MAGELLAN MSS - Mobile Satellite Internet System HARDWARE INSTALLATION MANUAL For Internal Use Only Updated January 2006 1
Table of Contents HARDWARE INSTALLATION INTRODUCTION......................................................................... 3 PRE-INSTALLATION – BEFORE THE INSTALL ......................................................................... 3 TOOLS FOR AN INSTALLATION.................................................................................................... 6 SUPPLIES – ITEMS YOU NEED TO KEEP IN STOCK ................................................................ 7 DISH INSTALLATION ..............
HARDWARE INSTALLATION INTRODUCTION The installation of a MAGELLAN MSS (Mobile Satellite System) will normally take a full working day, and probably two if this if your first installation. This manual is an important guide that will show you everything you need to know about performing a quality installation and help keep you from making costly mistakes. The most common problems that can be avoided are being ill preparation before an installation.
• • Whether or not they want DirecTV* (which may affect which satellite Direcway Satellite they commission to…See *note) The customer credit card information for monthly billing Please Contact Ground Control Dealer Services for help in filling out your Bandwidth Activation form at 805-783-4620 during normal business hours. * DIRECTV / DISH NETWORK CUSTOMERS – Must order the Universal bracket mount for your DirecTV / Dish reception.
interference from AC power lines, make sure that you DO NOT run the cables parallel with any AC power cable (that also be inside of the roof). IMPORTANT FEATURE - The MAGELLAN is self-contained a wireless system, which means the location of the MAGELLAN equipment (Wi-Fi router, modems and control panel) does not necessarily need to be near the computer workstation(s). The discussion of where to drop the cable into the vehicle may be inside of a cabinet on the opposite side of the rig.
TOOLS FOR AN INSTALLATION Below are the tools you will need to perform a mobile installation. Making sure you have the proper installation tools will save you hours on your installation.
Scissors Flashlight Extension Cord Power Bar (for the extension cord) Rope – To help lift heavy things to roof Level Wire cutters Etherent and Phone cable crimper (RJ11 and RJ45) OTHER RECOMMENDED TOOLS – These could be helpful for your installations. Handheld GPS (when you do not have a zip code) Multimeter – to help troubleshoot wiring connections Fish Tape Spring Steel – helps in running wires through walls Stud Finder – for finding support beams on roof to screw into.
Dielectric Grease –Auto Parts stores carry this. Self-Tapping Sheet Metal Screws Assorted hardware Colored Electrical Tape – To help mark cables Cable Ties (small, black and white are most common) Split Loom – For long cable runs Packing Tape for shipping. Tape- Assorted Extra Ethernet Cables Ethernet Connectors Bulk Ethernet Cable Sunscreen for those hot all-day outside installations. Batteries Windex and Paper Towels Twine for unknown issues.
DISH INSTALLATION The MAGELLAN comes shipped in one box (120 lbs) with these items: SHIPPED ITEMS • The MAGELLAN ships with this equipment: • The MAGELLAN Dish • The DW6000 Direcway Modems • The Linksys Wi-Fi Router • The MAGELLAN Remote Panel Step 1 – Check to make sure everything has been shipped in the box.
to help determine if a disturbance exists .) STEP 5 – Use a measuring tape to center the plate on the roof. Step 6 – Mark the corners of the dish. This is used later on to accurately lower the mounting plate onto sealant. STEP 7 – Mark all screw holes for drilling pilot holes. Note that you don’t need to use the factory holes, and can drill your own in the mounting plate.
STEP 9 – Drill all marked pilot holes. Make sure that you only drill down only for the distance of the length of the bolt to avoid hitting any wires that are traveling inside the roof. STEP 10 – Clean off the roof surface… Make sure that there is no residue that will keep the sealant from working. STEP 11 – Dicor White Sealant is the standard STEP 12 – Put a dab of Dicor Sealant over the top for all roof top installations for the industry. It of each of the pilot holes you drilled.
STEP 13 – Using the marking you made earlier, gently lower the mounting plate on top of the dicor & pre-drilled holes. STEP 14 – The dicor should bubble out (slightly) from each of the holes. Use liberal amounts of paper towels to clean up excess Dicor. WARNING – Do not step in Dicor because it will track on the roof create unsightly footprints. STEP 15 – Place all the screwbolts into their respective holes STEP 16 – Using a ratchet wrench, tighten all of the screwbolts into place.
TRICK - If you have a curved roof, such as a Airstream trailer… you may use rubber washers between the dish plate and the mounting plate so the mounting plate may bow to the curve of the roof. DRILLING THE CABLE ACCESS HOLE IN THE ROOF Drilling the large access hole for the MAGELLAN Cable run to inside the vehicle should be a process taken with great care.
