Ground Control TOUGHSAT T-100 User manual

Toughsat T-100
Communications Trailer
Users Manual
TOUGHSAT T-100 COMMUNICATIONS TRAILER USERS MANUAL
Ground Control
V.3
June 2014

Toughsat T-100 Users Manual Ground Control
- 2 -
Important warning regarding your
Ground Control TOUGHSAT T-100 System
All power to the system (controller, modem, external network devices)
MUST be disconnected if connecting the satellite mount (dish) to the
rack-mounted equipment (controller and modem).
Permanent damage will occur to the unit causing it to cease functionality
until the unit is returned to Ground Control’s facility for repairs. This
damage is NOT covered under the unit’s warranty.
If you have any questions regarding connecting or operating your Ground
Control Toughsat system, stop and please contact our Technical Support Team
immediately for assistance to prevent damaging your equipment. You can
contact our 24/7 Support Team at the following:
GROUND CONTROL SUPPORT
USA Toll Free: 1-800-931-5559
International: 00-1-805-783-4633
Email: [e-mail]

Toughsat T-100 Users Manual Ground Control
- 3 -
TOUGHSAT T-100 System Information
Please fill out the information on this page with the account information supplied to you from Ground Control
and keep the manual in the rack-mount electronics case. It will be helpful both for on-site setup as well as
required information if you need to contact Ground Control for support.
Ground Control Account Number: GC____________________
iDirect or CPE Serial Number: _______________________
Modem Static IP Address: _______________________
System Type (Trailer/ Trailer & Flyaway) _______________________
Mobile System IP Address: _______________________
Router IP Address: _______________________
Contacting Ground Control Technical Support
Ground Control technical support representatives are available 24 hours per day for your convenience. Please
note that our standard hours of operation are Monday –Friday, 8AM to 5PM Pacific Standard Time. If you call
outside of these hours, support response may be delayed and certain resources may not be available to the
support agent.
For Technical Support, please call 1-800-931-5559 from the U.S. or 805-783-4633 from abroad. You may also
email [e-mail] from a computer connected to working Internet connection.

Toughsat T-100 Users Manual Ground Control
- 4 -
Table of Contents
System Information Page…………………………………………………………… Page 3
System Features & General Specifications…..…………………………………… Page 5
Included Equipment………………………………………………………………….. Page 6
Setup & Operation………………………...…………………………………………. Page 7
Starting The Generator…………………...…………………………………………. Page 10
Wiring Diagram…………………………...…………………………………………. Page 11
Deploying The Dish….…………………...…………………………………………. Page 12
Security Belt ……..….…………………...…………………………………………. Page 13
Connecting To The Internet………………………………………………………… Page 14
Accessing The Wireless Router……………………………………………………. Page 14
Access The Toughsat Web Interface……………………………………………… Page 14
Stowing the Dish.....…………………………………………………………………. Page 17
Dual Matrix……….…………………………………………………………………. Page 17
Final Walk-Around Checklist………………………………………………………. Page 18
Contact Ground Control Support…….……………………………………………. Page 19
The large rear bay of the T-100 is fully enclosed and includes a spare tire and securing straps.

Toughsat T-100 Users Manual Ground Control
- 5 -
ToughsaT T-100 TRAILER FEATURES
One Person Setup –Requires little or no training to use.
Establishes a half-mile 802.11 wireless "G" network automatically.
Download speeds of 5Mbps, Upload of 2Mbps with iDirect from Ground Control.
iDirect Evolution X5 1.5RU Satellite Router
AC Power Conditioner (1RU) for 8 - 120 VAC outlets - Good for keeping power clean.
A portable rack-mount case (6RU) for all electronics that may be easily moved.
50' (14 meters) cable run so electronics case may be moved into a structure or tent.
Four easy crank stabilization jacks - Good for high winds and uneven terrain.
Security belt for crowd control.
Spare tire
Optional - Ultra Quiet Honda 1000 Watt generator for 8 hr. run time on one tank. (2000 Watt available).
Optional trailer dolly
Works in extreme environments (rain, hail, hot, cold)
Works with any wired or wireless SIP phone. Or consider our VOIP Phone service.
Excellent back-up Internet at any location for emergency organizational use.
Rated to withstand wind speeds up to 70 MPH when using leveling jacks.
T-100 Communications Trailer General Specifications
Trailer Dimensions
138"L x 66"W x 58"H (Stowed Dish - Exterior Dimensions)
Rear Storage Space
62"L x 24"H x 46"W (Interior Dimensions)
Weight (loaded)
Under 1400 lbs (includes spare tire, gas & dolly)
Hitch Ball Size
2 Inch
Removable Tongue Length
23" (when removed, trailer is 115 inches long)
Trailer Lights Plug/cable
7-Pole, RV-Style Trailer Connector (male)
Generator
Honda EUi Ultra Quiet 1000 Watt Generator (upgradable to 2000W)
Electronic Components
Dish Controller 1 RU (Wireless "G" Access point 100' radius range)
Satellite Modem 1.5 RU - iDirect Evolution X5 Router
Power Conditioner 1 RU (with 8 AC plugs)
2.5 RU available for customer use (front) 6 RU available on back.
50' (15.3M) Quick-disconnect cable run (between dish and controller)

