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Hughes Network Systems DiRECWAY DW4000, Installation Manual

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16

INSTALLING THE MOUNT ON A WOOD FRAME ROOF

17. Install a 3/8-inch washer on the 3/8-inch x 4-inch lag screw. 

18. Use a 9/16-inch socket wrench to screw the lag screw into

the lower center hole. Do not tighten the screw fully.

19. Re-plumb the mast and snug down the lag screw.

20. Use a torque wrench with 1/2-inch socket to torque the mast

adjustment nuts to 18 ft.-lbs. Confirm the mast is plumb
after torquing. Note: the mast must be plumb before you can
proceed. If you cannot plumb the mast, repeat the installation or
find another installation site.

21. Adjusting the drilling depth for the 3/8-inch by 2-inch lag

screws, repeat step 6 and step 7 to drill holes for the four
corner holes. See Figure 15. 

Note: the base plate must not move when you drill the holes.

22. Fill the holes with silicone sealant.

23. Install a 3/8-inch washer on each of the 3/8-inch x 2-inch

lag screws. 

24. Use a 9/16 socket wrench to screw the lag screws into the

four holes. Note: do not overtighten the screws. You may
strip the screw threads.

25. Re-plumb the mast and snug down the four screws firmly.

INSTALLING THE BRACE KIT

1. Slip the short 18-inch strut collar onto the mast as shown in

Figure 17.

2. Secure the collar to the mast by using a 7/16-inch socket

wrench to tighten the Nylock nut installed on the bolt.

3. Position the strut mounting plate below the mast and base

plate so the two screw holes are exactly in line vertically
with the mast base plate center holes (see Figure 17).

4. Mark the center of the bottom mounting plate screw hole

(see Figure 18).

5. Drill a hole on the center mark in the manner described

below.  Note: to avoid drilling too deeply, wrap a piece of
masking tape around the drill bit shank at the appropriate
depth so that you can see when you should stop drilling.

Drill a 5/32-inch hole 4 inches deep.

Going into the 5/32-inch hole, drill a 1/4-inch hole to a 
depth equal to the unthreaded portion of the 1/4-inch x 4-
inch lag screw.

6. Fill the holes with silicone sealant, and apply silicone seal-

ant to the bottom of the mounting plate.

7. Install a 1/4-inch washer on the 1/4-inch x 4-inch lag screw.  

8. Use a 7/16-inch socket wrench to screw the lag screws into

the mounting plate hole.

Note: do not pound the lag screws into the rafter or truss with a ham-
mer or mallet. Doing so may split the wood and damage it.

Figure 17

Figure 18

Center line

Top center hole

Bottom center hole

Summary of Contents for DiRECWAY DW4000

Page 1: ...Satellite Dish Installation Guide Model DW4000 Two Way 1031362 0201 Revision B November 19 2001 ...

Page 2: ... ensure the correctness and completeness of the material in this document Hughes Network Systems shall not be liable for errors contained herein The information in this document is subject to change without notice Hughes Network Systems 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 purp...

Page 3: ...nry Walls 18 Installing the Mount Onto a Metal Pole 20 Installing the AZ EL Cap Onto the Satellite Dish 21 Installing the Transmitter Tria Assembly on the Feed Arm 23 Connecting the Feed Arm to the Satellite Dish 24 Installing the Satellite Dish Cap Assembly Onto the Mast 25 Installing and Routing Interior Cable 26 Installing Exterior Cables and Connecting to Ground Block 27 Connecting the Cable t...

Page 4: ...iv ...

Page 5: ...ing Qty 1 Bolts 5 16 18 x 1 1 2 inch Qty 2 Star washer toothed for use with ground ing 1 4 inch Qty 1 Flat washer 5 16 inch Qty 5 Wedge nut 5 16 18 Qty 1 Hex head bolt 5 16 18 x 2 inch Qty 1 Lock washers 5 16 inch Qty 3 Galvanized washers 1 4 inch Qty 5 Hex head nut 1 4 20 Qty 1 Galvanized washers 3 8 inch Qty 6 Flat washers narrow 5 16 inch Qty 2 Satellite Dish rear view Mast and Base Plate Feed ...

