This guide explains how to install the TracPhone V11 mini-VSAT Broadband satellite
communications system. Operation instructions are provided in the Quick Start Guide.
Installation Steps
1. Inspect Parts and Get Tools ................. 3
2. Plan the Antenna Installation .............. 4
3. Plan the Belowdecks Installation ........ 6
4. Prepare the Belowdecks Units............. 7
5. Prepare the Antenna Site.................... 10
6. Prepare the Antenna Cables .............. 11
7. Rig and Hoist the Antenna................. 14
8. Wire the Antenna ................................ 15
9. Mount the Antenna ............................. 18
10. Prepare the Data Cable ....................... 20
CAUTION - RF Radiation Hazard
The antenna transmits radio frequency
(RF) energy that is potentially harmful.
While the system is powered on, make
sure everyone stays more than 42 feet
(13 m) away from the antenna. As
shown in the illustration, this distance
increases to 101 feet (31 m) if a person
is more than 6.5 ft (2 m) above the
plane of the antenna’s base. No hazard
exists directly below the antenna.
13. Turn On the System .............................26
14. Update the System Software...............27
15. Customize the Web Interface..............28
16. Set Up No-Transmit Zones .................29
17. Test the System .....................................31
18. Connect Vessel Computers.................32
19. Connect Vessel Phones & Options.....34
20. Educate the Customer..........................35
101 ft (31 m)
6.5 ft (2 m)
42 ft (13 m)
-24°
Who Should Install the System?
To ensure a safe and effective installation, only a KVH-certified technician should install the
TracPhone system. To find a technician near you, visit www.kvh.com/wheretogetservice.
The undersigned of this letter declares that the following equipment complies with the
specifications of EC directive 1999/5/EC Radio & Telecommunications Terminal Equipment.
Equipment Included in this Declaration
TracPhone V11 system, consisting of:
•02-1982-XX
•02-1875-02 TracPhone CommBox-ACU
•19-0773 TracPhone Modem
1
The part number is followed by two alphanumeric characters which designate non-performance-
affecting customer-specific branding.
Equipment Applicability
The TracPhone V11 system provides broadband Internet connectivity between a ship and any
destination in the world. The equipment is not intended for SOLAS applications.
Declaration and Certification
The TracPhone V11 system complies with the following harmonized standards under the
R&TTE Directive 1999/5/EC:
KVH Industries, Inc.
50 Enterprise Center
Middletown, RI 02842-5279 USA
Rick Jones, Director of Corporate QualityDate
Page 4
Radome
Antenna
(KVH part #02-1982-01)
Baseplate
CommBox-ACU
(KVH part #02-1875-02)
Modem
(KVH part #19-0773)
Service Hatch (x2)
Figure 1: TracPhone V11 System Components
•NMEA 0183 talker and interface cable (see
page 22)
•Isolation transformer, if required (see page 24)
•Utility knife
•Flush cutters
•File
•Ruler or tape measure
•Voltmeter
•Laptop PC with the latest TracPhone V11
CommBox-ACU/antenna software (.kvh) and
modem configuration files (.sscf/.sed)
downloaded from the KVH Partner Portal
(www.kvh.com/partners)
1
Before you begin, follow these steps to make sure
you have everything you need for installation.
a. Unpack the box and ensure it contains
everything shown in Figure 1 and on the
Kitpack Contents List. Save the packaging.
b. Carefully examine all of the supplied parts to
ensure nothing was damaged in shipment.
c. Gather all of the following tools and
materials that you will need:
•Flat-head and Phillips-head screwdrivers
•Electric drill and 5/8" (16 mm) bit
•3.75" (95 mm) hole saw (for cable access
•5/32" hex key
•7/16" open-end torque wrench set to
Inspect Parts and Get Tools
hole, if needed)
20 in.-lbs (2.25 N-m)
•1/2" open-end wrench
•3/4" socket/ratchet or wrench
•1/4" socket/ratchet or nut driver
•7/16" socket/ratchet or nut driver
•3/4" socket/torque ratchet capable of
settings between 35 and 40 ft-lbs (47 and
54 N-m) of torque
•Light hammer and center punch
•Adhesive tape
•Eye protection
•Shop towels
•Silicone sealant, self-vulcanizing tape, or
equivalent
•Two 75RF coax cables, “F” connectors,
and termination tools (see page 11)
•Power cable (see page 13)
•Heat gun (for heat shrink)
•Wire stripper/terminal crimper
•Forehead light
3
Page 5
Figure 2: Antenna Dimensions
2
Before you begin, consider the following antenna
installation guidelines.
Plan the Antenna Installation
Choose a Suitable Mounting Surface
•Make sure the mounting surface is wide
enough to accommodate the antenna’s base
(see Figure 2).
•Make sure the mounting surface is flat, level
(within ±1º), rigid enough to withstand heavy
vibration, and strong enough to support the
antenna. The antenna weighs 240 lbs (109 kg),
excluding cables.
•Select a location that is as close as possible to
the intersection of the vessel’s centerline and
midships.
•If available, install the antenna on a platform
or pedestal, rather than on a deck, and ensure
the diameter of the mounting surface matches
the diameter of the antenna’s base (19.01"
(48.29 cm)). Both service hatches should be
fully accessible for installation and service.
•Avoid placing the antenna near any magnetic
compasses or other onboard antennas to
prevent potential interference.
Side View
57.28"
(145.50 cm)
19.01"
(48.29 cm)
Ø51.30"
(130.31 cm)
9.74"
(24.74 cm)
FWD
Bottom View
Prevent RF Radiation Exposure
Select a location that is well above any areas
accessible to passengers and crew to reduce the
risk of RF radiation exposure. (See page 1 for an
illustration of the hazard area.)
If mounting the antenna near an accessible area is
unavoidable, you may configure one or two notransmit zones to prevent transmissions in
hazardous directions. (See “Set Up No-Transmit
Zones” on page 29 for details.)
4
Service
Hatch
Ø13.78"
(35.00 cm)
Service
Hatch
Cable Connectors
(cable cover not shown)
9.74"
(24.74 cm)
Mounting Hole
4x Ø0.63" (1.59 cm)
Page 6
Blocked!
Antenna
Vessel Platform
-24° to 119°
Look Angle
Mast
Figure 3: Blockage from Obstruction
RF emissions from radars and high-power
radio transmitters may damage the antenna
or impair its performance if it’s improperly
positioned within the beam path.
IMPORTANT!
Figure 4: Minimum Distances from Radar
* Not permitted
Radar
Type
Radar
Power
Min. distance (d) at ±xxº
vertical separation
15º40º60º
X-bandUp to
50 KW
3 ft
(0.9 m)
3 ft
(0.9 m)
3 ft
(0.9 m)
S-bandUp to
10 KW
N/P*6.6 ft
(2 m)
6.6 ft
(2 m)
30 KWN/P*N/P*9.8 ft
(3 m)
50 KWN/P*N/P*16.4 ft
(5 m)
2
Continued Plan the Antenna Installation
Minimize Satellite Blockage
The antenna requires a clear view of the sky to
transmit and receive satellite signals (see
Figure 3). The fewer obstructions, the better the
system will perform.
Avoid RF Interference
Although many variables determine the exact
distance required between the antenna and
radar/high-power radio transmitters, including
transmitter beam properties and the reflective
properties of nearby surfaces, consider the
following general guidelines when selecting a
safe antenna location:
•Mount the antenna as far away as possible
from the radar and any high-power radio
transmitters.
•The minimum distance between the antenna
and the radar varies depending on the power
level of the radar and the vertical separation
you maintain between them. Using the
guidelines provided in Figure 4, mount the
antenna at least the minimum distance away
from the radar.
Radar
Antenna
d
+xx°
-xx°
Antenna
d
5
Page 7
Side View
Front View
19.00"
(48.26 cm)
16.75"
(42.55 cm)
2.63"
(6.68 cm)
18.31"
(46.51 cm)
1.75"
(4.45 cm)
11.18"
(28.40 cm)
16.31"
(41.43 cm)
1.30"
(3.30 cm)
4.90"
(12.45 cm)
4 x ø.25"
(0.64 cm)
Strain-Relief Bracket
(Modem Only)
Top View
0.44"
(1.12 cm)
Figure 5: CommBox-ACU or Modem Dimensions (Identical)
Figure 6: Case Dimensions
3
Plan the Belowdecks Installation
Before you begin, consider the following
installation guidelines for the belowdecks units.
•Select a mounting location in a dry, wellventilated area belowdecks away from any
heat sources or salt spray.
•Be sure the front panels will be easily
accessible to the user.
•Leave enough room at the rear panels to
accommodate the connecting cables.