Toughsat T-100 Users Manual Ground Control
- 6 -
T-100 Included Equipment
●The Toughsat XP or SP Mobile System.
● A 6RU rackmount case for system electronics
● The Toughsat Controller with integrated 4-port wireless router.
● iDirect Evolution X5 1.5 RU Satellite Router.
● Power Conditioner (1 RU) for 8 AC plugs.
● 50' (14 meters) cable-run so electronics case may be located in a structure or tent.
● Optional Honda EUi 1000 Watt generator (2000 watt available).
System uses about 90 to 150 Watts during normal usage (300 Watts Max for power up spike)
● Two High-Gain range extending antennas for half-mile connectivity
These High-Gain antennas MUST be connected for any wireless connectivity.
(Antennas may be removed and stored for safety).
● Onboard battery powered cabinet lights and trailer flashers for night set-up
● Large enclosed storage area
● Quick-Release straps & railing for securing stored equipment
● Spare Tire
● Trailer Dolly
● Helicopter D-Rings (System weight under 1400 lbs).

Toughsat T-100 Users Manual Ground Control
- 7 -
T-100 SETUP & OPERATION
No Need to Disconnect Tow Vehicle
The T-100 may be operated while connected to the
tow vehicle. If connected, the trailer lights will be
supplied power from the tow vehicle. Other electronics
are powered by the trailer’s onboard generator.
If the tow vehicle is disconnected, power to the trailer
lights and flashers will be supplied by the on-board
trailer battery.
STEP 1 –FIND A LEVEL AREA. If the Toughsat is within three degrees of level, it will normally find satellite within
3.5 minutes. A bullseye level in the tow vehicle or trailer top helps. Chock the trailer wheels for both level or non
level terrain for safety.
STEP 2 –DISCONNECT THE TRAILER hitch from the tow vehicle. Don’t forget to unplug the 7 Pole connector.

Toughsat T-100 Users Manual Ground Control
- 8 -
STEP 3 –Pull the pin the holds the front wheel jack against the trailer frame. Rotate it 90 degrees so that the jack
locks into place with the wheel side down. Carefully unlock the hitch from the ball.
STEP 4 –Begin to crank up the front of the trailer so that the hitch clears the 2” ball on the tow vehicle.
The trailer dolly is a good way of moving the trailer to a different location. Also note the trailer tongue itself may be
removed by unlocking the locking pin that holds it to the trailer frame. Removing the tongue may reduce theft of the
system, or allow other tongue configurations to quickly be used on the trailer.

Toughsat T-100 Users Manual Ground Control
- 9 -
STEP 5 –RETRACT THE SUPPORT LEGS. Although use the supporting leveling legs is not mandatory, it is
recommended for high winds or accidental shifting if bumped. Unpin the legs and arms and slide both into place.
STEP 6 –Crank all jacks to level the trailer. STEP 7 –Hand tighten the two high-gain antennas
into the two bulkhead connectors on top of the trailer.
No wireless is available unless these antennas are on.
STEP 8 –OPEN THE GENERATOR CABINET. If dark, you may use the toggle switches for cabinet lights as well
as emergency flashers, both of which may run on internal battery. The rear bay has a single switch to turn on the
bay lights. The generator may say in the cabinet (running with door open), or removed from the cabinet.

Toughsat T-100 Users Manual Ground Control
- 10 -
STARTING THE GENERATOR
STEP 9. START THE GENERATOR. Close the choke if the generator is cold and open the air vent on the gas cap.
Turn on the POWER Switch to ON, and then firmly and quickly pull the starter cord to start the generator.
IMPORTANT - Make sure to turn off the choke after the motor has started.
STEP 10 –TURN ON ELECTRONICS. Inside of the electronics case is a portable 6RU rackmount case with an 50
foot cable run that allows you to move the electronics a distance from the trailer. The electronics case includes the
iDirect satellite gateway, the 8 AC plug power conditioner, and the Toughsat wireless controller. Both the gateway
and controller should power on (lights will appear) with the single toggle switch on the power conditioner.