KVH Industries V7, TracPhone V7 Installation Manual

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Page 1

TracPhone® V7

32" (82 cm) Configuration

Installation Guide

Page 2

RF Cable Pigtails

Use of the supplied pigtail cables is mandatory for every new installation. Do not connect the customer’s RF cables directly to the antenna.

IMPORTANT!

Antenna Baseplate

Rubber Washer

Rubber Boot

Apply Silicone Grease

To Modem

Apply Silicone Grease

I G T A

I L

T A

Feed-thru Adapter

Seal connection with silicone sealant or self-vulcanizing tape, then apply heat-shrink

Addendum

PLEASE READ! Important Addendum to the Installation Guide

Two LMR-400-75 pigtail cables and rubber connector washers are provided in the kitpack. Follow the steps below, while referring to Figure 1, to connect these cables in-line between the antenna and the customer’s RF cables, providing a reliable, weatherproof connection to the antenna.

NOTE: Before you begin, be sure you have properly terminated, labeled, and routed the customer’s “TX” and “RX” RF cables, as explained in the Installation Guide.

Figure 1 LMR-400-75 Pigtail Connections

1. Clean and dry the antenna’s two RF connectors and the RF cables’ connectors.

2. Heat shrink is supplied with each pigtail cable to protect the connection between the customer’s RF cables and the

54-0841 Rev. A

pigtail cables. Slide a heat shrink sleeve onto the end of each pigtail cable (opposite the boot end) for later use.

Page 3

RF Cable Pigtails

The integrity and reliability of the RF cables and their connections are critically important. Make certain that these cables are properly terminated, sealed against seawater and corrosion, strain-relieved, protected from abrasion, and free of stress. Refer to the Installation Guide for details.

IMPORTANT!

Addendum

3. 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).

4. 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.

5. 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.

6. 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 2).

7. Place one of the supplied rubber connector washers over the “MTx” jack on the bottom of the antenna, as shown in Figure 1.

8. Fill half of the inner body of the “TX” pigtail cable’s male connector with silicone grease.

9. 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.

10. 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.

11. 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.

12. 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.

13. Wipe off any excess grease from the cable.

14. Repeat steps 3-13 to connect the “RX” RF cable and the

other pigtail cable to the “MRx” jack on the bottom of the antenna.

Page 4

PLEASE READ!

KVH Antenna System

Ground

50-120 VAC

Shipboard Two-Phase, Split-Phase, or Delta Power

50-120 VAC

Leakage Current

KVH Antenna System

Shipboard 3-Wire Single-Phase AC Power

Ground

Neutral

100-240 VAC

Ground

Neutral

100-240 VAC

Single-Phase

Power Input

Ground Fault

Monitor

(when required)

Isolation Transformer

Ground

50-120 VAC

Shipboard

Two-Phase,

Split-Phase,

or Delta Power

Important Addendum to the Installation Guide

AC Power and Grounding Requirements

Addendum

The KVH antenna system is AC powered, just like the other onboard equipment to which it connects. Therefore, installing the system requires careful examination of the AC power and grounding onboard the vessel.

Figure 1 AC Power Options

54-0831 Rev. A

Page 5

AC Power and Grounding Requirements

Addendum

AC Power Requirements

The KVH antenna system is designed to run on 3-wire single-phase AC power (hot, neutral, and ground). Voltage between hot-neutral and hot-ground 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 KVH antenna systems 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 be sure to check with the customer or ship's electrician and get permission before you run the antenna system on two-phase power. Also be sure to ground the system, as explained on the next page.

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 single-phase 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.

Page 6

AC Power and Grounding Requirements

Addendum

Grounding Requirements

Proper grounding of the antenna system to ship's ground is critically important, as it protects the equipment from lightning and electrostatic discharges (ESD). Failure to ground the chassis of the antenna's control unit risks damage to the antenna and electric shock.

In a standard installation with a connection to single-phase AC power, the antenna system is normally connected to ship's ground through the ground wire of the antenna control unit's power plug. As an alternative, you may run a separate ground wire from the antenna equipment's chassis to ship's ground, or mount the equipment within a grounded equipment rack.

WARNING

Failure to ground the antenna 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.

You are responsible for the quality and safety of the system’s installation. Be sure that it meets these critical power and grounding requirements.

Page 7

RF Cable Tool Kits

You need to run two RF coax cables (transmit and receive) for every TracPhone antenna installation, so be sure to order a quantity of two cables for a new installation.