•You have three options for mounting the
belowdecks equipment:
Option 1 - In the optional case
Option 2 - In an onboard equipment rack
Option 3 - To a horizontal surface
NOTE: The CommBox-ACU and modem are sized to
fit a standard 19" (482.6 mm) rack, occupying 3U of
space.
•To use the supplied data cable, the
CommBox-ACU must be located close
enough to the antenna to allow a 100 ft (30 m)
cable run between them. However, you can
order a longer data cable, if necessary:
150 ft (45 m): KVH part no. 32-1157-0150
300 ft (90 m): KVH part no. 32-1157-0300.
•Be sure the location provides adequate Wi-Fi
reception. Do not install it in an area
surrounded by metal or near any electrical
devices that emit RF noise.
6
11.3"
(28.7 cm)
20.5"
(52.1 cm)
20.5"
(52.1 cm)
Page 8
M4 x 16 mm Screw (x4)
Mounting Bracket (x2)
Top Cover
Bottom Cover
M4 x 12 mm Screw (x4)
Plastic Foot (x4)
1
2
3
4
5
6
7
8
9
10
11
12
Figure 7: Assembling the Case
Figure 8: Attaching the Strain-Relief Bracket
U
Figure 9: Securing the CommBox-ACU/Modem in the Case
4
Prepare the Belowdecks Units
If you plan to use the optional case, follow these
steps to assemble the case.
a. Remove the four M4 screws securing the rear
cover to the case. Discard the rear cover.
b. Attach the top cover to the case using four
M4 x 12 mm screws (see Figure 7). Attach the
bottom cover and the two mounting brackets
using four M4 x 16 mm screws.
c. Attach the four plastic feet to the bottom
cover (see Figure 7).
d. At the front of the case, insert eight cage nuts
into the following locations on the frame
(four on each side) (see Figure 7): no. 2, no. 5,
no. 9, and no. 12.
e. At the back of the case, insert four cage nuts
into the following locations on the frame (two
on each side): no. 1 and no. 3.
f.Remove the four #6-32 screws and washers
securing the two retaining straps to the sides
of the modem. Do not remove the top screws
securing the straps to the CommBox-ACU.
Case Mount
CommBox-ACU
Retaining
Strap (x2)
g. Attach the supplied strain-relief bracket to
the retaining straps and modem using the
screws and washers you removed in Step f
(see Figure 8).
h. At the top 3U section of the case, insert the
CommBox-ACU/modem assembly and
secure the front mounting brackets to the case
using four M6 screws and washers (see
Figure 9).
i.Secure the back of the CommBox-ACU to the
back of the case using the two supplied “Z”
brackets. Attach the brackets to the case
frame using four M6 screws and washers.
Attach the brackets to the rear panel of the
CommBox-ACU using four #6-32 screws and
washers (see Figure 9).
j.At the bottom 3U section of the case, attach
the supplied blank panel using four M6
screws and washers (see Figure 9).
k. Once you have completed all system wiring,
mount the case to the vessel using fasteners
appropriate for the mounting surface.
Modem
Tie-Wrap
Holes (x42)
Attach to Case
Plastic Washer (x4)
CommBox-ACU
and Modem
Blank Panel
Strain-Relief
Bracket
M6 Screw (x4)
Case
Plastic Washer (x8)
M6 Screw (x8)
#6-32 Screw (x4)
#6 Washer (x4)
Attach to CommBox-AC
#6-32 Screw (x4)
#6 Washer (x4)
“Z” Bracket (x2)
Cage Nut (x4)
Cage Nut (x8)
7
Page 9
Figure 10: Attaching the Strain-Relief Bracket
Figure 11: Securing the CommBox-ACU/Modem in the Rack
4
Prepare the Belowdecks Units
If you plan to use an existing equipment rack,
follow these steps to secure the equipment in the
rack.
a. Remove the four #6-32 screws and washers
securing the two retaining straps to the sides
of the modem. Do not remove the top screws
securing the straps to the CommBox-ACU.
b. Attach the supplied strain-relief bracket to
the retaining straps and modem using the
screws and washers you removed in Step a
(see Figure 10).
c. Insert the CommBox-ACU/modem assembly
into the rack and secure the front mounting
brackets to the rack using four M6 screws and
washers (see Figure 11).
CommBox-ACU
Tie-Wrap
Holes (x42)
Retaining
Strap (x2)
Strain-Relief
Bracket
Rack Mount
Modem
#6-32 Screw (x4)
#6 Washer (x4)
CommBox-ACU
Modem
Attach to Rack
M6 Screw (x4)
Plastic Washer (x4)
8
Page 10
Figure 12: Attaching the Strain-Relief Bracket
Figure 13: Attaching the Mounting Brackets
#6 Washer (x4)
#6-32 Screw (x4)
Bracket (x2)
CommBox-ACU
Modem
Ø.156" (Ø3.96 mm)
Mounting Hole (x4)
4
Prepare the Belowdecks Units
If you plan to mount the CommBox-ACU and
modem to a horizontal surface, without using the
optional case or an equipment rack, follow these
steps to attach the strain-relief bracket and “L”
mounting brackets.
a. Remove the four #6-32 screws and washers
securing the two retaining straps to the sides
of the modem. Do not remove the top screws
securing the straps to the CommBox-ACU.
b. Attach the strain-relief bracket to the
retaining straps and the modem using the
screws and washers you removed in Step a
(see Figure 12).
c. Attach the supplied “L” mounting brackets to
the sides of the modem using four #6-32
screws and washers (see Figure 13).
d. Once you have completed all system wiring,
mount the modem/CommBox-ACU
assembly to the vessel using fasteners
appropriate for the mounting surface.
Horizontal Surface Mount
CommBox-ACU
Retaining
Strap (x2)
Tie-Wrap
Holes (x42)
Strain-Relief
Bracket
#6-32 Screw (x4)
#6 Washer (x4)
Modem
9
Page 11
Figure 14: Antenna Mounting Holes Layout
Deck
Gooseneck
Gooseneck
FoamSeals
ABC
D
Foam
Seals
Antenna Cables
Figure 15: Antenna Mounting Examples
5
Once you have identified a suitable antenna
mounting site, follow these steps to prepare the
site for installation.
Prepare the Antenna Site
Drill the Mounting Holes
a. Unfold the antenna mounting template
(supplied in the Customer Welcome Kit) and
place it onto the mounting surface. Make sure
the “FWD” (forward) arrow points toward
the bow and is parallel to the vessel’s
centerline (see Figure 14).
NOTE: You don’t need to mount the antenna exactly
on the vessel’s centerline, but the antenna’s forward
arrow must be parallel to it.
9.74"
(247.40 mm)
Face Vessel Bow
FWD
Ø3.75" (Ø95.3 mm)
Cable Access Hole
Foam Seal
(if necessary)
b. Using a light hammer and center punch,
mark the locations for the four mounting
holes on the mounting surface in the
locations indicated on the template.
c. Drill a 5/8" (16 mm) hole at the four
mounting hole locations. Later, you will
insert four 1/2"-13 bolts through these holes
to mount the antenna.
Cut Out the Cable Access Hole, If Needed
If you plan to route the antenna cables
belowdecks through a hole directly underneath
the antenna (such as examples C and D in
Figure 15), follow the steps below.
a. Using the supplied template, mark the
location of the cable access hole in the center
of the mounting hole pattern (see Figure 14).
b. Cut out the 3.75" (95 mm) cable access hole in
the location you marked in Step a. Smooth
the edges of the hole to protect the cables.
(You may also apply anti-chafe material
around the cables to prevent abrasion.)
c. Clean and dry the antenna mounting surface.
Good Bolt
Pattern
9.74"
(247.40 mm)
Ø.63" (Ø15.88 mm)
Mounting Hole (x4)
Poor Bolt
Pattern
10
d. Peel off the paper backing from one of the
supplied foam seals to expose the adhesive.
Then press the foam seal down firmly onto
the mounting surface, ensuring the hole in
the foam seal aligns with the cable access hole
in the mounting surface (see Figure 14).
Page 12
Figure 16: RF Cable Requirements
25 -100 ft (8-30 m) Cable Run
CableLMR-400-75
(KVH part no. 32-0944-0100,
100 ft (30 m))
Loss: 0.06 dB/ft (0.195 dB/m)
ConnectorTimes Microwave EZ-400-FMH-75*
ToolsTimes Microwave TK-400EZ-75
(KVH part no. 72-0374-75**)
Strip
Lengths
101-300 ft (31-90 m) Cable Run
Call KVH for lengths over 200 ft (60 m)
CableLMR-600-75
(KVH part no. 32-0945-0200, 200 ft
(60 m))
Loss: 0.04 dB/ft (0.13 dB/m)
ConnectorTimes Microwave EZ-600-FMH-75*
ToolsTimes Microwave TK-600EZ
(KVH part no. 72-0375-75**)
Strip
Lengths
0.250" (6.35 mm)
0.370" (9.40 mm)
0.108" (2.74 mm) dia.
