KVH Industries TracPhone V3, TracPhone V3-IP, TracPhone V3-HTS Replacement Instructions Manual

®

TracPhone

V3/V3IP/V3HTS Gyro

Replacement Instructions

The following instructions explain how to replace a gyro in a TracPhone V3/V3-IP/V3-HTS
antenna.

Replacement Steps

1. Remove the Radome ............................. 2

2. Identify the Gyro Location................... 2

3. Replace the Gyro.................................... 3

4. Update the Software ............................. 7

5. Calibrate the Gyros................................ 9

Tools Required

This procedure requires the following tools:

• #1 and #2 Phillips screwdrivers

•Cutting pliers

• 5/16" nut driver or wrench

• 5/16" open-end wrench and 5/16" torque wrench set to 8 in.-lbs

(for skew gyro replacement only)

• Heat gun or electrical tape

• Laptop PC with the latest TracPhone V3-IP/V3-HTS ICM/antenna software or TracPhon
ries Flash Wizard

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e

Important - Please Read!

To perform the calibration step at the end of this procedure, the vessel must remain stationary in
calm seas.

Avoid causing sharp bends in cables when securing or routing cables in this procedure. Sharp
bends or kinks in cables can degrade antenna performance. Also be sure to trim the excess
portion of any tie-wraps you install and collect all trimmings from the antenna to avoid damage.

Gyros are sensitive to shock. Handle the gyro carefully to avoid damage.

Technical Support

If you need technical assistance, please contact KVH Technical Support:

Europe, Middle East, Africa, Asia-Pacific:

Phone: [phone]
Email: [e-mail]

North/South America, Australasia:

Phone: [phone] (U.S. only) or [phone]
Email: [e-mail]

KVH, TracPhone, and the unique light-colored dome with dark contrasting baseplate are registered trademarks of KVH Industries, Inc.
All other trademarks are property of their respective companies. The information in this document is subject to change without notice.
No company shall be liable for errors contained herein. © 2011-2018 KVH Industries, Inc., All rights reserved. 54-0757 Rev. D | 72-0489

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Step 1 - Remove the Radome

Figure 1: Radome Screws

Skew

Elevation

Azimuth

Figure 2: Gyro Locations (V3-IP Shown)

CAUTION

For your own safety, be sure to disconnect
power from all wired components before
performing this procedure.

a. Disconnect all power from the TracPhone

system– turn off and unplug the ICM
(V3-IP/V3-HTS) or control unit and modem
(V3).

b. Remove the three #10-32 screws securing the

radome to the baseplate (see Figure 1). Set the
radome and screws aside in a safe place.

Step 2 - Identify the Gyro Location

Identify the location of the gyro you need to
replace (see Figure 2). Then follow the associated
instructions in Step 3:

#10-32 Screw (x3)

Gyro Go to Page:

Azimuth 3

Elevation 4

Skew 5

2

Step 3 - Replace the Gyro

In-line Connector

#6-32 Lock Nut

#6-32 Screw (x2)

Azimuth Gyro

P-clip

Figure 3: Azimuth Gyro Connector (V3-IP Shown)

Azimuth Gyro

M2.5 Screw (x2)

Shoulder Washer (x4)
(not used with
replacement gyro)

Figure 4: Azimuth Gyro Bracket, Screws, and Washers (if present)

Do not overtighten the M2.5 screws when you
attach the replacement gyro. Overtightening
will strip the inside threads of the gyro.

IMPORTANT!

Replacing the Azimuth Gyro

a. Carefully strip back the heat shrink covering

the gyro wires’ in-line connector (see
Figure 3).

b. Disconnect the gyro wires’ connector.

c. Using a 5/16" nut driver or wrench, remove

the #6-32 lock nut securing the P-clip that
guides the gyro wires to the connector.
Remove and save the P-clip and lock nut.

d. From the front of the reflector, remove the

two #6-32 screws securing the gyro bracket to
the reflector (see Figure 3).

e. Using a #1 Phillips screwdriver, remove the

two M2.5 screws and four shoulder washers
(if present) securing the gyro to the bracket
(see Figure 4). Discard the old gyro, screws,
and shoulder washers.

f. Attach the replacement gyro to the bracket

with two M2.5 screws (supplied in the kit) as
shown in Figure 4. Be sure to orient the gyro
so that its wires will face the reflector.

g. Reattach the bracket to the reflector with two

#6-32 screws (supplied in the kit) (see
Figure 3).

h. Route the gyro wires as shown in Figure 3

and connect them to the in-line connector.
Protect the connection with heat shrink
tubing or electrical tape.

i. Secure the gyro wires in place using the

P-clip you removed earlier (see Figure 3).
Ensure the flat side of the P-clip is against the
reflector.

j. Update the software as explained on page 7.

k. Calibrate the gyros as explained on page 9.

