok nuts can’t be hand turned so it’s a lot more labor
intensive without the socket wrench.
1. You will probably find that it is easiest to build the boom on the ground as opposed
to mounting it on the temporarily mounted boom to mast plate. Locate and position
the six sections of boom tubing and the respective fasteners.
It is advisable to spray a small amount of WD40 or apply a thin film of anti-seize
grease (provided) around the circumference of all male boom splice pieces and on 6”
of the 2 1/2” tube that slides into the 2 ¾” tube at joints 2 and 4 before sliding the female sections over them.
Do NOT twist the aluminum tubing excessively as that can cause binding.
Apply some anti-seize lubricant to the insides of all the nuts prior to assembly. As-
semble the boom by sliding the six sections together in the order shown in Figure 1.
Insert the required bolts into the holes and loosely attach them with the ¼” Nylok
nuts. Note that, in some cases you may find it necessary to assist the bolts that you
are installing by “threading” them in with a wrench. DO NOT attempt to hammer
them into place, you can lightly tap the bolts in after threading them in as far as possible.
SteppIR Antennas — MonstIR
NOTE: The boom section with the number “1” engraved on it has two 3 lb. counter
weights in the end of it to make the weight center and provide zero mast torque
near the same point on the boom.
2. Orient the vertical bolts so the heads are pointing skyward as shown in Picture 4.8.
This prevents chafing of the boom truss on joints 1 and 5 and if the nuts did ever
come off, gravity would keep the bolts in place.
3. There are also three holes 5/16” in diameter and three 5/16” eye bolts. Two are for
the boom truss and the third is for the EZ-eye feature that is explained in a later section. The eye of the bolt goes on the topside of the boom with the Nylok nut on the
bottom side (Picture 4.8).
4. After assembling each of the five joints as shown in Fig 1. Tighten the nuts on each
bolt and eye bolt securely. Before continuing to the next step, verify that all nuts and
bolts, including those installed at the factory, are securely tightened.
Element Bracket Assembly
1. Mount the assembled boom upside down on the mast plate as shown in Picture 5 us-
ing two 2 ¾” u-bolts. Apply anti-seize to the two U-bolts and lightly tighten. The
boom will be rotated into the correct position, after the element plates and element
housings have been installed.
Picture 4.8
18
Picture 5
Picture 5.5
SteppIR Antennas — MonstIR
2. Picture 5.5 shows how the element will look when complete and right side up.
3. Mount the three large element plates oriented as shown in Figure 2 using six ¼” x 20
x 1” flat head bolts. Tighten securely.
NOTE: If the mounting holes for the element plates do not line up with the holes in the
element bracket it may be necessary to loosen the horizontal bolts that hold the element bracket to the boom. After mounting the element plates to the element
bracket be sure to re tighten the element bracket bolts.
4. Each element plate has eight machined U-saddles mounted to them. There are two
types of saddles, notice the difference in height of the semi-circle cutout. One is
much lower than the other. Mount the saddles as shown in Picture 6 & 7 on all three
of the large element plates.
There are two saddles used at each of the four position, one must be a “low” one and
one must be a “high” one, never two of the same together. Refer to Picture 6 for
proper assembly. Use eight 3/8” x 16 x 4-1/4” bolts to assemble the saddles and truss
support bracket as shown in Picture 7. Tighten the nuts only enough to keep them
from falling off.
19
Picture 6
Picture 7
SteppIR Antennas — MonstIR
20
5. When assembling the element housings:
• Before mounting the 40m element housings (Figure 3) make sure each one has two rubber
boots installed as shown in Picture 7.4.
• The 20m housing (Figure 4) rubber boots will be installed with the 18’ telescoping poles
Picture 32.
• Remove any packing material in the back of each element housing.
• Do a visual check to verify nothing looks out of order.
• Using the “A” screws install the gasket and back cover on each housing.
• Mount the three 40m element housings to the element plates making sure they are oriented
correctly as shown in Picture 7.4 using the “B” & “C” screws.
• Mount the 20m element housings (Dir 1) to the small element bracket. (Ref Figure 2)
• Tighten securely.
Note: The Director 1 element plate can be mounted two ways, the correct position puts the
element support tubes closest to the mast plate, see Figure 1 & 2. The #10-32 screws
do not need anti-seize lubricant, they have special lubricated nuts.
40m Element Housing Installation
A
C
Figure 4
A
B
A
Figure 3
==> 10-32 X 3/4
A
(60-0017)
==> 10-32 X 1-1/4
B
(60-0072)
A
20m Element Housing Installation
==> 10-32 X 7/8
C
(60-0061)
SteppIR Antennas — MonstIR
6. At this time complete the assembly of the Ez-eye by first installing a 3/8” Nylok nut
then two 3/8” flat washers on the 3/8”x3” Ez-eye bolt, as shown in Picture 4.1.