0.870" (22.10 mm)
•RF cables must be rated for 75, not 50.
•Low-quality, poorly terminated, or
improperly installed RF cables are the
most common cause of system problems.
Terminate all RF cables with high-quality
“F” connectors using the proper
stripping/crimping tools, exactly to the
manufacturer’s specifications.
•Make sure the center conductor pin at
each end of the finished cables is 1/4"
(0.20"-0.28") (5-7 mm) in length, measured
from inside the nut to the tip, to ensure
proper engagement. Instructions for
terminating LMR-400-75 cable are provided
on page 36.
•Each RF cable run must not exceed 6.5 dB
of insertion loss. Keep in mind that an inline connector adds at least 0.2 dB of loss.
•Cables must be at least 25 ft (8 m) in
length.
•Call KVH Technical Support if you need
to use cables longer than 200 ft (60 m). An
antenna setting might need to be adjusted
over the air for the longer cable run.
•When determining cable lengths, don’t
forget to account for service loops,
approximately 8" (20 cm) at each end.
IMPORTANT!
6
Follow these steps to prepare and route the RF,
power, and data cables to the antenna location.
Prepare the Antenna Cables
Prepare the Customer’s RF Cables
You need to connect two 75 RF coax cables
from the antenna location to the belowdecks
equipment. Refer to Figure 16 to determine the
type of cables and connectors required for your
cable run. Then prepare both of them as
described below.
0.065" (1.65 mm) dia.
0.170" (4.32 mm)
0.344" (8.74 mm)
0.610" (15.49 mm)
a. Terminate both ends of the cables with the
proper “F” connectors (see Figure 16 for
connector and tool part numbers).
b. Label both ends of the two RF cables. Label
one cable “TX,” and label the other “RX.”
11
Page 13
Use of the supplied pigtail cables is
mandatory. Do not connect the customer’s RF
cables directly to the antenna.
IMPORTANT!
Figure 17: Connecting the Pigtail Cables to the RF Cables
6
Continued Prepare the Antenna Cables
Connect the Customer’s RF Cables to the
Supplied Pigtail Cables
a. Clean and dry the RF cables’ connectors.
b. Heat shrink is supplied with each 3 ft (90 cm)
pigtail cable to protect the connection
between the customer’s RF cables and the
pigtail cables. Slide a heat shrink sleeve onto
the end of each 3 ft (90 cm) pigtail cable
(opposite the boot end) for later use.
c. Fill half of the inner body of the customer’s
“TX” RF cable’s connector with the supplied
silicone grease to prevent moisture and
corrosion.
Seal connection with
silicone sealant or
self-vulcanizing tape,
then apply heat-shrink
P
I
G
T
A
I
L
Feed-thru Adapter
Apply Silicone Grease
d. Connect and SLOWLY hand-tighten the
“TX” RF cable to the feed-thru adapter of one
of the supplied LMR-400-75 pigtail cables,
allowing the grease to diffuse and settle into
the entire space within the connector (see
Figure 17).
e. Make sure the RF cable’s connector is
tightened all the way into the pigtail cable’s
feed-thru adapter. Then tighten it with a
7/16" torque wrench set to 20 in.-lbs.
f.Seal the RF cable-to-pigtail connection using
silicone sealant, self-vulcanizing tape, or
equivalent. Then protect the connection with
the heat shrink (see step b).
g. Repeat steps c-f to connect the “RX” RF cable
to the other pigtail cable.
To Modem
R
F
C
A
B
L
E
12
Page 14
Figure 18: Power Cable Recommendations
Cable LengthSuggested Gauge
Up to 100 ft (30 m)14 AWG
101-300 ft (31-90 m)12 AWG
Be sure to comply with all applicable
electrical codes and safety standards for the
vessel’s country of origin and vessel type.
IMPORTANT!
Figure 19: Cables Ready to Connect to Antenna
Figure 20: Minimum Bend Radius of RF Cables
Cable TypeMinimum Bend Radius
LMR-400-754.5" (11.5 cm)
LMR-600-756" (15.3 cm)
6
Continued Prepare the Antenna Cables
Prepare the Customer’s Power Cable
You will need to connect a power cable from the
antenna to the vessel’s 100-240 VAC power
supply. The cable must be a marine-grade,
3-conductor, stranded (flexible, bend radius of at least 3" (8 cm)) power cable suitable for carrying
500 watts AC power to the antenna with less than
a 5% voltage drop across its length. Refer to
Figure 18 for the suggested cable gauge for your
cable run.
Route the Cables Belowdecks
a. Keep the ends of the data, power, and RF
cables shown in Figure 19 at the antenna
location.
b. Route the opposite ends of the cables
belowdecks through the cable access hole.
Leave an adequate service loop,
approximately 8" (20 cm) of slack, in all of the
cables at the antenna location for easy
serviceability.
RF Pigtails
TX
RX
DataPower
Foam Seal
(if necessary)
c. Route the cables to the belowdecks
equipment. Be sure to always maintain the
minimum bend radius in the RF cables (see
Figure 20). Later, you will connect the data
cable to the CommBox-ACU, the power cable
to the vessel’s AC power supply, and the RF
cables to the modem.
WARNING
Do not connect the power cable to vessel AC
power yet. You will connect power in Step 12
on page 24.
13
Page 15
Take protective measures to avoid gouging or
scratching the radome during the rigging
operation.
IMPORTANT!
Figure 21: Service Hatches
1/2"-13 Shipping
Bolt (x4)
Do not remove the 4 inner
bolts securing the antenna
assembly to the baseplate!
Figure 22: Shipping Bolts (Antenna Bottom View)
Lift Bracket (x4)
Rope to Prevent
Tipping
Rope
Center of Gravity
Figure 23: Crane Rigging (Example)
7
Follow these steps to detach the antenna from the
pallet and safely rig the antenna for crane
hoisting.
a. Using a 7/16" socket/ratchet or nut driver,
unlock the three hex latches securing each of
the antenna’s service hatches (see Figure 21).
Then gently lower the hatches. You can now
access the four shipping bolts securing the
antenna’s baseplate to the pallet.
b. Using a 3/4" socket/ratchet or wrench,
remove the four outer 1/2"-13 bolts securing
the antenna to the pallet (see Figure 22). Do
not remove the four inner bolts that secure
the internal antenna assembly to the
baseplate.
Rig and Hoist the Antenna
Hatch (x2)
1/4-turn Hex Latch (x6)
c. Close both antenna service hatches. Secure
each hatch using the three hex latches.
d. Secure the crane rigging to the antenna’s four
lift brackets (see Figure 23). Be sure the
rigging and crane are suitably rated to safely
lift the 240 lbs (109 kg) antenna.
WARNING
Be sure no personnel stand underneath the
antenna at any time while it is suspended in
the air.
e. Carefully hoist the antenna to its mounting
location.
14
Page 16
Foam Seal
(if necessary)
MTX MRX
Data
Power
Figure 24: Foam Seal and Connectors on Base of Antenna
Figure 25: Connecting the Pigtail Cables to the Antenna
8
Follow these steps to connect the antenna cables.
Wire the Antenna
Attach the Second Foam Seal, If Needed
If you routed the cables belowdecks through a
hole directly underneath the antenna location
(see “Cut Out the Cable Access Hole, If Needed”
on page 10), follow these steps to attach the
second foam seal to the base of the antenna.
a. Clean and dry the bottom of the antenna.
b. Peel off the paper backing from the second
foam seal to expose the adhesive. Align the
foam seal so it is centered on the antenna (see
Figure 24). Then press the foam seal firmly
onto the underside of the antenna.
Connect the RF Pigtail Cables
a. Clean and dry the antenna’s two RF
connectors, labeled “MTX” and “MRX” (see
Figure 24).
b. Place one of the supplied rubber connector
washers over the “MTX” jack on the bottom
of the antenna, as shown in Figure 25.
c. Fill half of the inner body of the “TX” pigtail
cable’s male connector with silicone grease.
d. Connect and SLOWLY hand-tighten the
“TX” pigtail cable to the antenna’s “MTX”
jack, allowing the grease to diffuse and settle
into the entire space within the connector.
e. Make sure the “TX” pigtail cable’s connector
is tightened all the way into the antenna’s
connector and the rubber washer is
compressed against the antenna’s base. Then
tighten the connector with a 7/16" torque
wrench set to 20 in.-lbs.
f.Apply a thin layer of silicone grease to the
jacket of the “TX” pigtail cable, along the
wider segment at the base of the connector.
g. Slide the rubber boot up the cable until it
covers the entire connector and mates with
the rubber washer. This will protect the
connection from the elements.
h. Wipe off any excess grease from the cable.
i.Repeat steps b-h to connect the “RX” pigtail
cable to the antenna.