Page 6: ...is used with the alert symbol to indicate the likelihood and potential severity of injury DANGER Indicates an imminent hazard or unsafe practice which if not avoided will result in death or severe personal injury WARNING Indicates a hazard or unsafe practice which if not avoided could result in death or severe personal injury CAUTION Indicates a hazard or unsafe practice which if not avoided might...

Page 7: ...rch Park Quincy MA 02269 Contact your dealer or call 1 866 347 3292 for information on having your system installed by an authorized professional installer INSTALLATION AND YOUR HOME The Federal Communications Commission FCC has a rule that generally forbids local governments and homeowners associations from preventing installation of DBS dishes one meter or smaller in size in Alaska the dish size...

Page 8: ...by rotating the satellite dish The polarization setting rotates the satellite dish to the correct orientation for your geographic location This varies from one part of the country to another and is different for different satellites Polarization is positive in the eastern United States and negative in the western United States Remember that it is important to pay attention to positive and negative...

Page 9: ... aligned with magnetic north Note Metal near the compass may affect your reading If you are standing near a metal structure such as a shed or air conditioning unit moveseveral feet away and repeatthemeasurement Holdingthe compass too close to a large metal belt buckle can have the same effect 3 Draw an imaginary line from the center of the compass to the azimuth value you recorded on page 4 This i...

Page 10: ...n page 4 Sight along the straight edge to verify that there are no obstruc tions such as buildings or trees blocking the view Take into account future tree growth if you install during the fall or winter account for spring and summer leaf growth Also avoid installing the satellite dish next to electrical equip ment such as air conditioning units because they can cause signal interference Figure 2 ...

Page 11: ... about grounding Note that meeting the National Electrical Code grounding requirements is easier if you use RG 6 with solid copper center conductor and quad shield However you can also meet the requirements by using RG 6 with solid copper center conductor only and grounding the mast as described in the Overview Recommended cable specifications for One Way and Two Way Systems Cable length from sate...

Page 12: ...ellite dish on a 6 inch x 6 inch Southern Pine wood deck post See Installing The Mount on a Wooden Deck Post on page 10 INSTALLING THE SATELLITE DISH ON TYPICAL WOOD FRAMED ROOF CONSTRUCTION You can use the universal mount and brace kit to install the sat ellite dish on typical wood framed roof construction See Installing the Mount on a Wood Framed Roof on page 13 CAUTION Before installing the uni...

Page 13: ... for greater stability but is not required See Installing the Mount on Concrete or Concrete Masonry Walls on page 18 INSTALLING THE SATELLITE DISH ON A METAL POLE You can install the satellite dish directly on an 9 foot metal pole If you choose this mount option you will not need the universal mount or universal mount brace kit Store them for possible future use See Installing the Mount Onto a Met...

Page 14: ...Southern Pine Posts made of other species of wood whose material properties do not match or exceed those of Southern Pine require engineering evaluation and approval before being used The satellite dish may not be installed on an unsupported wooden post PARTS NEEDED TOOLS NEEDED Lag screws 3 8 inch x 4 inch Qty 6 Washers 3 8 inch Qty 6 Silicone sealant Carpenter s level Pencil Ruler 9 16 and 1 2 i...

Page 15: ...to avoid drilling too deeply wrap a piece of masking tape around the drill bit shank at the proper depth so that you can see when you should stop drilling Drill a 1 8 inch pilot hole 2 inches deep Going into the pilot hole drill a 1 4 inch hole 4 inches deep Going into the 1 4 inch hole drill a 3 8 inch hole to a depth equal to the unthreaded portion of the 3 8 inch x 4 inch lag screw 8 Fill the h...

Page 16: ...as it marks the hole center Note the base plate must not move when you drill the holes 16 Fill the holes with silicone sealant 17 Install a 3 8 inch washer on each of the 3 8 inch x 4 inch lag screws 18 Use a 9 16 inch socket wrench to screw the lag screw into the four holes Tighten the screws loosely 19 Re plumb the mast and snug down the four screws firmly 20 Loosen the mast adjustment nuts and ...