7. Then loosen the two 2 ¾” u-bolts and rotate the boom to its right side up orientation
(element housings are on the underside of the boom). You may need to loosen the 2
¾” u-bolts a bit to get the Ez-eye bolt to go into the eye bolt Put the last two 3/8” flat
washers on the bolt and then a 3/8” Nylok nut Picture 4.1. Roughly adjust the boom
to level by alternately turning the two 3/8” nuts on the Ez-eye. Final adjustment can
be made on the tower to insure the antenna is level and then securely tighten both
nuts against the eye bolt when done.
8. Install the two aluminum vertical element truss angles as shown in Picture 7.5. The
bottom of the support angles are attached using the middle hole and it's 3/8-16 x 4-
1/4” bolt that holds the element bracket to the boom (Ref. Figure 1.2). The top is
bolted to the element truss support with a 1/4-20 x 1-1/2” bolt. Repeat for the other
two large brackets.
NOTE: Director 2 has a zip tie installed in the center hole to keep the two counter-weights
from sliding out of position and blocking the bolt hole so keep the boom level when
doing Director 2. After removing the zip tie you may need to separate the counter
weights using a thin screwdriver to allow clearance to install the 3/8-16 x 4-1/4”
center bolt. This bolt will need some effort to install. You will need to thread it
through the first side of the bracket/boom then tap it across to the other side of the
boom tube and thread it through the second side. Then tap it in all the way put a
small amount of ‘Connector Protector’ on the threads and install and tighten the
Nylok nut (no washer required).
Picture 7.4
21
Picture 7.5
SteppIR Antennas — MonstIR
22
Install the Boom Truss
Locate:
● Four ¼ in. galvanized thimbles
● Sixteen ¼ in. galvanized cable clips
● Two galvanized turnbuckles
● Two 5/16 x 18 x 4 galvanized eye bolts with Nylok nuts
● One 5/16 x 18 x 3 ½ bolt and Nylok nut
● Four 3/8 flat washers
● One 1 ¾ in. OD x 32 in. boom truss mast
● Two 1 ¾ in. u-bolts
● One 151 in. length and one 164 in. length of ¼ in. non-conductive
Phillystran Kevlar cable.
1. Mount the truss mast using the 1 ¾ in. u-bolts as shown in Picture 3 and Figure 1.
2. Using a vise, as shown in Picture 8, press the thimble onto the eye bolt Press the
thimble back together as close as possible once it is through the eye bolt Repeat the
procedure to attach a thimble to one end of a turnbuckle (Picture 9).
Picture 8
Attach the four cable clips to the Phillystran, with the first one as close to the end of
the thimble as possible so the cable will be “locked” in. Attach three more
approximately 1” apart as shown in Picture 9.
You will want to thread the Phillystran into the cable clip exactly as shown in Picture
10, the saddle must be as shown for the clamp to function properly.
Picture 9
SteppIR Antennas — MonstIR
Picture 10
23
The two truss cable halves are different lengths, one is 142” and the other is 129”, both are
to be plus or minus .5” for the tolerance. They are measured from the ends of the thimbles,
not the ends of the captivated eye bolt or turnbuckle. Use the 151” Phillstran to make the
129” truss cable half, the loop back length will be about 10”. Use the 164” Phillstran to
make the 142” truss cable half, the loop back length will also be about 10”.
Warning: Do NOT completely tighten the wire clips until you have double checked that
the lengths are correct, because once the clips are fully tightened the
jacket is deformed so much it will expose the kevlar to sunlight if the
clip is moved.
A good way to check the cable length is to place supports under each end of the boom so the
boom is not sagging but fairly straight and temporarily attach each truss half cable to ensure
it is the right length. Do not put the truss under any strain until the clips are all tight.
The nuts may now be tightened to approximately 8ft-lbs of torque each. This cannot be
accomplished by holding the clamp and Phillystran in your hand, you will need some small
jawed vise grips or a portable vise. A ¾” wrench works even better as shown in Picture 11.
The vinyl jacket of the Phillystran will be severely deformed where each clamp grabs it, this
is normal
SteppIR Antennas — MonstIR
Picture 11
The boom truss halves should look like Picture 12 when completed. The cable in the
picture is shortened for photographing ease.
Picture 12
24
3. Attach the two 3/8” x 16 x 6” turnbuckles of each truss half as shown in Picture 13 us-
ing a 5/16” x 18 x 3 ½” bolt, a 5/16” x 18 Nylok nut, and four 3/8” flat washers. Adjust
both turnbuckles for maximum length. Don’t tighten the 5/16” nut so tight the turnbuckles can’t move, just barely snug is fine.
4. While holding the Phillystran in one hand (this will prevent the cable from twisting
while you tighten the turnbuckles), tighten the turnbuckles using a wrench or screwdriver
as a lever, until the boom is evenly supported and level on both sides. Don’t be overzealous when tightening the boom truss, you don’t want to be pulling it so hard it is bent
upward. That not only looks bad, but it puts undue strain on the truss.
5. Locate the four black plastic caps and apply a small amount of silicon adhesive and put
one over each cut end of the Phillystran (Picture 10).