To Modem
Antenna Baseplate
Rubber Washer
Apply Silicone Grease
Rubber Boot
P
I
G
T
A
I
L
R
F
C
A
B
L
E
15
Page 17
Figure 26: Connector Module Cover
Insert AC Power Cable
Through Sealing Gland
Pass Wires Through Access Hole
and Wire to Terminal Block
On/Off Switch
Line
(100-240 VAC)
Neutral
Ground
L2
L1
GRD
Figure 27: Power Cable Wiring
8
Continued Wire the Antenna
Connect the Data Cable
Connect the data cable to the “Data” jack on the
base of the antenna (see Figure 24 on page 15).
Hand-tighten until the connector locks in place;
do not use excessive force.
Connect the Power Cable
WARNING
Cover
Connector Module
Do not connect the power cable to vessel AC
power yet. You will connect power in Step 12
on page 24.
a. Using a 7/16" socket/ratchet or nut driver,
unlock the three hex latches securing each of
the antenna’s service hatches (see Figure 21
on page 14). Then gently lower the hatches.
b. Loosen the four captive screws securing the
cover to the connector module (see
Figure 26). Detach the cover.
c. Pass the power cable through the sealing
gland on the antenna baseplate then through
the vacant access hole in the connector
module (see Figure 24 on page 15 and
Figure 27).
d. Strip the jacket from the end of the power
cable. Then strip back the insulation of all
three wires approximately 1/4" (6 mm) and
gently twist each wire to ensure a good
connection.
Captive Screw (x4)
e. Crimp a ring terminal (supplied in the
kitpack) onto the end of each power wire.
f.Connect the wires to the terminal block as
shown in Figure 27.
g. Reattach the connector module’s cover.
h. Make sure the On/Off switch on the side of
the connector module is set to On (|).
i.Extract any excess cable through the sealing
gland, then tighten the gland by twisting its
nut onto the cable.
16
Page 18
Label
Label
Label
Label
Label
#6-32 Captive
Screw and
Washer (x6)
Cable
Cover
Foam
Seals
(if needed)
Figure 28: Cable Cover
Figure 29: Strain-relief Example
Strain-relief and
Service Loops
(cutaway view)
Seal Access Hole
Deck
Maintain minimum
bend radius!
Gooseneck
To Belowdecks
Equipment
The integrity and reliability of the RF cables is
critically important. Make certain that these
cables are properly terminated, sealed against
seawater and corrosion, strain-relieved,
protected from abrasion, and free of stress.
IMPORTANT!
8
Continued Wire the Antenna
Protect the Cables
a. Position the cable cover (supplied in the
kitpack) over the antenna’s cable connectors
and secure in place with the six #6-32 captive
screws and washers (see Figure 28).
b. Secure the cables near the antenna connectors
to relieve stress (such as the example in
Figure 29). The cable cover is designed for
aesthetics only – it does not provide any
support for the cables and may become
damaged if cables are not properly strainrelieved.
c. Weatherproof and seal the cable access hole,
as required.
Power/Data
13V
18V
18V/22KHz
13V/22KHz
17
Page 19
Cable Connectors
(Face Stern)
Forward Arrow
Inside Baseplate
(Point Toward Bow)
Hatch
Hatch
FORWARD
Antenna
(Top View)
Figure 30: Forward Arrow in Antenna Baseplate
If the foam seals are used, do not reposition
the antenna laterally once the antenna’s foam
seal has made contact with the foam seal on
the mounting surface. If you need to
reposition the antenna, lift the antenna first to
avoid damage to the foam seals.
IMPORTANT!
1/2"-13 Bolt (x4)
1/2" Flat
Washer (x4)
Rubber
Foot (x4)
Mounting
Surface
1/2" Flat
Washer (x4)
1/2"-13 Lock
Nut (x4)
Antenna
Baseplate
Isolation
Bushing (x4)
(preinstalled)
IMPORTANT!
Apply anti-seize
to threads
Foam Seals
(if used)
Stationary
Plate
Figure 31: Mounting the Antenna (Side View)
9
Mount the Antenna
Follow these steps to mount the antenna to the
mounting surface.
a. Position the antenna over the holes drilled in
the mounting surface and make sure the
forward arrow inside the baseplate points
toward the bow and is parallel to the vessel’s
centerline (see Figure 30).
b. Carefully lower the antenna onto the
mounting surface and ensure the mounting
holes (and foam seals, if used) are aligned.
CAUTION
Observe the safety warnings printed on the
tube of Loctite
“Contains mineral oil, calcium hydroxide,
and copper. May cause skin, eye, and
respiratory irritation. Wear eye protection
and gloves. First aid: In case of eye or skin
contact, flush with water. Obtain medical
attention for any eye or internal contact.”
c. Apply a thin layer of the supplied anti-seize
lubricant to the threads of the four supplied
1/2"-13 mounting bolts to prevent galling.
d. At each of the four antenna mounting holes,
place a 1/2" flat washer on a 1/2"-13 bolt and
insert the bolt into the hole from above (see
Figure 31).
e. Secure each mounting bolt to the mounting
surface using a 1/2" flat washer and a 1/2"-13
lock nut from below (see Figure 31).
f.Tighten the mounting bolts in a cross pattern
until the four rubber feet on the baseplate are
bottomed against the mounting surface. KVH
recommends that you tighten the nuts to
between 35 and 40 ft-lbs (47 and 54 N-m) of
torque.
18
®
anti-seize lubricant:
Page 20
k
Figure 32: Removing the Lift Brackets
k
Figure 33: Reinstalling the Radome Hardware
9
g. Disconnect the crane rigging.
h. Remove the eight screws, flat washers, and
lock nuts securing the four lift brackets to the
antenna (see Figure 32). Use a 5/32" hex key
to keep the screws from turning, and use a
1/2" open-end wrench to loosen and remove
the nuts. Remove the lift brackets and
hardware and set them aside.
NOTE: Save the brackets and bracket hardware in
case the antenna needs to be moved in the future.
i.Install eight 1/4"-20 screws and washers
(supplied in the kitpack) in place of the
longer mounting bracket screws you
removed in the previous step (see Figure 33).
j.Close both antenna service hatches. Secure
each service hatch using the three hex latches.
Continued Mount the Antenna
1/4"-20 x 1.5"
Screw (x8)
Counter-sun
Washer (x8)
Lift Bracket
(x4)
1/4"-20 Flat
Washer (x8)
1/4"-20 Lock
Nut (x8)
1/4"-20 x 7/8"
Screw (x8)
Counter-sun
Washer (x8)
19
Page 21
Figure 34: Removing the Cable Jacket
Figure 35: Cutting the Cable Braid Bulge
Figure 36: Cutting the Drain Wire, Foil, and Fiber
10
Follow these steps to attach the supplied
grounding sleeve to the antenna’s data cable.
a. At the CommBox-ACU location, cut the end
of the antenna’s data cable to the desired
length, being sure to maintain an 8" (20 cm)
service loop in the cable for easy
serviceability.
b. Using a ruler, measure 7.5" (19 cm) back from
the end of the cable. Then, using a utility
knife to carefully cut in a rocking motion,
sever only the cable’s plastic jacket (outermost layer) (see Figure 34). Then twist off the
severed length of the plastic jacket.
c. Measure 6" (15 cm) back from the end of the
cable. At that point, carefully pinch the cable
braid to create a bulge. Then, using needlenose cutting pliers, cut the braid along the
center of this bulge (see Figure 35).
Prepare the Data Cable
d. Cut the cable’s drain wire, foil insulation, and
fiber to the same length so that their ends are
flush with the end of the cable braid (see
Figure 36).
Drain Wire
Foil
Fiber
20
Page 22
Grounding
Sleeve
Figure 37: Aligning the Grounding Sleeve
Figure 38: Attaching the Grounding Sleeve
Grounding
Sleeve
Heat Shrink
Tubin g
Figure 39: Heat Shrink Tubing
Figure 40: Ring Terminal
10
e. Thread the data cable through the supplied
grounding sleeve. Position the grounding
sleeve by aligning the end of its attached
ground wire with the ends of the other wires
in the data cable (see Figure 37).
f.Using a heat shrink gun, begin evenly heating
the grounding sleeve at the end farthest from
the end of the cable to create a seal with the
cable’s plastic jacket (see Figure 38).
g. Slowly begin applying heat evenly to the
grounding sleeve moving toward the far end
of the grounding sleeve until you reach the
grounding sleeve’s solder ring. Continue
applying heat evenly to the ring until the
ring’s solder begins to wick into the cable
braid. Then continue applying heat while
working toward the grounding sleeve’s
remaining length (see Figure 39).