IMPORTANT!

Addendum

PLEASE READ! Important Addendum to Your Product Manual

KVH now includes a torque wrench and silicone grease with the LMR-400-75 and LMR-600-75 RF cable termination tool kits. The torque wrench is set to 20 in.-lbs, which KVH has found to be the ideal torque for external RF cable connections.

The table below lists the updated part numbers for these tool kits, as well as the associated RF cables.

Item KVH Part # Length

One RG-11 cable (for V3) 32-1087-50 50 ft (15 m)

One RG-11 cable (for V7) 32-0566-50 50 ft (15 m)

RG-11 tool kit 72-0493 N/A

One LMR-400-75 cable 32-0944-0100 100 ft (30 m)

LMR-400-75 tool kit 72-0374-75 N/A

One LMR-600-75 cable 32-0945-0150 150 ft (45 m)

LMR-600-75 tool kit 72-0375-75 N/A

54-0815 Rev. A

Page 8

RF Cable Connectors

This addendum applies to products with antenna serial number 110601833 or later.

Addendum

PLEASE READ! Important Addendum to Your Product Manual

A small packet of silicone grease is supplied in the kitpack. Apply this grease to the inner body of all RF cable connectors that you connect to the KVH antenna and any inline feed-thru adapters above deck. This grease will help prevent moisture from seeping into or forming inside the connector and protect the center conductor from corrosion.

Figure 1 Silicone Grease

Directions for Use

When connecting RF cables above deck to the KVH antenna, as well as to any inline feed-thru adapters, follow the steps below to protect and seal each connection:

1. Clean and dry the male connector on the RF cable and the female connector on the antenna or feed-thru adapter.

2. Fill half of the inner body of the RF cable’s connector with silicone grease. Connecting the cable in the next step will

displace the grease to fill the entire space within the connector.

3. Connect and SLOWLY hand-tighten the RF cable to the antenna or feed-thru adapter, allowing the grease to diffuse and settle into the entire connector body.

4. Make sure the RF cable’s connector is tightened all the way into the female connector of the antenna or feed-thru adapter. Then tighten the connection with a 7/16" torque wrench set to

5. Wipe off a connector.

 in.-lbs.

ny excess grease from the outside of the

6. Seal the connection with silicone sealant, self-vulcanizing tape, or equivalent. If using self-vulcanizing tape, be sure to wrap the tape CLOCKWISE around the connector (the same direction in which you tightened the connector). Wrapping the tape in the opposite direction will result in tension that might loosen the connector over time.

The procedure is complete.

54-0779 Rev. A

Page 9

TracPhone V7 Installation Guide

Antenna

Radiation

Hazard

Radiation

Hazard

(

)

(

1 m)

KVH’s Complete mini-VSAT Broadbandsm System

These instructions explain how to install the TracPhone V7 mini-VSAT Broadband satellite communications system. Instructions on how to use the system are provided in the User’s Guide.

Installation Steps

1. Inspect Parts and Get Tools ................. 3

2. Plan the Antenna Installation.............. 4

3. Plan the Belowdecks Installation ........ 5

4. Prepare the Belowdecks Units............. 6

5. Prepare the Antenna Site...................... 9

6. Prepare the Antenna ........................... 10

7. Wire the Antenna ................................ 11

8. Mount the Antenna............................. 12

9. Remove the Restraints ........................ 13

CAUTION - RF Radiation Hazard

The antenna transmits radio frequency (RF) energy that is potentially harmful. Whenever the system is powered on, make sure everyone stays more than 36 feet (11 m) away from the antenna within its 5-80° elevation range. No hazard exists directly above the antenna and anywhere below the antenna’s mounting plane.

10. Wire the Belowdecks Units.................14

11. Connect Power .....................................16

12. Configure the Computer(s) ................18

13. Turn On the System.............................21

14. Update the System Software..............22

15. Set Up RF Hazard Zones.....................23

16. Test the System.....................................24

17. Educate the Customer.........................26

Who Should Install the System?

To ensure a safe and effective installation, only a KVH-certified technician should install the TracPhone system. KVH-certified technicians have the tools and electronics expertise necessary to install the system. To find a technician near you, visit www.kvh.com/wheretogetservice.

Technical Support

North/South America, Australia:

Phone: +1 401 847-3327 E-mail: V7Support@kvh.com

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.