Picture 13
Picture 14
SteppIR Antennas — MonstIR
1 Flat Washer
3 Flat Washers
25
Safety wire each turnbuckle as shown in Picture 14 to prevent the turnbuckles from
loosening in the wind.
Element Truss Assembly
The three 70’ elements have trusses. Each truss consists of two halves just as the boom truss
does. All of the element truss halves are the same length, 149” +/- .5”.
Materials:
● 48 3/16” galvanized wire clips
● 12 3/16” galvanized thimbles
● 3 ¼” x 20 x 2 ½” bolts and Nylok nuts
● 6 ¼”x 4” stainless turnbuckles
● 6 3/8” flat washers
● 6 168” lengths of non-conductive 3/16” Phillystran Kevlar cable.
● 6 Element truss u-bolt plates
● 6 2” u-bolts with Nylok nuts
SteppIR Antennas — MonstIR
Attach the two 1/4” x 20 x 4” turnbuckles of each truss half as shown in Picture 14 using a
1/4” x 20 x 2 ½” bolt, a 1/4” x 20 Nylok nut, and two 3/8” flat washers. Adjust both turnbuckles for maximum length. Don’t tighten the 1/4” nut so tight the turnbuckles can’t move,
just barely snug is fine.
Make sure you measure the length from the end of the thimbles on each end of the truss half.
The loop back length at each cable end is about 8.5”. The element trusses will be installed
after the elements are completely assembled. Each element truss should look like the
combination of Picture 14.1 & 15 when completed. Note that the cable shown in the
picture is not really 149”, it is a shortened piece for picture taking purposes.
Picture 14.1
26
Picture 15
Assemble 70’ Elements
1. Each of the three 70 foot long elements have a ¾” CPVC “liner” in the first two
sections of each element half consisting of two lengths of CPVC pipe as shown in
Picture 16. Assemble the two halves using the plastic couplers provided. Glue this
joint as shown in Picture 17 with the CPVC primer/glue provided , you don’t want this
joint to come apart.
Picture 16
Picture 17
NOTE: If you need to take the antenna apart in the future you can cut the 3/4” diameter
plastic pipe (after homing the copper) a minimum of 1 in. beyond the coupler and
when you are ready to reinstall the plastic pipe glue in a new coupler .
SteppIR Antennas — MonstIR
2. Route the CPVC tube through the bracket saddles and a Mission rubber
boot as shown in Picture 18 & Picture 21.5. Make sure you engage the
CPVC tube completely into the coupler on the element housing tube
(Picture 19) and install a # 2 x .25 (Picture 18.5) coupler housing screw
in the predrilled hole, in the coupler, to secure the CPVC tube. Repeat
this process for the other five large elements.
NOTE: Be careful not to over-stress the joint between the two PVC liner
halves, you can easily crack the coupler.
Picture 19
Mission Boot
27
Picture 18.5
3. Being careful not to over stress the connecting coupler, slide the first section of the 2”
Picture 20
Picture 18
O.D. element support tube extension over the CPVC tubing. The end with the thin wall
aluminum sleeve goes on first, see Picture 20. Make sure the aluminum sleeve hasn’t
slipped and is in the position shown. Position the first element such that the first alumi-
num ring is just covered by the saddle, see Picture 21. When you are sure you have the
first element correctly positioned tighten the four 3/8” bolts holding the saddles and truss
bracket, but not so tight you crush the fiberglass. Slide the rubber boot into the position
shown in Picture 21 and tighten. The boot keeps water out so make sure it is positioned
so the hose clamps can securely clamp it at both ends. Repeat this process for all six long
element halves.
Picture 21
SteppIR Antennas — MonstIR
There are two different kinds of rubber couplers (Picture 21.5) for the MonstIR Antenna.
Below shows the location for the two different rubber couplers.
1. Mission- These are smaller rubber boots that are designed to fit to the 40m element
housing. You will find 6 of these boots for the joints shown below.
2. Fernco – These are the larger thicker rubber boots and are design for coupling the 18'
telescoping pole. You will find 8 of these boots for the joints shown below.
Couplers
28
Mission
Fernco
Picture 21.5
SteppIR Antennas — MonstIR
4. Slide the 1 ¾” O.D. second element support tube extension section over the CPVC tubing and mate it with the aluminum coupler on the 2” OD section 1 tube. Make sure the
male coupler “bottoms out” so only 3” is left exposed, see Picture 22. Install a 2” U-bolt
as shown in Picture 22 and tighten. Make sure to leave room to seal the joint with tape
by sliding the U-bolt to one side as shown Picture 22. Apply electrical tape as shown in
Picture 23 to seal it and then a layer of pure silicone tape to protect against sunlight.
The silicone tape is self-fusing and it only sticks to itself. End your last wrap on top of
the silicone tape, not on the aluminum. Repeat for all six element halves.
5. Changes have been made to reinforce the support tube extensions. A self tapping screw
has been placed on each tube. These screws need to be placed so that when the antenna is
in the air that the self tapping screw heads are oriented so that the heads are facing the
sky as shown in picture 22. It is important that the screws are placed properly so that the
screws will not attract RF that is given off by the element.