STEP 19 Use of a long, narrow drill bit is needed to drill the hole from inside of the vehicle. Before you start your pre-drill hole, make sure that you will not be drilling into anything on top of the roof. STEP 20 - You will be using a hole saw to make a hole large enough to run the cables through the roof. Note how the hole you drilled from inside will be the guide hole for your hole saw. STEP 21 – Be patient while you are drilling and only drill as far as there is resistance to your drilling.
RUNNING CABLES IMPORTANT NOTE FOR DIRECTV USERS – The MAGELLAN works with the Universal Bracket Kit for DirecTV which will work with most DirecTV and Dish Network Satellites. Remember that the Coax for TV may need to run different on the roof than for the Internet cable run if the TV receiver is located in a different part of the RV. There are 5 cables that run from the dish to inside the rig. They are: 1. RX Coax Cable to the DW6000 Modem 2. TX Coax Cable to the DW6000 Modem 3.
STEP 24 – Drop the cable from the MAGELLAN down the hole you’ve just drilled in the roof. STEP 24B – The cable wrap (shown here in white) is porous (meaning it will leak water), so it needs to be cut back 2 inches from the access hole in the vehicle roof as shown. STEP 24C – Tie Wrap the end of the cable wrap. The exposed area of the cables are where you will use generous amounts of Dicor sealant. STEP 25 – Strip off any unused cable casing, and then make your cable runs to various equipment.
STEP 27 – Once the clamps are in place, seal the entry hole with a liberal amount of DICOR. Make sure to squeeze DICOR BEWTWEEN THE CABLES. Make sure there are no holes exposed, or you will have a leak in the roof! STEP 28 – Now cover all exposed screwheads on the mounting plate with DICOR. Do this step last when you know you won’t be on the roof any longer (to avoid stepping in the wet sealant). IMPORTANT – Make one last check to see there are no “missed holes” that are exposed to the elements.
INTERNAL WIRING Below is a schematic of a correctly connected MAGELLAN system. There are 5 cables that come down from the MAGELLAN that connect to 3 different components. 1. 2. 3. 4. 5. The RX Coax Cable that connects to the DW6000 Modem The TX Coax Cable that connects to the DW6000 Modem. The Ethernet Cable that connects to the Router (Port 1-4). A Phone Cable that connects the remote control.
The DW6000 Direcway Modems will supply the Internet connection to the Linksys Router. A standard Ethernet cable runs from the single Ethernet port on the back of the DW6000 to the “Internet” port on the back of the Router. The Ethernet cable from the dish is used for communication and is connected to one of the Routers 4 ports. The dish communicates with the DW6000 modems as well as gives any connected computer access to the MAGELLAN Administrative screen.
MAKING COAX CABLES STEP 1 – Cut the Coax cable to length. Make sure the cut is clean STEP 2 – Place the Coax Use the Coax Stripper Tool Note where the red arrow shows the coax end is flush with the V notch of the coax stripper. STEP 3 – Place a finger in the hole of the coax stripper and twirl the stripper around the cable 4 or 5 times...making complete circles. STEP 4 – Pull the stripper away from the cable (without opening the stripper) so that you remove a segment of coax shielding.
If you are having trouble making the perfect cut on your cables, the razor blades inside of the stripper are adjustable. Use the Allen Wrench (3) to adjust the blade heights (1 & 2). Note here the Allen Wrench in one of the blade height adjustment screws. STEP 5 - Fold back the wire shielding over the STEP 6 - Twist the connector onto the coax cable outer jacket as shown. Make sure the white plastic shielding that covers the copper wire is free of debris that may short out the connection.
STEP 8 - Place the coax connector into the Grip the handles and crimp the fitting tightly… connector crimper. Make sure the crimper handles You may now removed the “compressed” coax are opened…and then close the head handle. connector. The finished connector. STEP 9 - Don’t forget to use colored tape to distinguish which cable is for transmit or receive.
CONNECTING THE DISH POWER SUPPLY The MAGELLAN system is powered by a 15VDC power supply that is included with the system. Locate the power wire from the dish and attach it to the provided connector. The MAGELLAN Dish connects to a power 15VDC power supply. It ships with blue connectors that you will need to remove before you run the wires from the roof to inside the vehicle. Unscrew an end of the connectors and remove the wire from power supply.
TROUBLESHOOTING Ground Control Technical Support is available 24-7 at 805-542-0688 or by email at support@groundcontrol.
MAGELLAN SPECIFICATIONS BANDWIDTH SERVICE (Via Direcway) Download Speed…………………….. Normally 400 to 1500 Kbps Upload Speed…….………………….. Normally 30 to 100 Kbps Public IP Address……………………. Optional Protocol………………………………. TDMA VOIP Phone Service………………… Included SATELLITE DISH Satellite Acquire Time (from stowed).. Automated Cross Poll acquisition…… Reflector Type……………………….. Mount Geometry…………………….. Polarization…………………………... Deployment Sensors………………….