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Replacing the Elevation Gyro

Elevation Gyro

In-line Connector

Tie-wrap

Tape

Azimuth Gyro Cable

Elevation Gyro Cable

Figure 5: Secured Gyro Cables (V3-IP Shown)

In-line Connector

Elevation Gyro

P-clip

Tape

Azimuth Gyro Cable

Figure 6: Elevation Gyro Connector

Elevation Gyro

M2.5 Screw (x2)

Shoulder Washer (x4)
(not used with
replacement gyro)

M2.5 Standoff (x2)

#6-32 Screw

Azimuth Gyro Cable

P-clip

Figure 7: Elevation Gyro Screws and Washers (if present)

Do not overtighten the standoffs when you
attach the replacement gyro. Overtightening
will strip the inside threads of the gyro.

IMPORTANT!

a. Cut and remove the tie-wrap securing the

elevation and azimuth gyro cables to the
cable bundle (see Figure 5).

b. Carefully strip back the heat shrink covering

the elevation gyro wires’ in-line connector
(see Figure 5 and Figure 6).

c. Disconnect the gyro wires’ connector.

d. Remove the tape securing the elevation gyro

wires to the azimuth gyro cable (see
Figure 6).

e. Remove the #6-32 screw securing the P-clip

that secures the elevation gyro wires to the
azimuth gyro cable (see Figure 7). Remove
and discard the P-clip and screw.

f. Using a #1 Phillips screwdriver, remove the

two M2.5 screws, four shoulder washers (if
present), and two M2.5 standoffs securing the
gyro to the antenna frame (see Figure 7).
Discard the old gyro, screws, and shoulder
washers.

g. Attach the replacement gyro to the frame

with two new M2.5 screws and two M2.5
standoffs (supplied in the kit) (see Figure 7).
Be sure to orient the gyro so that its wires are
on top.

h. Route the gyro wires as shown in Figure 6

and connect them to the in-line connector.
Protect the connection with heat shrink
tubing or electrical tape.

i. Secure the gyro wires in place using a new

j. Wrap the gyro wires and azimuth gyro cable

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P-clip and #6-32 screw (supplied in kit) as
shown in Figure 7.

with the supplied tape at the location shown
in Figure 6. This tape will protect the wires
from abrasion.

k. Using a tie-wrap, secure the elevation and

Tie-wrap

Tie-wrap

Tape

Tape

In-line Connector

Skew Gyro

RF Cable

BUC Cable

Motor Wires

OMT

Figure 8: Skew Gyro Connector (V3-IP Shown)

Mounting Plate

Skew Gyro

#6-32 Lock Nut (x2)

Figure 9: Gyro Mounting Plate Attached to Skew Assembly

Mounting Plate

Skew Gyro

M2.5 Screw (x2)

Figure 10: Skew Gyro Attached to Mounting Plate

Do not overtighten the M2.5 screws when you
attach the replacement gyro. Overtightening
will strip the inside threads of the gyro.

IMPORTANT!

azimuth gyro cables to the cable bundle in the
location shown in Figure 5 on page 4.

l. Update the software as explained on page 7.

m. Calibrate the gyros as explained on page 9.

Replacing the Skew Gyro

a. Carefully strip back the heat shrink covering

the gyro wires’ in-line connector (see
Figure 8).

b. Disconnect the gyro wires’ connector.

c. Using a 5/16" open-end wrench, disconnect

the BUC cable from the OMT (see Figure 8).

d. Cut and remove the two tie-wraps and tape

securing the gyro wires to the motor wires,
BUC cable, and RF cable (see Figure 8).

e. Using a 5/16" nut driver or wrench, remove

the two #6-32 lock nuts securing the gyro’s
mounting plate to the skew assembly (see
Figure 9). Detach the mounting plate from
the skew assembly.

f. Using a #1 Phillips screwdriver, remove the

two M2.5 screws securing the gyro to the
mounting plate (see Figure 10). Discard the
old gyro and screws.

g. Attach the replacement gyro to the mounting

plate with two M2.5 screws (supplied in the
kit) (see Figure 10).

h. Reattach the mounting plate to the skew

assembly with two #6-32 lock nuts (supplied
in the kit) (see Figure 9). Be sure to orient the

i. Loop the gyro wires as shown in Figure 8 and

gyro so that its wires are on the left.

connect them to the in-line connector. Protect
the connection with heat shrink tubing or
electrical tape.

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j. Wrap the gyro wires and motor wires with

the supplied protective tape (once around) at
the location shown in Figure 8 on page 5.
Then secure them together with a tie-wrap.

k. Reconnect the BUC cable to the OMT (see

Figure 8 on page 5). Hand-tighten, then
tighten with a 5/16" torque wrench set to
8 in.-lbs.

l. Wrap the gyro wires, motor wires, BUC

cable, and RF cable with the supplied
protective tape (once around) at the location
shown in Figure 8 on page 5. Then secure
them together with a tie-wrap.

m. Update the software as explained on page 7.

n. Calibrate the gyros as explained on page 9.

