Hughes DiRECWAY HNS 1035930-0001 Operating instructions

11717 Exploration Lane, Germantown, MD 20876
Tel: [phone] Fax: [phone]
1035678-0001
DRAFT Revision 1.04
October 11, 2004
Draft
Place D RAFT stam p here.
Ku/Ka Upgradeable Antenna
Site Preparation Guide
.98 m, 1.2 m
®

Copyright © 2004 Hughes Network Systems, Inc.,
a wholly owned subsidiary of The DIRECTV Group, Inc.
All rights reserved. This publication and its contents are proprietary to Hughes Network Systems,
Inc., a wholly owned subsidiary of The DIRECTV Group, Inc. No part of this publication may be
reproduced in any form or by any means without the written permission of Hughes Network
Systems, Inc., 11717 Exploration Lane, Germantown, Maryland 20876.
Hughes Network Systems, Inc. has made every effort to ensure the correctness and completeness
of the material in this document. Hughes Network Systems, Inc. shall not be liable for errors
contained herein. The information in this document is subject to change without notice. Hughes
Network Systems, Inc. makes no warranty of any kind with regard to this material, including, but not
limited to, the implied warranties of merchantability and fitness for a particular purpose.
Trademarks
All trademarks, marks, names, or product names referenced in this publication are the property of
their respective owners, and Hughes Network Systems, Inc. neither endorses nor otherwise
sponsors any such products or services referred to herein.

• Contents
1035678-0001 DRAFT Revision 1.04 i
Contents
Important safety information . . . . . . . . . . . . . . . . . . . . . xi
Types of warnings used in this manual . . . . . . . . . . . . . . . . . . . xi
About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Related publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Tool and fastener sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Revision record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Chapter 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
The DIRECWAY system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Chapter 2
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Installation safety policies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
DIRECWAY-SP installation policy document . . . . . . . . . . . .5
DIRECWAY-SP installation policy and this manual. . . . . . . .6
General safety specifications . . . . . . . . . . . . . . . . . . . . . . . . . .6
Other safety specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Permits, inspections, and approvals . . . . . . . . . . . . . . . . . . . . . . .8
Possible restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Tools needed for installation . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Items needed for installation . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Chapter 3
Site survey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
What is a site survey?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Preparing for the site survey. . . . . . . . . . . . . . . . . . . . . . . . . . . .15
The site survey and safety considerations . . . . . . . . . . . . . . . . .15
Installation specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Phone site survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Confirm installation date/time. . . . . . . . . . . . . . . . . . . . . . . .16
Determine or confirm building type . . . . . . . . . . . . . . . . . . .16
Confirm permits obtained . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Anti-ice electrical receptacle. . . . . . . . . . . . . . . . . . . . . . . . .16
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

• Contents
ii 1035678-0001 DRAFT Revision 1.04
Site survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Items to take on a site visit . . . . . . . . . . . . . . . . . . . . . . . . .17
Survey tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Determine where IDU will be located . . . . . . . . . . . . . . . . .18
Identify a location for antenna installation . . . . . . . . . . . . . .18
Line of sight check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Mounting options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Planning for IFL routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
IFL planning factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Calculating cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Choosing the route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Conditions affecting installation and operation . . . . . . . . . . . . .23
Weather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Line of sight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Cable grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Poor installation practices. . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Chapter 4
Installing mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Radiation Hazard Caution Signs and Labels . . . . . . . . . . . . . . .27
Installing the antenna mount . . . . . . . . . . . . . . . . . . . . . . . . . . .27
.98 m antenna mount installation locations . . . . . . . . . . . . . . . .28
Installing the .98 m antenna non-penetrating mount . . . . . . .28
Antenna Ballast Calculator Tool. . . . . . . . . . . . . . . . . . . . . .30
Possible non-penetrating mount installation locations . . . . .30
RF safety specifications for ground-level non-penetrating
mount installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
RF safety specifications for roof non-penetrating mount instal-
lations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Installing on rubber membrane, loose gravel on rubber mem-
brane, or tar and gravel roof . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Installing the non-penetrating mount on corrugated metal
roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Installing the .98 m mount on a wood-framed roof: discussion .
38
Effects of strut and truss distances and roof pitch on mast as-
sembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Reassembling the trimast in configuration 2 . . . . . . . . . . . . .44
Adjusting the support struts . . . . . . . . . . . . . . . . . . . . . . . . . .45
Installing the .98 m mast on a wood framed roof: procedures . .
48
Installing the support struts . . . . . . . . . . . . . . . . . . . . . . . . . .51
Installing the mount on a wooden wall . . . . . . . . . . . . . . . . . . .54
RF safety considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Installing the struts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