Picture 22
Self tapping screws
29
1.5
Second Element Section 1.75"
Leave room to tape joint
by positioning the U-bolt
as shown
Self tapping screws - silicone covered to protect from corrosion
6.0
3.0
1.5
First element section 2"
Picture 23
SteppIR Antennas — MonstIR
Wiring Elements
Each of the EHUs has a four
conductor control cable attached to it using a waterproof
strain relief fitting. These fittings were properly tightened
at the factory and should not
be disturbed. The other end of
these control cables have
stripped and tinned wires that
will be connected to the terminal strips that where shipped
inside the ABS terminal tube.
Locate the terminal strips
(Picture 24) and small blue
packet of connector protector.
Each EHU control cable also
has an un-insulated ground
wire. It needs to be connected
to all of the other un-insulated
ground wires using the single
position terminal strip as
shown in Pictures 24 & 25.
30
Picture 24
Picture 25
To Antenna
Reflector
Drain Wires from
Each Element
Dir 2
Driven
Dir 1
BLACK
RED
GREEN
WHITE
BLACK
RED
GREEN
WHITE
TERMINAL BLOCK 3
TERMINAL BLOCK 1
BLACK
RED
GREEN
WHITE
BLACK
RED
GREEN
WHITE
TERMINAL BLOCK 2
Shield
BLACK
WHITE
BROWN
BLACK
RED
BLACK
ORANGE
BLACK
YELLOW
BLACK
BLUE
BLACK
GREEN
BLACK
WHITE
RED
(drain wire)
10
11
12
14
15
16
17
1
2
Male 25 Pin Dsub.
3
4
5
6
7
8
To Controller
9
16 Conductor Cable
(4 Element to Controller)
Figure 4
SteppIR Antennas — MonstIR
31
Notice
Soon we will be shipping 16 conductor control cable from a new vendor so we are providing the wiring diagram and color scheme so you have the proper instructions for
which ever cable is shipped with your antenna. Both cables are essentially the same except for the wire color scheme.
To Antenna
Reflector
Drain Wires from
Each Element
Dir 2
TERMINAL BLOCK 1
BLACK
RED
GREEN
WHITE
BROWN (dark)
BLUE
ORANGE
YELLOW
PURPLE
GRAY
PINK
TAN
WHITE / BLACK
WHITE / RED
WHITE / GREEN
WHITE / ORANGE
Driven
Dir 1
BLACK
RED
GREEN
WHITE
BLACK
RED
GREEN
WHITE
Shield
TERMINAL BLOCK 3
BLACK
RED
GREEN
WHITE
BLACK
RED
GREEN
WHITE
TERMINAL BLOCK 2
(2 drain wires are twist together)
16 Conductor Cable
10
11
12
14
15
16
17
1
2
3
4
5
6
7
8
9
Male 25 Pin Dsub.
To Controller
(4 Element to Controller)
{Alternate Vendor}
Mark each four conductor control cable with a felt marker pen or better yet use colored heat shrink
or tape to identify each cable. It is easy to get them mixed up after taping them along the boom.
Leave a “drip loop” at each element so water doesn’t run down the cable into the seal on the element box, that’s just asking for trouble.
Pictures 25 & Figure 4 shows how these control cables are wired. Note the single position ground
terminal in between the two 8 position terminal strips. The right side shows how the 16 conductor
control cable (8 pairs of wires, each pair with colored wire and one black wire) that goes to the
shack is connected.
WARNING:
Do NOT connect the 16 conductor cable to the SteppIR controller until in-
structed to do so. The control cable connector has live voltages present even if
the power “off” button has been pushed. Shorting the wires of the control cable while connected to the controller with the power supply connected will permanently damage the driver chips.
Figure 4.5
SteppIR Antennas — MonstIR
Note: If you ordered the 16 conductor control cable, it is included in your antenna kit. The
required 25 pin connector has been installed on one end and the factory has stripped
and tinned the wires on the other end. If you did not order this cable you must supply
your own 16 conductor cable and DB-25 pin connector. In such case, a separate
connector, back shell and cable wiring drawing have been included in your kit. Call
the factory if you would like to order a cable already prepared.
Now start at one end of the boom and tape all the cables snugly to the bottom of the boom so
there are no loops or slack cables. This is to prevent the cables from becoming damaged
when moving the antenna and installing it on your tower. Secure the 16 conductor cable and
coax to the boom about 8” from the coax connector. Refer to Figure 5 for our suggested
cable configuration.
Warning: Be sure to secure the cables before placing the antenna on the tower, as you
will not be able to reach the driven element from the tower !!!
Be careful NOT to tape the cables over a sharp edge unless you provide extra
protection to prevent eventually cutting through the sheath and shorting the
wires.
Note: If you do not want to install or remove the antenna with the main coax feed line at-
tached, make a coax jumper that connects to the driven element and goes along the
boom back to the mast plate area where it can be connected to the main coax feed
line coming up the tower.