Continued Prepare the Data Cable
SealSolder Ring
h. Thread the data cable through the heat shrink
tubing (supplied in the kitpack). Align the
tubing so that the grounding sleeve
protrudes slightly and is barely visible (see
Figure 39).
i.Begin heating the tubing to create a seal by
applying heat and working from one end of
the tubing, in the same direction you heated
the grounding sleeve.
j.Strip a 1/4" (6 mm) length from the end of the
grounding sleeve’s ground wire. Then insert
the wire into the supplied ring terminal and
crimp it into place (see Figure 40).
k. Dress all of the data cable’s wires. Strip back
the insulation of each wire approximately
1/4" (6 mm) and gently twist each wire to
ensure a good electrical connection.
Ring
Terminal
21
Page 23
Figure 41: Antenna Data Cable Wiring
The diagram refers to wires by body color/
stripe color. For example, “Brown/White”
means the brown wire with white stripe.
IMPORTANT!
Figure 42: NMEA Wiring
11
Wire the Belowdecks Equipment
Follow these steps to wire the belowdecks
equipment (see page 43 for a complete wiring
diagram).
Connect the Antenna Data Cable
a. Connect the antenna data cable to the
supplied 16-position terminal strip connector
as shown in Figure 41.
AC Input
100-240V; 1.6-0.8A 50/60 Hz
Fuse 3A, 250V ~ Fast Acting
WiFi
N
Maintenance
RS232
Antenna
Red (+48V)
Black (Gnd)
White/Gray
CommBox-ACU
NMEA
Voice Lines (Analog)User Ethernet PortsEthernet
To Modem
Gray/White
White/Orange
Orange/White
White/Brown
RS422
Brown/White
White/Blue
Blue/White
White/Green
Green/White
Red/Orange
Orange/Red
Red/Green
Green/RedB A
1000
Tested to comply
with FCC Standards
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
12
RISK OF ELECTRIC SHOCK
1234
0
To Modem
CAUTION
DO NOT OPEN
BUC Power
24VDC , 2.5A
WiFi
b. Plug the terminal strip connector into the rear
panel of the CommBox-ACU.
c. Connect the data cable’s ground wire
(attached to the grounding sleeve) to the
ground screw on the rear panel of the
CommBox-ACU.
Connect a NMEA 0183 Talker
a. Connect a NMEA 0183 talker (customer-
supplied) to the supplied 2-position terminal
strip connector as shown in Figure 42. Make
sure the device is configured to transmit one
of the following messages at 4800 baud to
provide true or magnetic heading:
•$--HDG
Grounding
Sleeve
Red
Black
White/Gray
Gray/White
White/Orange
Orange/White
White/Brown
Brown/White
White/Blue
Blue/White
White/Green
Green/White
Red/Orange
Orange/Red
Red/Green
Green/Red
Terminal Strip Connector
12111098761254313 14
15 16
•$--HDM
•$--HDT
•$--OSD
•$--THS
•$--VHW
NOTE: The system does not accept heading messages
that conform to the NMEA 2000 standard.
b. Plug the terminal strip connector into the rear
panel of the CommBox-ACU.
22
AC Input
100-240V; 1.6-0.8A 50/60 Hz
WiFi
N
Fuse 3A, 250V ~ Fast Acting
NMEA 0183 Talker
Ship’s Heading
B
A
Maintenance
RS232
NMEA
Red (+48V)
Black (Gnd)
White/Gray
Gray/White
White/Orange
Orange/White
White/Brown
Brown/White
White/Blue
Blue/White
White/Green
Green/White
Wire Color/Stripe Color
To Antenna
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
(1) This device must not cause harmful interference, and (2) This device must accept any
interference received, including interference that may cause undesired operation.
Manufactured in USA.
CommBox-ACU
NMEA
Voice Lines (Analog)User Ethernet PortsEthernet
To Modem
12
RS422
Red/Orange
Orange/Red
Red/Green
Green/RedB A
1000
Tested to comply
with FCC Standards
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
Terminal Strip
12
Connector
RISK OF ELECTRIC SHOCK
1234
0
To Modem
CAUTION
DO NOT OPEN
BUC Power
24VDC , 2.5A
WiFi
Page 24
If you are using LMR-600-75 RF cables, do not
connect them directly to the modem. Connect
the supplied 1 ft (30 cm) LMR-400-75 pigtail
cables in-line between the RF cables and the
modem.
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
(1) This device must not cause harmful interference, and (2) This device must accept any
interference received, including interference that may cause undesired operation.
J4
ACU
CommBox-ACU
White/Brown
To Antenna
Brown/White
Manufactured in USA.
NMEA
White/Blue
Blue/White
White/Green
Green/White
Red/Orange
Orange/Red
Red/Green
Green/RedB A
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
J6
BUC PWR
J8USERENET
User ENet
J7
ACU
ENET
White/Gray
Gray/White
White/Orange
Orange/White
To Modem
J5
To Modem
RS422
1000
Tested to comply
with FCC Standards
CAUTION
NO OPERATOR
SERVICEABLE
PARTS INSIDE,
DO NOT OPEN
Voice Lines (Analog)User Ethernet PortsEthernet
Ethernet 0
12
RISK OF ELECTRIC SHOCK
CAUTION
DO NOT OPEN
0
To Modem
1234
BUC Power
24VDC , 2.5A
WiFi
23
Page 25
TracPhone Equipment
Ground
Neutral
100-240 VAC
Ground Fault
Monitor
(when required)
TracPhone Equipment
Ground
50-120 VAC
Shipboard
Two-Phase,
Split-Phase,
or Delta Power
50-120 VAC
Leakage Current
TracPhone Equipment
Shipboard
3-Wire
Single-Phase
AC Power
Ground
Neutral
N
100-240 VAC
OR
OR
Single-Phase
Power Input
Isolation Transformer
Ground
Ground
50-120 VAC
50-120 VAC
Shipboard
Two-Phase,
Split-Phase,
or Delta Power
N
Figure 45: AC Power Options
12
Before you begin, be sure that you understand
the following important requirements:
AC Power Requirements
The TracPhone system is designed to run on
3-wire single-phase AC power (hot, neutral, and
ground). Voltage between hot-neutral and hotground should each measure between 100-240
VAC.
Many large ships use two-phase, split-phase, or
delta power instead (3 wires: hot, hot, and
ground; no neutral). In this case, voltage between
hot-hot measures the proper voltage (100-240
VAC); while hot-ground measures only half the
voltage (50-120 VAC). Although the TracPhone
system can operate on this type of power, the
excess voltage present on the second phase will
cause a small amount of current to leak onto
ship's ground. This leakage current might be
unacceptable on some vessels. So check with the
customer or ship's electrician and get permission
before you run the system on two-phase power.
Also be sure to ground the system (see below).
If two-phase power is the only available power
source onboard, and if leakage current is
unacceptable, KVH recommends that you install
a suitable isolation transformer to supply singlephase power to the antenna system and run a
ground wire from the transformer to ship's
ground. In addition, since ground fault
protection devices cannot detect faults behind a
transformer, you will also need to install a
ground fault monitoring device between the
isolation transformer and the antenna system if
ground fault protection is required on the vessel.
Connect Power
24
Grounding Requirements
Proper grounding of the TracPhone system to
ship's ground is critically important, as it protects
the equipment from lightning and electrostatic
discharges (ESD). Failure to ground both the
chassis of the CommBox-ACU and the antenna’s
AC power cable to the ship’s common ground
risks damage to the antenna and electric shock.
Page 26
Figure 46: Power Wiring
12
Continued Connect Power
Once you understand the requirements listed on
page 24, follow these steps to connect power.
a. Before you begin, disconnect vessel power
and be sure the vessel is properly grounded
in accordance with marine standards.
b. Connect the supplied AC power cords to the
CommBox-ACU and modem (see Figure 46).
c. Connect the supplied ground wire from the
ground screw on the CommBox-ACU rear
panel to ship’s ground.
Failure to ground the TracPhone system
properly to ship's ground will cause an
unsafe floating ground condition, risking
damage to the antenna and electric shock,
potentially resulting in DEATH. In a
floating ground condition, the difference
between the equipment's chassis ground and
the ship's ground can measure well over
100 volts, when it normally should not
exceed 25 volts. Therefore, always measure
the difference in potential between chassis
ground and ship's ground to make certain
that there is no dangerous floating ground
condition, even if the ground pin of the
vessel's AC power plug appears to be intact.
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
(1) This device must not cause harmful interference, and (2) This device must accept any
interference received, including interference that may cause undesired operation.
100-240 VAC
Ship’s Ground
J5
CONSOLE
J4
ACU
Orange/White
White/Brown
To Antenna
Manufactured in USA.