Page 17: ...ce in home construction to be able to determine the exact location of rafters and trusses and their centers The satellite dish should not be installed on a wood frame roof unless the interior of the roof is unfinished so that placement of lag screws can be verified and the rafters or trusses reinforced if necessary If you do not have the knowledge and experience to accurately locate rafters and tr...

Page 18: ...t on cen ter The roof surface must consist of relatively thin resilient materials such as asphalt or composite shingles sheet metal or similar materials over wood sheathing with a thickness that must not exceed 3 4 inch Satellite dishes cannot be installed on slate roofs or Spanish tile roofing made of clay or other brittle materi als The roof pitch also called slope must be between 3 12 and 12 12...

Page 19: ...e and to the entire back side of the base plate Apply enough so that it will press out around the edges when the plate is fastened down 9 Install a 3 8 inch washer on a 3 8 inch x 4 inch lag screw 10 Use a 9 16 inch socket wrench to screw the lag screw into the top center hole of the base plate see Figure 15 You may need to swing the mast out of the way temporarily Tighten the screw snugly so the ...

Page 20: ...RACE KIT 1 Slip the short 18 inch strut collar onto the mast as shown in Figure 17 2 Secure the collar to the mast by using a 7 16 inch socket wrench to tighten the Nylock nut installed on the bolt 3 Position the strut mounting plate below the mast and base plate so the two screw holes are exactly in line vertically with the mast base plate center holes see Figure 17 4 Mark the center of the botto...

Page 21: ...ediately to the left or to the right if you prefer The 25 inch strut should be at approximately a 90 angle to the 18 inch strut At the same time minimize any angle formed between the 25 inch strut and the centerline of the mast base plate see Figure 19 13 Repeat step 3 through step 9 for the two screws holding the 25 inch strut mounting plate 14 Re plumb the mast If you had to loosen the adjustmen...

Page 22: ...l construction or on any synthetic stucco wall surface also called Exterior Insulation and Finish Systems EIFS Note that you can use the brace kit to improve the mount s stability if you wish If you use the brace kit do not install the strut mounting plates within 12 inches of any discontinuous surface such as a window door or edge of a wall The anchors must be tightened to 5 ft lbs PARTS NEEDED T...

Page 23: ...n so that you can move or plumb the mast be sure to tighten them snugly after re plumbing the mast 5 Mark the location of the top center bottom center and four corner holes of the base plate onto the concrete surface Figure 22 6 Use a 3 8 inch masonry drill bill and drill 3 8 inch x 3 inch holes where you made the pencil marks Clean out the holes with a blow out bulb 7 With the bolts flush to the ...

Page 24: ...held in place while the concrete is drying 6 Confirm the pole is still plumb and adjust if necessary 7 Prepare the quick drying concrete according to directions on the package and fill the hole Slope the top of the con crete downward away from the pole to improve drainage 8 Let the concrete dry for 24 hours Continue with section Installing the AZ EL Cap Onto the Satellite Dish on page 21 PARTS NEE...

Page 25: ...f the metal plate is the elevation reference mark 8 Use a 1 2 inch socket wrench or open end wrench to turn the elevation bolt head until the leading edge of the mark is at the correct value You may need to turn the bolt head a number of times until the leading edge of the red mark reaches the correct value 9 When the leading edge of the red mark is at the correct ele vation value tighten the brac...

Page 26: ...h the studs The elevation bolt should be on the right and that the arrow labeled TOP should point to the top of the satellite dish Make sure the satellite dish is oriented so that the sec tion that has a hole in its rim is on the bottom 15 Install four 5 16 inch Nylock nuts and 5 16 inch flat wash ers on the studs Use a torque wrench with 1 2 inch socket to tighten them to 12 ft lbs Figure 27 Elev...

Page 27: ...e transmitter tria assembly with the square end of the feed arm so that you can install the four M4 screws Install the lock washers on the screws Then use the Allen wrench to install the M4 Allen screws but do not fully tighten them 3 Align the bolt holes on the top of the transmitter with the bolt holes on the bottom of the feed arm 4 Install the 5 16 18 bolts in the aligned holes Finger tighten ...