Tape the cable every foot or so with electrical tape, we recommend taping it on the bottom
side to reduce exposure to UV. When going past an element bracket you can run the cable
between the bracket and the boom, it is much cleaner than routing it on the outside of the
bracket.
Warning: If you cut the element cables MAKE SURE
Carefully review Picture 25 & Figures 4 before proceeding. First complete the reflector,
director and driven element wiring then the 16 conductor cable going to the controller will
follow.
Starting with the driven element cable dip each wire into the connector protector- except
the bare ground wire (a thin coating is sufficient). Insert each of the four colored wire into
their respective location on the first 8 position terminal strip. Make sure you don’t insert the
wire so far in that you are clamping down on just the insulation. Figures 4 provides the ex-
act location the color codes.
Secure Cable to Boom
Rotor Loop:
Control Cable & Coax
Taped Together
Figure 5
Suggested Cable
Routing
you measure very carefully .
32
SteppIR Antennas — MonstIR
Tighten the set screws as each wire is inserted, but be careful not to over-tighten these
screws. Repeat this procedure for the first director, reflector and second director cables.
Twist the four bare ground wire from the four control cables together, dip them into the connector protector and insert them into one end of the signal position terminal strip. Secure
them by tightening the set screw. This completes the control cable wiring for the EHUs.
Locate the 16 conductor cable that goes to the controller. If it is not already coiled neatly,
coil it before proceeding. Follow the same procedure as above and connect each colored
wire. The 16 conductor cable has eight pairs of wires, each pair is twisted together and taped
at the factory.
Warning: It is imperative that these twisted pairs do not get mixed up, or you will
have to use a volt/ohm meter to ascertain which pairs match correctly.
Picture 28 shows the respective pairings: black/white; brown/black; red/black; orange/black;
yellow/black; blue/black; green/black and white/red. This sequence is exactly the order in
which to connect the wires as shown in Figure 4. Following the same procedure above connect each colored wire. Coat each wire end with connector protector. Don’t forget to
coat the bare ground wire.
Connect the un-insulated ground wire of the 16 conductor cable to the single position terminal strip that should already have the four grounds, from the four control cables, attached to
it.
Position the cables so they are parallel with the two 8 position terminal strips. The single 16
conductor control cable will be on one side and the four 4 conductor cables the other see Pic-
ture 26. Locate the wiring enclosure tube and plug as shown in Picture 27. Put a couple of
raps of electrical tape around the wire bundle where it will pass through the notch in the
threaded plug to protect the cable sheath from the threads in the tube. Slide the cables and
terminals strips into the tube, position the threaded plug cut over the cables and screw the
tube onto the threaded plug until it is tight.
Fasten the wiring enclosure to the boom using the two (2) stainless steel hose clamp as
shown in Picture 27.5 and position the tube so that the notch in the threaded plug will be to
the bottom to permit any moisture that might collect to drain.
There will be a fair amount of excess cable on certain elements. Neatly coil the excess cable
and secure it to the boom.
33
Picture 26
Picture 27
SteppIR Antennas — MonstIR
Warning: If you choose to cut the individual 4 conductor element cables
to a custom length eliminating the excess loop you must first:
• Know where you will mount the terminal enclosure (Picture 27)
• Measure ACCURA TEL Y before you cut the cables
• Strip and re-tin each wire tip
( DO BE CAREFUL)
Picture 27.5
34
Warning: Do not trap the cables between the clamp and the ABS tubing or over-
tighten the clamp.
Picture 28
Note: It is strongly recommended
tion described in the Operators manual. This will ensures the antenna is correctly wired and functioning before it is mounted on the tower.
, at this point, that you use the “Test Motor” func-
SteppIR Antennas — MonstIR
Prepare the Telescoping Fiberglass Element Support Tubes
Locate:
• Eight dark green fiberglass telescoping poles (Figure 29) *
• Eight black rubber boots with clamps (Fernco)
• Six black rubber boots with clamps (Mission)
• Roll (s) of black electrical tape **
• Roll (s) of black silicone self-curing tape **
• Your tape measure
** The quantity of tape provided will depend
on the number of elements.
Note: The reinforcing rings/sections on the first two pole sections provides extra
strength in potential high wind conditions (Figure 30.5).
The green fiberglass poles are all assembled in the same manner, and
when extended, become element support tubes (ESTs) for the flat
strip copper beryllium elements themselves. The copper-beryllium
strips are shipped retracted inside their respective element housing
units (EHUs).
Repeat the following procedure for each telescoping pole
Telescope a pole to full length by pulling each section out
firmly in a twisting motion until it is extended as far as possible. Each segment is tapered and should lock securely in
place when fully extended. Pole lengths may vary but, when
fully extended, each pole must be at least 17 feet 8 inches in
length as measured from the butt end of the pole to the tip
(Figure 29). Verify the length for each pole before
installa-
tion or wrapping the joints.