Europe, Middle East, Asia, Africa:

Phone: +45 45 160 180 E-mail: support@kvh.dk

U.S. Patent Pending

Page 10

Radome

Baseplate

Figure 1: TracPhone V7 System Components

Antenna

Control Unit

Modem

Ethernet Switch

Remote Service & Support Module

Multimedia Terminal Adapter (MTA)

Always lift the antenna by the baseplate and never by the radome or any portion of the internal antenna assembly (see Figure 1).

IMPORTANT!

Before you begin, follow these steps to make sure you have everything you need to complete the installation.

a. Unpack the box and ensure it contains

everything shown in Figure 1 and on the Kitpack Content Lists. Save the packaging for future use.

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

Inspect Parts and Get Tools

• Electric drill and 1/2" (13 mm) bit

• 2" (50 mm) hole saw

• Wire cutters, wire strippers, and terminal lug crimper

• Socket wrenches and extension

• 11/16" open-end or box wrench, and 7/16" open-end wrench

• Silicone sealant or self-vulcanizing tape

• Light hammer and center punch

• Adhesive tape and scriber or pencil

• Two RF coax cables and F-connector installation tools (see page 11)

• Isolation transformer, if required (see page 16)

•Windows the latest version of TPV7 Flash Update Wizard installed (software available to technicians on the KVH Partner Portal)

NOTE: KVH offers the optional KVH CommBox connecting multiple communication systems to the onboard local area network (LAN), providing least cost routing, firewall, bandwidth management, web caching, and optimization features (KVH part #72-0470 (compact) or #72-0472 (rack-mount)).

7, Vista™, or XP laptop with

™

for

Page 11

Blocked!

Antenna

Mast

Vessel Platform

5° to 80°

Look Angle

Figure 2: Blockage from Obstruction

Figure 3: Antenna Dimensions

Side View

Bottom View

Do not mount the antenna at the same level as the radar because the radar’s energy might overload the antenna and damage its internal components. Ideally, you should mount the antenna 4 ft (1.2 m) above the radar, outside the beam path of the radar.

IMPORTANT!

Plan the Antenna Installation

Before you begin, consider the following antenna installation guidelines:

• Minimize blockage. The antenna requires a clear view of the sky to transmit and re ceive satellite signals (see Figure 2). The fewer obstructions, the better the system will perform.

• Make sure the mounting surface is wide enough to accommodate the antenna’s base (see Figure 3). Also make sure it is flat, level, strong enough to support the antenna’s weight (100 lbs, 45 kg), and rigid enough to withstand heavy vibration.

• Select a location that is as close as possible to the intersection of the vessel’s centerline and midships.

• Select a location that is well above any areas accessible to passengers and crew to reduce the risk of RF radiation exposure.

• Avoid placing the antenna near any magnetic compasses or other onboard antennas to prevent potential interference.

38.86"

(987 mm)

17"

(432 mm)

Ø35"

(Ø889 mm)

12"

(305 mm)

(152 mm)

Hatch

FWD

(152 mm)

12"

(305 mm)

4 x Ø.50" (4 x Ø13 mm)

Page 12

Figure 4: Control Unit or Modem Dimensions (Identical)

20.5"

(52.1 cm)

11.3"

(28.7 cm)

20.5"

(52.1 cm)

Figure 5: Case Dimensions

Figure 6: Dimensions of Ancillary Components

Component Dimensions (W x D x H)

Switch 6.7" x 3.9" x 1.1"

(17 cm x 9.9 cm x 2.8 cm)

MTA 4.6" x 5.12" x 1.18"

(11.7 cm x 13 cm x 3 cm)

Remote Service & Support Module

5.12" x 3.54" x 1.5" (13 cm x 9 cm x 3.8 cm)

Before you begin, consider the following installation guidelines for the belowdecks units.

Plan the Belowdecks Installation

Control Unit and Modem

• 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 panel to accommodate the connecting cables.

• You have several options for mounting the control unit and modem:

Option 1 - Inside the optional case Option 2 - To a horizontal surface together

using two L-brackets

2.61"

(6.6 cm)

16.75"

(42.5 cm)

11.31"

(28.7 cm)

Option 3 - To a horizontal surface

separately using four L-brackets

NOTE: The control unit and modem are sized to fit a standard 19" (482.6 mm) equipment rack.

• To use the supplied data and power cables, the control unit must be located within 100 ft (30 m) of the antenna. However, you can order 150 ft (45 m) cables if a longer cable run is necessary (see Figure 18 on page 11).