Page 28: ...sh before installing it on the mast or metal pole 1 Insert the 5 16 18 wedge nut thin end first into the slot pro vided on the back of the satellite dish The wedge nut is keyed so that it will fit properly in its slot in the satellite dish in only one way Make sure the hole in the wedge nut is aligned with the hole in the dish so the bolt can be installed see Figure 33 2 Install the feed arm into ...

Page 29: ...ver the mast or metal pole 3 Lift the satellite dish cap mount assembly and slide the AZ EL cap mount onto the mast or metal pole see Figure 34 The satellite dish should face toward the satellite 4 Tighten the clamp nuts all the way then loosen them just enough to move the satellite dish side to side and adjust the azimuth The clamp bolts should be as snug as possible but still allow the satellite...

Page 30: ...ery 3 feet along its length Marking the cable ensures that you can tell the cables apart when you connect them later 2 Choose a spot on the outside wall where you will drill a hole It should be near the satellite dish 3 After verifying that there are no wires or pipes blocking the location where you want to feed the coaxial cables into the building drill a one inch hole through the outside wall 4 ...

Page 31: ...mine where you will install the ground block It must be near where the coaxial cables enters the building Plan a short and straight path for the ground wire from the ground block to the grounding scheme 2 Secure the ground block to a stable mounting surface with two screws see Figure 35 3 Connect one end of the 14 AWG copper 8AWG aluminum ground wire to the ground terminal of the ground block 4 Co...

Page 32: ...in Figure 37 2 Connect the receive modem cable to the LNB connection see Figure 38 3 Tighten the cable connection with a wrench 4 Apply silicone gel to the connection 5 Secure with cable ties 6 Run the marked transmit modem cable to the back of the transmitter Do not connect the cable 7 Add up all the cable lengths for the Receive cable and con sult the cable specifications on page 7 to determine ...

Page 33: ...eet NEC requirements These items are available through your local electronics supply store POLE MOUNT GROUNDING The mast which is the metal pole in this mount method is grounded to the satellite dish via an NEC approved ground wire and clamp The mast clamp must have a good electrical connection to the mast pole The RG6 coaxial cable shield con nects the satellite dish to the ground block An NEC ap...

Page 34: ...o bend the ground wire clockwise around the ground screw in between the washer and the transmitter 6 Tighten the transmitter ground screw 7 If necessary secure the ground wire using the cable ties or insulated U shaped tacks The final configuration should match Figure 41 PARTS NEEDED TOOLS NEEDED 1 4 20 x 1 2 inch hex head grounding bolt 1 4 inch star washer 1 4 inch washer 1 4 inch Nylock nut 5 8...

Page 35: ...ure 41 G G GND Block 1 Gnd Rod 2 Water Pipe AC Mains 1 Gnd Rod 2 Water Pipe 3 AC Gnd Wire GND Block Wire AC GND Wire Receive cable RG6 Quad shielded Transmit cable RG6 Quad shielded Ground wire 8 AWG aluminum ...

Page 36: ...en the start washer and 1 4 inch washer then use a wrench to tighten the nut 4 Run the ground wire from the base plate to the ground block 5 Install the split bolt and clamp nut 6 Install that ground wire and the ground block ground wire on the split bolt and clamp nut 7 If necessary secure the ground wire using the cable ties or insulated U shaped tacks depending on the mounting surface The final...

Page 37: ...hold the coaxial cable and ground wire to the mast The final configuration should match Figure 45 PARTS NEEDED TOOLS NEEDED 5 8 inch x 10 foot ground rod Ground rod clamp 1 inch x 2 3 8 inch ground clamp for metal pole available at local hardware store Cable ties 8 AWG aluminum ground wire 14 AWG copper ground wire optional 6 AWG copper ground wire optional Adjustable wrench Lineman pliers Ladder ...

Page 38: ...34 GROUNDING THE METAL POLE Figure 45 RG6 Metal Pole Ground wire 8 AWG alumimum Receive cable RG6 Quad shielded To ground block Transmit cable RG6 Quad shielded RG6 To ground block Ground Clamp ...