If a pole comes up a little short (1/2” to 1”) try collapsing the
pole and starting over, this time aggressively “jerk” each section out instead of twisting. The pole cannot be damaged and
you may gain a minimum of 1/2” or more. If you have trouble
collapsing the pole try carefully striking one end on a piece of
wood or other similar surface placed on the ground.
Picture 29
Rubber Boots
Electrical Tape
Silicone Tape
20’
35
10’
17’ 8” min
SteppIR Antennas — MonstIR
36
Warning: Make sure to remove the black rubber plug from the base section of each of the telescop-
Note: The telescoping element support tubes will not all be the same length, this is not a problem as
Next wrap each joint on the fiberglass poles with the all weather elec-
trical tape, see Picture 30. Each joint should have at least the full
width of the tape on both sides of the joint. Use common sense on the
amount of tape or you will not have enough of the silicon tape used
later to cover the electrical tape.
Exception: On joints with metal reinforcing rings (Picture 30.5), the
Apply one complete wrap of electrical tape around the fiberglass tube as you begin, and then work
your way across the joint and back using half overlap wraps, so that the entire area is seamlessly cov-
ered. Carefully stretch and smooth the tape with your fingers as you apply it, especially when you
change directions - this will help avoid ripples and have the tape lie as smoothly as possible. At the
end of the run, cut the tape with a knife or scissors and press the end onto the pole. Then run your hand
over the tape a couple of times to firm up the bonding.
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 !!!
ing element support tubes (poles). This is a shipping plug for handling convenience and
will seriously damage the copper-beryllium strips and drive mechanisms if not removed.
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 foam plugs glued in the small end of each of the dark green telescoping
poles. These plugs allow the poles to breathe preventing the buildup of condensation
inside. Do NOT remove, block, cover, plug, cap or in any way inhibit air flow
through this foam plug filter.
Picture 30
long as they are a minimum of 17’ 8”. They are interchangeable and can be used in any ele-
ment position
tape must go further so it extends a minimum of 3/4” beyond the metal ring and onto the fiberglass pole.
Picture 30.2
New
Original
Picture 30.5
SteppIR Antennas — MonstIR
Recommended Lengths for Silicone Tape Wrapping
37
A -
18 in / 46 cm
16 in / 41 cmB -
A
Next, you will weatherproof and UV protect each joint with the black self-curing silicone tape see Picture 26. It is important that you pre-cut the silicone tape to the recommended lengths. If you do
so, you will have more than enough for each joint. Refer to Figure 6 for proper lengths for each joint.
In the event you require more silicone wrap, you can order more from SteppIR. Sometimes it can be
found at a hardware store or a marine supply store.
IMPORTANT: Per the manufactures specifications the silicone tape has a shelf life of 12
months before it is used and should be stored in a cool dry environment. Silicone tape
will not stick to just any surface. It only bonds to itself. Be sure to remove all the
connector protector residue from your hands before handling silicone tape, as that
residue will cause the silicone wrap not to adhere to itself in places. Take care to keep
the silicone wrap free of dirt or debris. Also, this tape MUST be cut. Do not tear it.
Wash your hands before completing the following steps.
Position the black silicone tape about 1/2” to the right of the black electrical tape and wrap one layer,
continually stretching the silicone tape a minimum of 100 % its original length, completely around
the pole so the tape fully overlaps itself. Then slowly wrap the silicone tape to the left using half
overlap wraps, extending about 1/2” beyond the black electrical tape. When you reach the end, wrap
one layer completely around the pole so the tape fully overlaps itself just as you did at the beginning of
the wrap. If you are stretching the tape correctly you will get about two layers of tape at each joint. As
before, carefully stretch and lay the tape down as smooth as possible. The final joint should look like
Picture 30.2.
Important: After the silicone tape has been applied, be sure to rub each wrap with your hand
several times to ensure that it is flat and has adhered to itself.
B
C
Figure 6
C -
11 in / 28 cm
SteppIR Antennas — MonstIR
38
Installing the Fiberglass Element Support Tubes (EST's)
The butt ends of the green fiberglass poles may vary slightly in outside diameter. Some of
them may have been sanded, while others were not. The colors at the ends will be either
beige, or black. The difference in colors has no affect on performance. Do not be concerned
if they vary slightly in tightness when being installed on the EHUs. this is normal. All poles
are tested for proper fit at the factory prior to shipping. In the event a pole is too tight you
can sand it to fit.
The EHTs on the Director 1 EHU have aluminum
reinforcing rings attached to provide extra strength
in high wind conditions (Picture 31) and prevent
the boot from ever sliding off. There are 8 EST’s,
two of them attach directly into the Director 1
EHU. The other six form the last section of each
70’ element half.
Place a Fernco rubber boot (Picture 21.5) on the butt end of the EST and insert the butt end
of that EST into the Director 1 Element Housing Tubes (EHT) on an EHU, as shown Picture
32. It is very important to ensure that the butt end of the EST firmly bottoms out inside the EHT. After making sure the EST is seated all the way into the EHT it is equally
important to push the rubber boot firmly onto the EHT until it bottoms positioning the
clamp completely past the aluminum ring (Picture 32a), then tighten the clamp sealing the
boot on the fiberglass EHT. After insuring both stainless steel hose clamps are firmly tighten,
one over the EHT and the other over the EST, test the connection by pulling and twisting it.