Switch and MTA

• To use the supplied Ethernet cables, select a mounting location within 25 ft (7.5 m) of the modem (maximum length = 200 ft (60 m)).

• If you install a wireless access point (supplied by customer), be sure the location provides adequate WiFi reception. Do not install it in an area surrounded by metal or near any electrical devices that emit RF noise.

Remote Service & Support Module

• To use the supplied serial data cable, select a mounting location within 25 ft (7.5 m) of the control unit (maximum length = 50 ft (15 m)).

• Be sure the location provides adequate GPRS cellular reception.

Page 13

M4 x 16mm Screw (x4)

Mounting Bracket (x2)

Top Cover

Bottom Cover

M4 x 12mm Screw (x4)

Plastic Foot (x4)

1 2 3 4 5 6 7 8

9 10 11 12

Figure 7: Assembling the Case

#6 Washer (x4)

#6-32 Screw (x4)

Strain-Relief Bracket

Tie-Wrap

Holes (x12)

Retaining Strap (x2)

Control Unit

Modem

Figure 8: Attaching the Strain-Relief Bracket

M6 Screw (x4)

Plastic Washer (x4)

#6 Washer (x4)

#6-32 Screw (x4)

“Z” Bracket (x2) Cage Nut (x4)

Attach to Case

Attach to Control Unit

M6 Screw (x8)

Plastic Washer (x8)

Cage Nut (x8)

Blank Panel

Control Unit and Modem

Case

Figure 9: Securing the Control Unit/Modem in the Case

Prepare the Belowdecks Units

If you plan to mount the control unit and modem inside the optional 19" (482.6 mm) 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): #2, #5, #8, and #11.

e. At the back of the case, insert four cage nuts

into the following locations on the frame (two on each side): #1 and #3.

Option 1 - Mounting in the Case

f. Remove the four #6-32 screws and washers

securing the two retaining straps to the rear panel of the control unit. Do not remove the

bottom screws securing the straps to the modem.

g. Attach the strain-relief bracket to the

retaining straps and control unit using the screws and washers you removed in Step f (see Figure 8).

h. At the top 3U section of the case, insert the

control unit/modem assembly and secure the front mounting brackets to the case using four M6 screws and washers (see Figure 9).

i. At the bottom 3U section of the case, attach

the supplied blank panel using four M6

screws and washers (see Figure 9).

j. Secure the back of the control unit 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 control unit using four #6-32 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.

Page 14

Figure 10: Attaching the Strain-Relief Bracket

#6 Washer (x4)

#6-32 Screw (x4)

Strain-Relief Bracket

Tie-Wrap

Holes (x12)

Retaining Strap (x2)

Control Unit

Modem

#6 Washer (x4)

#6-32 Screw (x4)

Bracket (x2)

Control Unit

Modem

Ø.156" (Ø3.96 mm)

Mounting Hole (x4)

Figure 11: Attaching the Mounting Brackets

Prepare the Belowdecks Units

If you plan to mount the control unit and modem together as an assembly, 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 rear panel of the control unit. Do not remove the

bottom screws securing the straps to the modem.

b. Attach the strain-relief bracket to the

retaining straps and control unit using the screws and washers you removed in Step a (see Figure 10).

c. Attach two of the supplied “L” mounting

brackets to the sides of the control unit or modem using four #6-32 screws and washers (see Figure 11). You can attach the brackets to either the top of the control unit or the bottom of the modem, depending on your desired mounting location.

Option 2 - Mounting Units Together

d. Once you have completed all system wiring,

mount the modem/control unit assembly to the vessel using fasteners appropriate for the mounting surface.

Page 15

Figure 12: Detaching the Control Unit from the Modem

#6 Washer (x4)

#6-32 Screw (x4)

Strain-Relief Bracket

Tie-wrap

Holes (x12)

Control Unit

Figure 13: Attaching the Bracket to the Control Unit Figure 14: Attaching the Bracket to the Modem

Prepare the Belowdecks Units

If you plan to mount the control unit and modem separately, follow these steps to detach the control unit from the modem, attach the strainrelief brackets, and attach the “L” mounting brackets.

a. Remove the 28 #6-32 screws and washers

securing the two rack-mount brackets and four metal retaining straps to the control unit and modem (see Figure 12). Remove the brackets and straps.

b. Attach a strain-relief bracket to the back of

the control unit using four of the screws and washers you removed in Step a (see Figure 13).

c. Attach a second strain-relief bracket to the

back of the modem using four of the screws and washers you removed in Step a (see Figure 14).

d. Attach two of the supplied “L” brackets to

the sides of the control unit using four #6-32 screws and washers (see Figure 11 on page 7). You can attach the brackets at either the top or bottom of the control unit, depending on your desired mounting location.