6

Step 4 - Update the Software

Figure 11: Updates Page on ICM Web Interface

Figure 12: Update File Selected for Upload (V3-IP Shown)

Follow these steps to ensure the latest software is
installed in the TracPhone system.

The software update process differs depending
on antenna model:

• TracPhone V3-IP/V3-HTS - see below

• TracPhone V3 - refer to page 8

TracPhone V3-IP/V3-HTS

This procedure explains how to update the software
using the TracPhone V3-IP/V3-HTS 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.

Check the current software version as follows:

a. Go to the TracPhone V3-IP/V3-HTS web

interface and click the Updates tab. Note the
displayed ICM/Antenna software version
(see Figure 11).

®

/iPod Touch® app, a USB drive,

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 as follows:

a. Click Choose File.

b. At the Login window, enter the

Administrator password.

c. Click Browse and navigate to the file you

saved on your laptop (see Figure 12).

d. Click Check File.

e. At the confirmation message, click Update.

Wait for the software update to complete. It
might take up to 40 minutes.

7

TracPhone V3

Figure 13: Software Versions Displayed on the Control Unit

Figure 14: TracPhone V-series Flash Wizard Help Menu

Check the current software version as follows:

a. At the control unit, press MENUS until the

display shows “ANTENNA STATUS” (see
Figure 13). Then press ACCEPT.

b. Press MENUS until the display shows

“ANTENNA MAIN BOARD.” Note the
reported software (SW) version.

c. Press MENUS to view the software versions

for the RF board, AZ/EL motor, skew motor,
and control unit. Note all of these versions.

d. Compare the software versions you just

noted on the control unit with the latest
versions listed in the TracPhone V-series
Flash Wizard’s Release Notes.

NOTE: Before using the TracPhone V-series Flash
Wizard, be sure to check for updates to ensure it has
all of the latest software files (Internet access
required). If you don’t yet have the Wizard installed
on your PC, download it from the KVH Partner
Portal (KVH-certified technicians only).

e. Use the TracPhone V-series Flash Wizard to

update any older versions of software in the
TracPhone system. Refer to the Wizard’s
Help menu for complete details (see
Figure 14).

ANTENNA STATUS
NEXT MENU ACCEPT

PRESS TO VIEW
EACH ANTENNA ITEM

ANTENNA MAIN BOARD
SW VERSION 2.34

ANTENNA RF BOARD
SW VERSION 1.23

ANTENNA AZ/EL MOTOR
SW VERSION 1.28

ANTENNA SKEW MOTOR
SW VERSION 1.04

Press MENUS twice

Press ACCEPT

Press MENUS
to scroll through
the status screens

8

CTRL UNIT
SW VERSION 2.14

Step 5 - Calibrate the Gyros

Figure 15: PuTTY Configuration Screen

Important!

Calibrate the gyros only while the vessel is
stationary in calm seas.

NOTE: Complete calibration details are provided in
the User’s Guide.

The calibration process differs depending on
antenna model:

• TracPhone V3-IP-V3-HTS - see below

• TracPhone V3 - refer to page 10

TracPhone V3-IP/V3-HTS

NOTE: These instructions assume you will be using
PuTTY to enter antenna commands. However, you
may use a different terminal emulator program, such
as HyperTerminal.

a. Turn on the ICM and wait five minutes for

system startup.

b. Connect your computer to the “User Ethernet

1” port on the rear panel of the ICM.

c. Start PuTTY and enter the ICM’s IP address

and port number (see Figure 15). Select

Telnet for “Connection type” then select
Open to start a Telnet session and open a

command line window.

NOTE: By default, the ICM uses a gateway of

192.168.5.1 and port 50001. You may change these

settings at the ICM’s web interface (see the
instructions in the Installation Guide, User’s Guide,
or Help).

d. At the command line, enter and send the

following commands to the antenna:

•HALT

•DEBUGON

• EEUNLOCK

• =CALNEWGYRO

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Verify that the calibrations for azimuth (AZ),

Figure 16: Control Unit Gyro Calibration (V3)

elevation (EL), and skew gyros all pass.

e. Enter and send the following command:

•ZAP

f. The system will restart. Wait five minutes for

system startup. Then test the system for
normal operation. If the problem persists,
contact KVH Technical Support.

The replacement procedure is complete!

Press MENUS four times

DIAGNOSTICS
NEXT MENU ACCEPT

TracPhone V3

You can calibrate the gyros from the front panel
of the control unit. Turn on the TracPhone
system then follow the steps shown in Figure 16.

The replacement procedure is complete!

ENTERING DIAGNOSTICS

CAL GYRO= NO
NEXT ITEM CHANGE

CAL GYRO= YES?
CHANGE ACCEPT

DO NOT MOVE VESSEL
DURING CALIBRATION

CALIBRATING GYROS

AZ:P EL:P SKEW:P

Ensure all three gyros pass (“P”).
If any fail (“F”), retry the calibration.
If it continues to fail, contact KVH
Technical Support.

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