There should be no slippage at the joints
EHU
Picture 31
EHT
Picture 32
NOTE: You should re-tighten each clamp a second time (at least 30 minutes after the first
time you tightened them) before raising the antenna to the tower, to be sure that
there has been no cold flowing of the PVC material on the boot.
Picture 32a
SteppIR Antennas — MonstIR
The remaining six EST’s are used as the last section of the 70’ elements. The EST slides
into the end of the 1 ¾” O.D. second section of the big elements (Picture 32b). The EST’s
are attached as described in the previous paragraph covering EST attachment to the Director
1 EHT. The only difference is there is no stop in the 1 ¾” O.D. second section, so you must
ensure that you only slide the EST in until the painted surface is flush (Picture 32b) with the
end of the 1 ¾” tube (about 4”). Repeat with all six 70’ element halves.
Picture 32b
39
Installing Element Trusses
Locate:
● Six 149” x 3/16” element truss assemblies
● Six 2” u-bolts and nuts
● Three ¼” x 20 x 2 ½” bolts
● Three ¼” x 20 Nylok nuts
● Six 3/8” flat washers.
One end of each element truss clamps directly to the 1 ¾” second section of each 70 foot ele-
ment half as shown in Picture 33. Place the bracket at approximately the mid point of the 1
¾” section. DO NOT tighten the clamp at this time. Leave the clamp loose enough so that it
will slide on the pole. Repeat this process for all six truss halves. Now adjust each of the
six turnbuckles to maximum length. Bolt each pair of turnbuckles to their element support
structure at the center of each 70 foot element as shown Picture 34. Don’t over tighten the
nut, barely snug is just fine. Next go back to each of the six truss clamps attached to the 1
¾” sections and slide them outward until the Phillystran truss cable is taught then tighten the
four clamp bolts.
Picture 33
SteppIR Antennas — MonstIR
Picture 34
40
Finally adjust the turnbuckles as you did on the boom truss to get the elements reasonably
straight and level with each other. Again, don’t go overboard with having the elements
“arrow” straight. The tension goes up dramatically once the element is very nearly straight.
Take your time and sight down the boom to get all of the elements horizontally aligned by
adjusting each trusses half. Horizontal misalignment is much more noticeable and annoying.
Safety wire each turnbuckle, on both the boom truss and element trusses, as shown in Pic-
ture 14 in the boom truss section.
6M Passive Element Installation (Optional)
If you have purchased the optional 6M passive element kit:
Locate: (Ref: Picture 35)
● One 6M passive element kit 112.0” (long)
● One mounting kit (long)
● One 6M passive element kit 104.5” (short)
● One mounting kit (short)
● Blue packet of Connector Protector
Using their respective hardware kits (long & short - Picture 35 ) assemble the two 6M pas-
sive elements. Identify the ends of the 3/8” tubing that have the shortest distance from the
end of the tubing to the drilled hole. Lightly coat the circumference of these ends with a
very thin film of the connector protector. Slide the coated ends of the 3/8” tubing into the
1/2” tubing and align the holes.
Note: Verify that the long element measures 112.0” and the short element measures 104.5”.
Securely fasten the pieces together with the 6-32x3/4” machine screws and Nylok nuts.
Install the U-bolt on the center bracket as shown in Picture 36.
The 6M passive elements should be mounted on the bottom side of the boom, the same as the
other elements, using the U-bolt and saddle shown in (Picture 36). Using a tape measure,
determine the correct passive element placement as shown in Figure 2. Be sure to measure
from the actual center line of the 6m passive element, NOT from where the U-bolt attaches
(Picture 37) to the center line of the correct element support tube Figure 2. Make sure the
elements are aligned with the green fiberglass poles. Tighten securely.
Warning: When attaching the 6m passive to the boom be careful not to trap the element
Picture 35
SteppIR Antennas — MonstIR
control cable under the U-bolts.
41
Picture 36
Picture 37
SteppIR Antennas — MonstIR
42
SteppIR Performance
SteppIR antennas are developed by first modeling the antenna using YO-PRO and EZNEC. We created antennas that had maximum gain and front to rear without regard
for bandwidth.
The antennas that reside in our controllers memory are all optimized for gain and front
to rear with a radiation resistance of approximately 22 ohms (16 ohms to 30 ohms is
considered ideal for real world yagis. The modeling also takes into account the changing electrical boom length as frequency changes. When the 180 degree function is enabled, a new Yagi is created that takes into account the change in element spacing and
spacing and in the case of 4 element antennas creating a two reflector antenna to get
maximum use of all elements . The result is slightly different gain and front to rear
specifications.
We then go to the antenna range and correlate the modeled antenna to the real world.
In other words, we determine as closely as possible the electrical length of the elements.
We are very close to the modeled antennas, but it is virtually impossible to get closer
than a few tenths of a dB on gain and several dB on front to rear.