Brown/White
White/Blue
Blue/White
White/Green
BUC PWR
Green/White
Red/Orange
Orange/Red
J6
Antenna
NMEA
To Modem
RS422
Red/Green
Green/RedB A
1000
Tested to comply
with FCC Standards
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
J8
USER
ENET
J7
ACU
ENET
CommBox-ACU
Voice Lines (Analog)User Ethernet PortsEthernet
CAUTION
NO OPERATOR
SERVICEABLE
PARTS INSIDE,
DO NOT OPEN
12
RISK OF ELECTRIC SHOCK
CAUTION
DO NOT OPEN
0
To Modem
1234
BUC Power
24VDC , 2.5A
Modem
WiFi
d. Using tie-wraps, secure all wires to the strain-
relief bracket at the back of the CommBoxACU and modem. Leave enough slack for
easy serviceability.
e. Plug the CommBox-ACU and modem power
cords into the vessel’s 100-240 VAC supply.
f.Connect the antenna’s AC power cable to the
vessel’s 100-240 VAC supply via a marinegrade circuit breaker (or equivalent) that
complies with all applicable electrical codes
and safety standards. If the breaker is not
located within sight of the antenna, it must be
able to be locked open. Be sure to connect the
cable’s ground wire to the ship’s common
ground.
NOTE: Consider installing an uninterruptible power
supply (UPS) to avoid service interruptions during
power outages and transitions to/from shore power.
25
Page 27
Power Buttons
STATUS
CommBox-ACU
Modem
Figure 47: Power Buttons
Once the system is online, do not turn it off
for 30 minutes to allow the modem to
download the latest SSCF/SED configuration
files via the satellite. If the modem is unable
to connect, you may upload the files
manually via the modem’s web interface.
Details are available to technicians on the
KVH Partner Portal and in the Help.
IMPORTANT!
Figure 48: Status Lights
Figure 49: Connecting Your Laptop to the CommBox-ACU
13
Turn On the System
Follow these steps to turn on the TracPhone
system for the first time.
a. Double-check all of your wiring.
b. Ensure the antenna has a clear, unobstructed
view of the sky.
c. Apply vessel power to the TracPhone system.
d. Press the power buttons on the front of the
modem and CommBox-ACU (see Figure 47).
The buttons’ lights should illuminate green.
e. Wait 5 minutes for system startup.
f.Verify that the status lights on the CommBox-
ACU and modem (see Figure 48) exhibit the
following conditions:
•Control Unit: Lit green
•Antenna: Lit or flashing green
•Modem: Lit or flashing green
•Status: Any condition except off
g. Connect your PC to the “User Ethernet 1”
port on the rear panel of the CommBox-ACU
(see Figure 49).
h. Open a web browser on your PC and enter
the following address: http://minivsat.kvh.
Verify that the TracPhone V11 web interface
appears in your browser. If the web interface
is not displayed, enter the CommBox-ACU’s
IP address (you can find this address on the
LCD: go to Settings > Network Settings > IP
Assignments) andmake sure your PC is
configured for DHCP addressing (see
page 40).
26
CommBox-ACU
STATUS
AC Input
100-240V; 1.6-0.8A 50/60 Hz
Fuse 3A, 250V ~ Fast Acting
Maintenance
WiFi
N
CommBox-ACU
RS232
Red (+48V)
Black (Gnd)
White/Gray
Gray/White
White/Orange
Orange/White
White/Brown
Brown/White
Wire Color/Stripe Color
To Antenna
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
(1) This device must not cause harmful interference, and (2) This device must accept any
interference received, including interference that may cause undesired operation.
Manufactured in USA.
Modem
User Ethernet
NMEA
To Modem
White/Blue
Blue/White
White/Green
RS422
Green/White
Red/Orange
Orange/Red
Red/Green
Green/RedB A
1000
Tested to comply
with FCC Standards
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
Voice Lines (Analog)User Ethernet PortsEthernet
12
CAUTION
RISK OF ELECTRIC SHOCK
DO NOT OPEN
0
To Modem
1 2 3
1234
BUC Power
24VDC , 2.5A
4
WiFi
Laptop
PC
Page 28
Figure 50: Updates Page on Web Interface
Figure 51: Update File Selected for Upload
14
Update the System Software
Follow these steps to ensure the latest software is
installed in the TracPhone system.
Check the Current Software Version
a. Go to the TracPhone V11 web interface and
click the Updates tab. Note the displayed
CommBox-ACU/Antenna software version
(see Figure 50).
b. If the reported software version is earlier than
the latest version you downloaded from the
KVH Partner Portal, update the system
following the steps below.
Update the Software, If Necessary
NOTE: This procedure explains how to update the
software using the TracPhone V11 web interface.
However, you can also update the software using the
mini-VSAT iPhone
or, if the system is activated, via the antenna’s
Internet connection (airtime charges may apply).
Details are available in the Help.
®
/iPod Touch® app, a USB drive,
If Necessary
a. Click Choose File.
b. At the Login window, enter the default
password: “password”.
c. Click Browse and navigate to the file you
saved on your laptop (see Figure 51).
d. Click Check File.
e. At the confirmation message, click Update.
f.Wait for the software update to complete. It
might take up to 40 minutes.
27
Page 29
Figure 52: Setting the Administrator Password
Figure 53: Entering the Vessel Name
Figure 54: Assigning Phone Line Names
15
Follow these steps to customize the web interface
for the customer’s use.
Customize the Web Interface
Set the Administrator Password
The user must be logged in as an administrator to
make changes to the system’s configuration.
Follow these steps to change the administrator
password to something unique.
a. At the TracPhone V11 web interface, click the
Settings tab. Then click Account.
b. In Security, click Edit.
c. For the current password, enter the default
password: “password” (see Figure 52).
NOTE: The password must be between 4 and 20
characters in length, with at least one letter and one
number, case-sensitive.
d. Enter and then re-enter the new password.
Then click Save Settings.
Enter the Vessel Name
The vessel name is displayed on the home page
and in all support communications. Follow these
steps to enter the correct vessel name.
a. At the TracPhone V11 web interface, click the
Settings tab. Then click Account.
b. In Vessel Name, click Edit.
c. Enter the vessel name (see Figure 53). Then
click Save Settings.
Assign Phone Line Names
The phone line names are displayed on the home
page and in all support communications. Follow
these steps to assign a name (i.e., location) to each
phone line.
a. At the TracPhone V11 web interface, click the
28
Settings tab. Then click Other.
b. In Phone Line Names, click Edit.
c. Enter names for Lines 1 and 2 (see Figure 54).
Then click Save.
Page 30
Azimuth
Range
080°
015°
Figure 55: Example of No-Transmit Zone Azimuth Range
Figure 56: Azimuths Relative to Antenna’s Forward Arrow
Figure 57: Example of No-Transmit Zone Elevation Range
16
Set Up No-Transmit Zones
To prevent exposure to RF energy (see the hazard
area illustration on page 1), you can configure up
to two no-transmit zones for areas where crew
and/or passengers frequent (see Figure 55). The
system will disable the transmitter whenever the
antenna is pointing within one of these zones.
Follow these steps to set up a no-transmit zone.
a. Determine the necessary azimuth range for
the no-transmit zone(s). You will need to
enter, in clockwise order, beginning and
ending azimuths that define the outer
boundaries of the zone(s) relative to the antenna’s forward arrow, which should be
pointing toward the bow (see Figure 56).
b. Determine the necessary elevation range for
each no-transmit zone(s) (see Figure 57).
NOTE: Each no-transmit zone must span at least 5°
in both azimuth and elevation.
315
Beginning
Azimuth
000
Forward
015
No-Transmit Zone
(Example)
Optional
Ending
Azimuth
225
90°
Antenna
180
080
090270
135
Ending Elevation
15°
0°
No-Transmit Zone
(Example)
-25°
Beginning Elevation
29
Page 31
Figure 58: No-Transmit Zones Page of Web Interface
16
c. At the TracPhone V11 web interface, click the
Settings tab. Then click No-Transmit Zones.
d. Click Edit.
e. Make sure Enforce Zones is selected(see
Figure 58).
f.Enter the azimuth and elevation ranges for
Zone 1.
g. Enter the azimuth and elevation ranges for
Zone 2, if required.
h. Click Save Settings.
i.At the confirmation message, click Save.
Continued Set Up No-Transmit Zones
30
Page 32
Figure 59: Good Service Connection Indicated on Home Page
Figure 60: Heading Displayed on Home Page
Figure 61: Welcome Page for Testing
AC Input
100-240V; 1.6-0.8A 50/60 Hz
Maintenance
RS232
To Modem
RS422
NMEA
12
0
WiFi
1234
Voice Lines (Analog)User Ethernet PortsEthernet
To Antenna
Red (+48V)
Black (Gnd)
White/Gray
Gray/White
White/Orange
Orange/White
White/Brown
Brown/White
White/Blue
Blue/White
White/Green
Green/White
Red/Orange
Orange/Red
Red/Green
Green/RedB A
Wire Color/Stripe Color
To Modem
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
(1) This device must not cause harmful interference, and (2) This device must accept any
interference received, including interference that may cause undesired operation.