• Contents
1035678-0001 DRAFT Revision 1.04 iii
Installing the .98 m mount on concrete or concrete masonry walls
61
RF safety considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Table 9 lists the tools required to install the mount on concrete
64
Installing the .98 m antenna mount on a metal pole. . . . . . . .68
RF safety considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
1.2 m antenna mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Installing the 1.2 m antenna non-penetrating mount. . . . . . .72
Installing the 1.2 m metal pole mount. . . . . . . . . . . . . . . . . .72
RF safety considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Fencing specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Minimum dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Fencing materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Chapter 5
Grounding requirements. . . . . . . . . . . . . . . . . . . . . . . . .77
Grounding the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Grounding using RG-6 quad-shielded cable . . . . . . . . . . . . .80
Grounding using RG-6 non-quad shielded cable . . . . . . . . . .82
Grounding the metal pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Grounding using RG-6 quad-shielded cable . . . . . . . . . . . . .86
Grounding using RG-6 non-quad shielded cable . . . . . . . . . .87
Grounding the non-penetrating mount . . . . . . . . . . . . . . . . . . . .89
Grounding the non-penetrating mount installation in an enter-
prise setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Appendix A
Building cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

• Contents
iv 1035678-0001 DRAFT Revision 1.04

• Tables
1035678-0001 DRAFT Revision 1.04 vii
Tables
1. Tools needed for antenna installation, pointing, and initial testing . . . . . . . . . .10
2. Items needed for installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3. Antenna manual part numbers (PN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4. Parts required for non-pen mount installation . . . . . . . . . . . . . . . . . . . . . . . . . 29
5. Tools required for non-pen mount installation . . . . . . . . . . . . . . . . . . . . . . . . . 29
6. Parts required for a wood framed roof installation. . . . . . . . . . . . . . . . . . . . . . 40
7. Tools required for a wood framed roof installation . . . . . . . . . . . . . . . . . . . . . .40
8. Parts required to install the mount on concrete . . . . . . . . . . . . . . . . . . . . . . . . 64
9. Tools required to install the mount on concrete . . . . . . . . . . . . . . . . . . . . . . . . 64
10. Additional parts and tools needed for .98 m metal pole mount . . . . . . . . . . . . 68
11. Additional parts and tools needed for 1.2 m metal pole mount . . . . . . . . . . . . .72
12. Fencing dimensions requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
13. Parts required to ground the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
14. Tools required to ground the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
15. Parts required for grounding the metal pole . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
16. Tools required for grounding the metal pole . . . . . . . . . . . . . . . . . . . . . . . . . . .85

• Tables
viii 1035678-0001 DRAFT Revision 1.04

• Figures
1035678-0001 DRAFT Revision 1.04 ix
Figures
1. Remote site with DW6000 installed, single computer . . . . . . . . . . . . . . . . . . . . .1
2. Line of sight check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3. Clearing gravel from the installation location . . . . . . . . . . . . . . . . . . . . . . . . . .32
4. Leveling the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5. Supporting the mount on a corrugated aluminum roof. . . . . . . . . . . . . . . . . . . .34
6. Installing lag bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
7. Beam location and the mast and ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
8. Leveling the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9. Installing the mount on a wood framed roof . . . . . . . . . . . . . . . . . . . . . . . . . . .39
10. Strut placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
11. Locations for lag bolt installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
12. Relocating the mast foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
13. Relocating struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
14. Strut collars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
15. Aligning the mounting bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
16. Revolving the struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
17. Orienting the mast foot for a wood framed roof install . . . . . . . . . . . . . . . . . . .49
18. Adjusting the mast orientation for a wood framed roof install. . . . . . . . . . . . . .49
19. Installing the lag screw and large flat washer. . . . . . . . . . . . . . . . . . . . . . . . . . .52
20. Positioning the strut mounting bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
21. Installing the trimast on a wooden wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
22. Orient mast foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
23. Plumb mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
24. Installing support struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
25. Concrete wall attachment detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
26. Orienting the mast for a concrete wall install. . . . . . . . . . . . . . . . . . . . . . . . . . .66
27. Plumbing the mast for a concrete wall install. . . . . . . . . . . . . . . . . . . . . . . . . . .66
28. Installation illustration and specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
29. Plumbing the pole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
30. Staking for drying; sloping for runoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
31. Installation illustration and specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
32. Plumbing the pole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
33. Staking for drying; sloping for runoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
34. Ground schemes for ground block wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
35. The ground screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

• Figures
x1035678-0001 DRAFT Revision 1.04
36. Grounding the mast using RG-6 quad-shielded cable . . . . . . . . . . . . . . . . . . . .82
37. Inserting the grounding bolt through the grounding hole. . . . . . . . . . . . . . . . . .83
38. Grounding the mast using RG-6 non-quad shielded cable . . . . . . . . . . . . . . . . .84
39. Grounding the metal pole using RG-6 quad-shielded cable. . . . . . . . . . . . . . . .87
40. Grounding the metal pole using RG-6 non-quad shielded cable . . . . . . . . . . . .88
41. Radio ground screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
42. Wrap ground wire once around canister screw . . . . . . . . . . . . . . . . . . . . . . . . .90
42. Cable stripper, crimper, and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
43. Place in stripper tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
44. Fold back braid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
45. White insulator flush with metal flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
46. Insert connector and cable into crimp tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
47. Start of squeeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
48. Finishing crimp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94