Option 3 - Mounting Units Separately

Contr

Unit

dem

Bracket (x2)

#6 Washer (x28) #6-32 Screw (x28)

Strap (x4)

e. Attach the two other supplied “L” brackets to

the sides of the modem using four #6-32 screws and washers (see Figure 11 on page 7). You can attach the brackets at either the top or bottom of the modem, depending on your desired mounting location.

f. Once you have completed all system wiring,

mount the control unit and modem to the vessel using fasteners appropriate for the mounting surface.

Tie-wrap Holes (x12)

#6-32 Screw (x4)

#6 Washer (x4)

Modem

Strain-Relief Bracket

Page 16

FWD

Foam Seal

Ø1/2" (Ø13 mm)

Mounting Hole (x4)

12"

(305 mm)

6" (152 mm)

12"

(305 mm)

Ø2" (Ø50 mm)

Cable Access Hole

6" (152 mm)

Baseplate Footprint

Ø17"

(Ø432 mm)

Figure 15: Antenna Mounting Holes Layout

Once you have identified a suitable antenna mounting site, according to the guidelines provided in Step 2, follow these steps to drill the mounting holes and cable access hole to prepare the site for installation.

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 15).

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.

b. Using a light hammer and center punch,

mark the locations for the four mounting holes and cable access hole on the mounting surface in the locations indicated on the template.

Prepare the Antenna Site

c. Drill a 1/2" (13 mm) hole at the four

mounting hole locations you marked in Step b. Later, you will insert four M10 bolts from below to secure the antenna to the mounting surface.

d. Cut out the 2" (50 mm) cable access hole in

the location you marked in Step b. Smooth the edges of the hole to protect the cables. Later, you will route the data, power, and RF cables through this hole and into the vessel.

e. Clean and dry the antenna mounting surface. f. Peel off the paper backing from the supplied

foam seal 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 15).

NOTE: Apply the foam seal to the vessel mounting surface, not to the antenna’s baseplate. You will have difficulty connecting cables to the antenna if the foam seal is attached to the baseplate.

Page 17

M4 Screw (x11)

Service Hatch

Figure 16: Baseplate Service Hatch

Figure 17: Removing the Radome

Follow these steps to remove the service hatch and radome. They must be removed before you can wire and mount the antenna.

a. Remove the eleven M4 screws securing the

service hatch to the antenna’s baseplate (see Figure 16). Set the hatch aside in a safe place.

b. Remove and save the two #10-32 Phillips

screws securing the radome to the baseplate.

(The six other radome screws are in the kitpack. You will use these later when you reinstall the radome.) Carefully lift the radome straight up

until clear of the antenna assembly and set it aside in a safe place (see Figure 17).

TIP: If you keep the radome topside, secure it with a lanyard to prevent it from falling overboard.

Prepare the Antenna

Radome

#10-32

Screw (x8)

Baseplate

Page 18

Figure 18: RF Cable Requirements*

* For alternate cable options, see the Application Notes

section of the KVH Partner Portal (technicians only).

15-50 ft (5-15 m) Cable Run

Cable: RG-11

Connector: SNS11AS Installation Tools: CST596711 and L3011B

51-100 ft (16-30 m) Cable Run

Cable: LMR-400-75

Connector: EZ-400-FMH-75 Installation Tools: TK-400EZ-75

101-150 ft (31-45 m) Cable Run

Cable: LMR-600-75

Connector: EZ-600-FMH-75 Installation Tools: TK-600EZ

0.250" (6.35 mm)

0.370" (9.40 mm)

0.108" (2.74 mm) dia.

0.870" (22.10 mm)

NOTE: Optional 150 ft (45 m) data and power cables: Data cable KVH part #32-0921-0150 Power cable KVH part #32-0924-0150

NOTE: RG-11 connectors/tools are manufactured by Thomas & Betts. LMR-400-75 and LMR-600-75 cables/ connectors/tools are manufactured by Times Microwave.