Page 39: ...emain exposed 3 Attach the 2 3 8 inch ground clamp 13 inches from the base of the metal pole mount 4 Attach the ground rod clamp to the ground rod 5 Bend one end of the 14 AWG copper ground wire in a 1 1 2 inch loop Attach the loop to the ground clamp or grounding lug on the metal pole and the other end of the grounding wire to the clamp on the ground rod 6 Bend one end of the 6 AWG copper ground ...

Page 40: ...rs 1 Facing the satellite dish place the shroud over the feed assembly so that the broad side is on the right Align the edge of the shroud with the groove in the feedhorn and insert it in the groove see Figure 47 Align the triangular sections also Note the shroud contains four hole plugs see see Figure 48 Make sure all the plugs stay in place and over the holes Doing so will pre vent direct rain a...

Page 41: ...r the strongest possible signal received by the DIRECWAY National Operations Center NOC Transmit pointing is done by certified professional satellite install ers After you have pointed the satellite dish you will turn off your computer and connect the transmitter Do not connect the transmit modem cable to the transmitter until you are instructed to do so The antenna pointing values calculated by t...

Page 42: ...ignal you have peaked the signal Begin by peaking the azimuth setting then peak the elevation setting and then readjust the azimuth setting if necessary After you have optimized the azimuth and elevation setting you may find that making adjustments in the polarization setting affects the optimum azimuth and elevation settings and you must go back and adjust them again You may achieve the strongest...

Page 43: ...have not already done so tighten the clamp nuts all the way then loosen them just enough to move the satellite dish side to side and adjust the azimuth The clamp bolts should be as snug as possible such that the satellite dish can still be moved from side to side Figure 51 Bracket Bolt Nut Elevation Bolt Head Clamp Bolts 3 Elevation Pivot Elevation Bolt Polarization Nuts 4 Polarization Scale TOP L...

Page 44: ...o the mast and label this mark 1 Mark the location on the AZ EL cap directly above Mark 1 This will be the azimuth alignment mark See Figure 52 Make another mark on the mast 3 4 inch to the right of Mark 1 and label it 2 Make another mark on the mast 3 4 inch to the left of Mark 1 and label it 3 5 Stand behind the satellite dish and point the front of the sat ellite dish to the left of the estimat...

Page 45: ...e modem the time it needs to lock on to the satellite signal 9 If you are receiving a signal and the tone has changed read After the satellite is detected on page 42 and go to step 11 If no signal is present and the azimuth alignment mark has not yet moved to Mark 3 on the mast return to step 8 and adjust it again You will keep moving the satellite dish a lit tle at a time until you get a signal 1...

Page 46: ...dish pointing software begin to fall When that happens slowly turn the satellite dish in the opposite direction until you regain the highest number that was previously achieved Achieving this maxi mum signal strength is called peaking the signal 13 You will now further adjust the elevation Loosen the two elevation nuts see Figure 54 Do not confuse the elevation nuts with the elevation pivot nuts N...

Page 47: ...etting by loosening the polariza tion nuts just enough to enable you to rotate the satellite dish a few degrees in each direction If the signal strength does not change set the polarization to the value you obtained from page 4 Otherwise set the polarization at the setting where you peaked the signal 20 While monitoring the signal strength number to ensure that it stays at maximum tighten the pola...

Page 48: ...ed installer ID number are required The Antenna Pointing Receiver screen shown in Figure 56 should be displayed on the monitor Note The antenna should be locked down with all adjustment nuts and bolts tightened before beginning Automated Cross Polarization 1 Click Next The Antenna Pointing Transmitter screen appears see Figure 57 Note that the Next button will be grayed out if the system senses th...

Page 49: ...again 13 Peak the elevation setting by making small adjustments to the elevation bolt Never turn it more than one quarter of a turn at a time 14 Tighten the two elevation nuts Torque them to 12 ft lbs 15 If Passed appears in the Last Results field and the Trans mitter Isolation meter is colored green stop the manual test and go to step 4 Otherwise go to step 16 16 Mark the present azimuth position...

Page 50: ...1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation This product is the subject of one or more U S or foreign patents pending DIRECWAY is a trademark of Hughes Electronics Corporation Document 1031362 0201 Rev B ...

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