Manufactured in USA.
BUC Power
24VDC , 2.5A
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
Tested to comply
with FCC Standards
CAUTION
RISK OF ELECTRIC SHOCK
DO NOT OPEN
1000
Fuse 3A, 250V ~ Fast Acting
N
WiFi
Voice LinesCommBox-ACU
Diagnostics
Phone
1
Figure 62: Connecting the Diagnostics Phone to the CommBox-ACU
Submission of the Installation Checklist is
required to certify the quality of your
installation.
IMPORTANT!
17
Test the System
Follow these steps to test the system for proper
operation.
a. Ensure the antenna has a clear, unobstructed
view of the sky.
b. Verify that the antenna is tracking the service
satellite and the modem is online, as
indicated by the Home page of the TracPhone
V11 web interface (see Figure 59).
c. On the Home page, make sure the vessel’s
heading is displayed in the Real-time Vessel
& VSAT Satellite Display (see Figure 60). If it
is not shown, check your wiring to the
NMEA 0183 talker.
d. Enter the following address in your web
browser: http://208.83.165.11/mbbtest.
Verify that the Welcome page appears,
indicating good communications between the
modem and the land-based hub (see
Figure 61).
e. If the customer has activated the system for
mini-VSAT Broadband service, verify that
you can place a voice call. Connect the
supplied diagnostics telephone to the “Voice
Line 1” jack on the rear panel of the
CommBox-ACU (see Figure 62). Then place a
call to someone on a terrestrial or cellular
network and ask them to call you back at the
customer’s phone number.
f.If the customer has activated the system, also
verify that the system can access the Internet
by entering any common website address
(URL) into your web browser.
g. Turn on all other electronic equipment above
deck within the proximity of the antenna.
Verify that the system continues to operate
without any degradation in performance.
h. Fill out the installation checklist (provided in
the Customer Welcome Kit) and return it to
KVH. Refer to the instructions on the form.
31
Page 33
Figure 63: Wired DHCP Configuration (Example)
Figure 64: Wireless DHCP Configuration (Example)
Establishing a wireless connection onboard a
steel vessel might require a special external
WAP and advanced networking expertise.
IMPORTANT!
18
Connect Vessel Computers
Follow these steps to connect the vessel’s
computers (or other network devices) to the
CommBox-ACU. There are three options:
Option 1 - Wired DHCP (default)
Option 2 - Wireless DHCP
Option 3 - Static IP
CommBox-ACU
User Ethernet
1 2 3
Voice Lines (Analog)User Ethernet PortsEthernet
To Modem
RS422
1000
Tested to comply with FCC Standards
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
0
12
To Modem
CAUTION
RISK OF ELECTRIC SHOCK
DO NOT OPEN
LAN 1: 192.168.5.1
1234
BUC Power24VDC , 2.5A
WiFi
Option 1 – Wired DHCP
In a wired DHCP configuration, vessel
computers connect via Ethernet cables and
receive IP addresses from the CommBox-ACU
(see Figure 63).
a. Connect the vessel computers to any of the
four “User Ethernet” ports on the CommBoxACU.
b. Make sure the computers are configured for
DHCP addressing (see page 40).
NOTE: By default, the CommBox-ACU has a
gateway of 192.168.5.1 and assigns IP addresses in
the 192.168.5.100-200 range. If this configuration
conflicts with an existing onboard network, you may
change the settings at the TracPhone V11 web
interface (go to Settings > Network Settings).
Option 2 – Wireless DHCP
In a wireless DHCP configuration, vessel
computers connect to the CommBox-ACU via its
built-in wireless access point (WAP) and receive
IP addresses from the CommBox-ACU (see
Figure 64).
192.168.5.100192.168.5.101192.168.5.102
Bridge PC
Crew PCOfficers PC
CommBox-ACU
User Ethernet
Voice Lines (Analog)User Ethernet PortsEthernet
To Modem
RS422
1000
Tested to comply
with FCC Standards
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
0
12
To Modem
CAUTION
RISK OF ELECTRIC SHOCK
DO NOT OPEN
LAN 1: 192.168.5.1
1 2
1234
BUC Power24VDC , 2.5A
WiFi
192.168.5.102
192.168.5.103
192.168.5.100192.168.5.101
Bridge PC
Officers PC
Crew PCs
a. Make sure the computers are configured for
DHCP addressing (see page 40).
b. At the TracPhone V11 web interface, click the
Settings tab. Then click Network Settings.
c. In Wireless Settings, click Edit.
32
Page 34
Figure 65: Wireless Settings on the CommBox-ACU
Failure to apply security settings will make
the vessel’s wireless network vulnerable to
outside intrusion.
IMPORTANT!
To Modem
RS422
12
0
WiFi
1234
Voice Lines (Analog)User Ethernet PortsEthernet
To Modem
BUC Power24VDC , 2.5A
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
Tested to comply
with FCC Standards
CAUTION
RISK OF ELECTRIC SHOCK
DO NOT OPEN
1000
User Ethernet
CommBox-ACU
Bridge PC
1 2
4
DHCP
Engine Room PC
Officers PC
192.168.5.100192.168.5.101192.168.72.100
LAN 1: 192.168.5.1LAN 0: 192.168.72.1
Static
Firewall
Figure 66: Static IP Configuration (Example)
A static IP address provides an open,
unprotected connection to the Internet.
Therefore, it should only be assigned to a
secure device, such as a firewall router.
IMPORTANT!
18
Continued Connect Vessel Computers
d. Select Enabled.
e. Set the following wireless options, then click
Save (see Figure 65):
•SSID: Keep the default name, or enter a
unique name for the vessel network.
•Security: Select either security type -
WPA2 or WEP (128-bit).
•Password/Passphrase: If you selected
WPA2, enter a password (between 8-20
characters). If you selected WEP, enter a
passphrase (must be 13 characters).
•Channel: Keep the default, or select a
channel for wireless communications.
f.At the confirmation message, click Save.
Option 3 – Static IP
In a static IP configuration, a network device is
assigned a static IP address that can be accessed
directly from the Internet. It does not receive an
IP address from the CommBox-ACU.
a. Ask the customer to fill out the request form
at www.kvh.com/mvbcustomercenter (click
the link in the sidebar). In addition, the
system must be activated for mini-VSAT
Broadband service, and it must remain online
until KVH configures the system over the air.
b. Connect the static IP device to the “User
Ethernet 4” port on the CommBox-ACU.
c. The customer will need to configure the
device’s TCP/IP properties according to the
instructions KVH will provide in an e-mail
upon fulfilling the static IP request.
33
Page 35
AC Input
100-240V; 1.6-0.8A 50/60 Hz
Maintenance
RS232
To Modem
RS422
NMEA
12
0
WiFi
1234
Voice Lines (Analog)User Ethernet PortsEthernet
To Antenna
Red (+48V)
Black (Gnd)
White/Gray
Gray/White
White/Orange
Orange/White
White/Brown
Brown/White
White/Blue
Blue/White
White/Green
Green/White
Red/Orange
Orange/Red
Red/Green
Green/RedB A
Wire Color/Stripe Color
To Modem
This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions:
(1) This device must not cause harmful interference, and (2) This device must accept any
interference received, including interference that may cause undesired operation.
Manufactured in USA.
BUC Power
24VDC , 2.5A
KVH and TracPhone are registered trademarks
of KVH Industries, Inc.; mini-VSAT Broadband
is a service mark of KVH Industries, Inc.
Tested to comply
with FCC Standards
CAUTION
RISK OF ELECTRIC SHOCK
DO NOT OPEN
1000
Fuse 3A, 250V ~ Fast Acting
N
Voice Lines
CommBox-ACU
Bridge Phone
1 2
Officers Phone
WiFi
Figure 67: Connecting Vessel Phones (Example)
Figure 68: Available Options
* As an alternative, one of the CommBox-ACU’s voice
lines can be configured for Crew Calling functionality
(KVH part #95-0036-1008). Contact KVH Network
Services at networkservices@kvh.com for details.
**If the customer is interested in a CommBox solution,
ask them to contact KVH Network Services at
networkservices@kvh.com for a consultation.
OptionKVH Part No.
UCH-250 Fax Server19-0520
Crew Calling Gateway*72-0349
CommBox Standard Bundle**35-0010
CommBox Enterprise Bundle**35-0011
19
Connect Vessel Phones & Options
Follow these steps to connect the vessel’s phones
and any purchased accessories to the system.