There are three factors that make our antennas outstanding performers:
1. They are tuned to a specific frequency for maximum gain and front to rear – wit
out the compromise in performance that tuning for bandwidth causes.
2. They are very efficient antennas with high conductivity conductors, a highly efficient matching system (99% plus) and low dielectric losses.
3. There are no inactive elements, traps or linear loading to reduce antenna performance.
Fixed Element Spacing and the SteppIR Yagi
First of all, there really is no "ideal" boom length for a Yagi. To get maximum gain the boom of a
three element beam should be right around .4 wavelengths long. This would allow a free space gain
of 9.7 dBi, however the front to back ratio is compromised to around 11 dB. If the boom is made
shorter, say .25 wavelengths, the front to back can be as high as 25 dB, but now the maximum gain is
about 8.0 dBi. Shorter booms also limit the bandwidth, which is why right around .3 wavelengths is
considered the best compromise for gain, front to back and bandwidth for a fixed element length
yagi. It turns out that being able to tune the elements far outweighs being able to choose boom
length. We chose 16 feet for our three element boom length which equates to .23 wavelength on 20
meters and .46 wavelength on 10 meters, because very good Yagi’s can be made in that range of
boom length if you can adjust the element lengths. This compromise works out very well because
10m is a large band and F/B isn’t as important so you get excellent gain with still very acceptable F/
B. When bandwidth is of no concern to you (as it is with our antenna), you can construct a Yagi that
is the very best compromise on that band and then track that performance over the entire
this ability to move the performance peak that makes the SteppIR actually outperform a mono-bander
over an entire band – even when the boom length isn’t what is classically considered "ideal". Bear in
mind that a Yagi rarely has maximum gain and maximum front to back at the same time, so it is
always a compromise between gain and front to back. This is the same philosophy we use on all of
our yagi antennas to give you the most performance available for a given boom length. With an
adjustable antenna you can choose which parameter is important to you in a given situation. For
example, you might want to have a pile-up buster saved in memory, that gets you that extra .5 – 1.0
dB of gain at the expense of front to back and SWR – when you are going after that rare DX!
band. It is
SteppIR Antennas — MonstIR
43
RF Power Transmission with the SteppIR Yagi
The RF power is transferred by brushes that have 4 contact points on each element that
results in a very low impedance connection that is kept clean by the inherent wiping action.
The brush contact is .08 in thick and has proven to last over 2 million band changes. The
copper beryllium tape is .545 inches wide and presents a very low RF impedance. The type
of balun we are using can handle tremendous amounts of power for their size because there
is almost no flux in the core and they are 99% efficient. That coupled with the fact that our
antenna is always at a very low VSWR means the balun will handle much more than the
3000 watt rating, how much more we don't know. Jerry Sevicks book "Transmission
Transformers" (available from ARRL) has a chapter (Chap. 11) that discusses the power
handling ability of ferrite core transformers.
WARNING: WHEN OPERATING WITH MORE THAN 500 WATTS, DO NOT
TRANSMIT WHILE THE ANTENNA IS CHANGING BANDS. A
MISMATCH AT ELEVATED WATTAGES MAY CAUSE DAMAGE
TO THE DRIVEN ELEMENT.
Balun / Matching System
The SteppIR has a matching system that is included in the 2 element, 3 element, 4 element
and MonstIR Yagi (a balun is available as an option on the dipole). Our antenna designs are
all close to 22 ohms at all frequencies, so we needed a broadband matching system that
would transform 22 ohm to 50 ohm. We found an excellent one designed by Jerry Sevick,
that is described in his book “Building and Using Baluns and Ununs”.
Our matching network (balun - Picture 38) is a transmission line transformer that is wound
on a 2.25 inch OD ferrite core that operates with very little internal flux, thus allowing it to
function at very high power levels. The transformer includes a 22 ohm to 50 ohm unun and
a balun wound with custom made, high power, 25 ohm coax for superior balun operation.
Jerry has espoused these transformers for years as an overlooked but excellent way to match
a Yagi, he would probably be proud to know they are being used in a commercial Yagi. This
matching network does not require compressing or stretching a coil, or separating wires to
get a good match – something that can easily be bumped out of adjustment by birds or installation crews.
Balu
Balun
Picture 38
SteppIR Notes
44
SteppIR Antennas — MonstIR
www.steppir.com
45
Limited Warranty
These products have a limited warranty against manufacturer's defects in
materials or construction for two (2) years from date of sale. Do not modify
this product or change physical construction without the written permission
of SteppIR Antennas Inc. This limited warranty is automatically void if the
following occurs: improper installation, unauthorized modifications, physical
abuse or damage from severe weather, beyond the manufacturer's control.
Manufacturer's responsibility is strictly limited to repair, or replacement of
defective components. The shipping instructions will be issued to the buyer
for defective components, and shipping charges will be paid for by the buyer
to the manufacturer. The manufacturer assumes no further liability.
Yagi Dipole Vertical
www.steppir.com
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