Connect Vessel Phones
Using the supplied RJ-11 cables, connect the
customer’s analog (not digital) phone(s), fax
machine, and/or PABX to the desired “Voice
Line” jack(s) on the CommBox-ACU (see
Figure 67). Each jack is linked to a phone line.
Connect Optional Accessories
KVH offers the following accessories that extend
the system’s voice/fax service capabilities:
•UCH-250 Fax Server: Enterprise-grade fax
solution; provides a dedicated fax line using a
fully managed, store-and-forward fax service
•Crew Calling Gateway: Provides a dedicated
phone line for crew members and charter
passengers to place ship-to-shore voice calls
using prepaid calling cards
Refer to the instructions provided with the
accessory to connect it to the TracPhone system.
Installing Optional CommBox™ Software
CommBox software extends the system’s
network capabilities. Two options are available:
•CommBox Standard Bundle: Provides least
cost routing, onboard firewall, web caching,
web image compression, ad removal, and
URL and content filtering
•CommBox Enterprise Bundle: Provides
everything in the Standard bundle, plus
automated file transfers, differential
synchronization, mail relay server, web mail
client, anti-spam and anti-virus filters,
roaming crew accounts, and prepaid Internet
and e-mail services; integration with a
CommBox hub is required
KVH will coordinate directly with the customer
to select, install, and configure the appropriate
bundle to meet their needs.
34
Page 36
Figure 69: Customer Welcome Kit
Figure 70: Example of Satellite Blockage
Figure 71: Help Options on Support Page
20
Give the Welcome Kit to the customer, make sure
they know the administrator password, and
show them how to use the system. Be sure they
understand the following:
•The antenna transmits RF energy that is potentially harmful. Whenever the system is
powered on, make sure everyone stays the
minimum safe distance away from the
antenna (see illustration on page 1). If notransmit zones were set up, make sure the
customer understands where they are.
•Read the End User Agreement carefully
(available at www.kvh.com/
mvbcustomercenter). Pay particular
attention to the Use of Service section.
•Keep the radome and service hatches
installed on the antenna at all times. The
radome protects the antenna’s moving parts
from wind, rain, and debris.
Educate the Customer
•The antenna must have a clear view of the
sky to communicate via satellite. Common
causes of blockage include masts, trees,
buildings, and bridges (see Figure 70). Dirt
buildup on the radome can also affect
communications.
•The vessel must be located within the
coverage area of the satellite (see
www.kvh.com/minivsatmap).
•The system must be activated for mini-VSAT
Broadband service (see www.kvh.com/
mvbservice).
For More Information
Refer to the Help provided on the web interface’s
Support page and on the documentation CD.
Two versions are available (see Figure 71):
•Condensed: Resides on the CommBox-ACU
locally; text-only format
•Extended: Resides on the KVH website
(airtime charges may apply); complete with
images and tutorials
Blocked!
NOTE: The Help is compatible with the following web
browsers: Internet Explorer, Mozilla Firefox, Google
Chrome, and Apple Safari.
35
Page 37
Figure 72: Cutting the Cable
Figure 73: Reshaping the Cable
Figure 74: Placing the Heat Shrink Tubing and Ferrule
Figure 75: Stripping the End to Expose the Center Conductor
A
Terminating LMR-400-75 Cable
These instructions explain how to terminate an
LMR-400-75 RF cable with an EZ-400-FMH-75
“F” connector using the tools from the
TK-400EZ-75 tool kit. For more detailed
instructions, refer to the Times Microwave
website (www.timesmicrowave.com).
1. Using the CCT-01 cutting tool, cut the cable
evenly (see Figure 72).
2. Since cutting the cable can deform the end,
gently round the end of the cable using a pair
of needle-nose pliers (see Figure 73). Also
make sure the center conductor is centered
within the cable.
3. Place the heat shrink sleeve and metal ferrule
onto the cable (see Figure 74).
4. Insert the end of the cable into the #1 end of
the ST-400EZ stripping tool (see Figure 75).
Then rotate the tool clockwise around the
cable until the tool turns easily. The end of
the cable should now be stripped to expose
the center conductor.
5. Using a utility knife, carefully remove any
residual plastic from the center conductor, if
necessary (see Figure 76).
6. Insert the end of the cable into the #2 end of
the ST-400EZ stripping tool (see Figure 77).
Then rotate the tool clockwise around the
cable until the tool turns easily. This removes
the cable jacket from the end of the cable,
exposing the braid and dielectric (see
Figure 78).
7. Using the DBT-02 tool, deburr and chamfer
the center conductor (see Figure 79). Avoid
nicking the aluminum tape covering the
dielectric.
Continued Terminating LMR-400-75 Cable
37
Page 39
Figure 80: Flaring the Braid
Figure 81: Pushing On the Connector
Figure 82: Trimming the Braid
Figure 83: Sliding the Ferrule Over the Braid
A
8. Gently flare the braid with your fingers (see
Figure 80).
9. Insert the end of the cable into the connector
body until the dielectric is firmly seated
inside the connector (see Figure 81). Be sure
all braid wires remain on the outside of the
connector.
10. Trim any excess braid (see Figure 82), if
necessary. The braid should assemble flush to
within 1/16" (1.6 mm) of the connector
shoulder.
11. Slide the ferrule over the braid until it is flush
against the connector shoulder (see
Figure 83).
Continued Terminating LMR-400-75 Cable
38
Page 40
Figure 84: Crimping the Ferrule onto the Cable
Figure 85: Applying the Heat Shrink Tubing
Figure 86: Proper Center Conductor Pin Length
A
12. Using an appropriate crimp tool (either the
CT-400/300 or the HX-4 with Y1719 dies),
crimp the ferrule in place (see Figure 84).
Crimp as close to the connector body as
possible.
13. Crimp the ferrule again, but further back
from the connector. However, be careful not
to crimp the cable jacket.
14. Slide the heat shrink sleeve over the
connector body and heat it to compress it into
place (see Figure 85). When you are done, the
heat shrink should extend from the rear of the
connector to the cable jacket. This forms a
weather-tight seal.
15. Using a multimeter or similar device, check
the continuity of the cable.
16. Ensure the center conductor pin measures
between 0.20" and 0.28" (5-7 mm) in length, to
ensure proper engagement with the mating
connector (see Figure 86).
Continued Terminating LMR-400-75 Cable
Center Conductor
1/4" (5-7 mm)
39
Page 41
Figure 87: Windows 7 - Local Area Connection Properties
Figure 88: Windows 7 - Internet Protocol Properties
B
Configuring Computers for DHCP
Follow these steps to configure your computer
for DHCP to allow it to receive an IP address
from the CommBox-ACU. The location of this
configuration setting varies slightly by operating
system.
NOTE: The computer must have a network interface
card installed and all cabling must be 100 Mbps fast
Ethernet UTP CAT-5 with RJ45 connectors.
Windows 7 or Windows Vista
1. Turn on the computer.
2. From the Windows Control Panel, navigate
to the Network and Sharing Center. (You
might need to click Network and Internet
first.) You can find the control panel either
through the Start menu or “My Computer.”
3. At the Network and Sharing Center window,
double-click the Local Area Connection link
(Windows 7) or View Status link (Windows
Vista) for the Ethernet connection you are
using.
Appendix
4. At the Local Area Connection Status window,
click Properties. This screen only displays if the
computer is currently connected to a network.
5. At the Local Area Connection Properties
window, click the Networking tab. Then
select Internet Protocol Version 4 and click
Properties (see Figure 87).
6. At the Internet Protocol Properties window,
select Obtain an IP address automatically
and Obtain DNS server address
automatically (see Figure 88). Then click OK.
7. At the Local Area Connection Properties window, click OK.
40
Page 42
Figure 89: Windows XP - Local Area Connection Properties
Figure 90: Windows XP - Internet Protocol (TCP/IP) Properties
B
Continued Configuring Computers for DHCP
Windows XP
1. Turn on the computer.
2. At the Windows Control Panel, double-click
Network Connections. You can find the control
panel either through the Start menu or “My
Computer.”
3. At the Network Connections window,
double-click the Local Area Connection icon
for the Ethernet connection you are using.
4. At the Local Area Connection Status window,
click the General tab. Then click Properties.
This screen only displays if the computer is
currently connected to a network.
5. At the Local Area Connection Properties
window, click the General tab. Then select
Internet Protocol (TCP/IP) and click
Properties (see Figure 89).
6. At the Internet Protocol (TCP/IP) Properties
window, click the General tab. Then select
Obtain an IP address automatically and
Obtain DNS server address automatically
(see Figure 90). Then click OK.
7. At the Local Area Connection Properties window, click OK.