Terminate RF cables with the proper type “F” connectors (see Figure 18). Instructions for terminating LMR-400-75 cable are provided in Appendix B on page 30.

IMPORTANT!

MRxMTx

Power

Data

Figure 19: Connectors on Bottom of Antenna Assembly

Follow these steps to connect the antenna cables. a. In addition to the data and power cables, you

will need to connect two 75 RF coax cables from the antenna to the belowdecks equipment. Use the guidelines in Figure 18 to determine the type of RF cables required.

Wire the Antenna

0.064" (1.63 mm) dia.

0.25" (6.35 mm)

0.5" (12.7 mm)

b. Label both ends of the two RF cables. Label

one cable “TX,” and label the other “RX.”

c. Route the data, power, and RF cables

belowdecks through the 2" (50 mm) cable access hole. Keep 2 ft (60 cm) of each cable outside the hole to allow enough slack to connect the cables and maintain a service loop inside the antenna.

d. Insert the other ends of the cables up th rough

the center hole in the bottom of the antenna’s baseplate.

e. Connect the data cable to the “Data” jack on

the bottom of the antenna assembly (see Figure 19). Hand-tighten until the connector locks in place; do not use excessive force.

f. Connect the power cable to the “Power” jack

on the bottom of the antenna assembly. Hand-tighten until locked in place.

g. Connect the RF cable labeled “TX” to the

“MTx” jack on the bottom of the antenna assembly. Hand-tighten, then tighten with a 7/16" wrench for 1/4 turn to ensure a good electrical connection.

0.065" (1.65 mm) dia.

0.170" (4.32 mm)

0.344" (8.74 mm)

0.610" (15.49 mm)

h. Connect the RF cable labeled “RX” to the

“MRx” jack on the bottom of the antenna assembly. Hand-tighten, then tighten with a 7/16" wrench for 1/4 turn.

i. Seal both RF cable connections with silicone

sealant, self-vulcanizing tape, or equivalent.

Page 19

Figure 20: Forward Arrow in Antenna Baseplate

Figure 21: Mounting the Antenna (Side View)

Follow these steps to mount the antenna to the mounting surface.

a. Place the antenna baseplate over the holes

drilled in the mounting surface.

b. Make sure the service hatch faces the stern of

the vessel. Also make sure the forward arrow inside the baseplate points toward the bow and is parallel to the vessel’s centerline (see Figure 20).

c. Make sure the four holes in the baseplate line

up with the four holes in the mounting surface.

d. At each of the four baseplate mounting holes,

place an M10 lock washer and flat washer on an M10 bolt and insert the bolt into the hole from below (see Figure 21).

Mount the Antenna

10 mm max.

e. Tighten all four bolts until the four rubber

feet on the baseplate are bottomed against the mounting surface and the foam seal is fully compressed. KVH recommends that you tighten the bolts to between 12 and 16 ft-lbs (16.2 and 21.7 N-m) of torque.

Antenna Base

Foam Seal

Mounting Surface M10 Flat Washer (x4)

M10 Lock Washer (x4)

M10 x 50 mm Bolt (x4)

Page 20

Figure 22: Removing the Shipping Restraint Brackets

3/8" Bolt (x2)

Lock Nut (x2)

Washer (x2)

Washer, Supplied

in Kitpack (x2)

Figure 23: Reinstalling the Mounting Bolts

Figure 24: Removing the Wire and Tie-wrap Restraints

Remove the Restraints

Inside the antenna, several shipping restraints prevent the antenna assembly from moving during shipment. Follow these steps to remove these shipping restraints.

a. Using an 11/16" wrench and a 9/16" socket

with 6" extension, remove the two 3/8" bolts, washers, and lock nuts securing the azimuth shipping restraints to the base of the antenna assembly (see Figure 22). Remove the “L” bracket restraints.

b. Place a 3/8" flat washer (supplied in the

kitpack) on the two 3/8" bolts that you removed in Step a. Reinstall the bolts and secure in place with the washers and lock nuts you removed in Step a (see Figure 23). These bolts secure the antenna assembly to the internal mounting platform.

c. Using wire cutters, cut and remove the wire

shipping restraint securing the reflector to the antenna frame (see Figure 24).

3/8" Bolt (x2)

Bracket (x2)

Washer (x2)

Lock Nut (x2)

d. Cut and remove the tie-wrap securing the

antenna’s LNB to the back of the reflector (see Figure 24).

e. Reinstall the radome onto the antenna. Secure

in place with the two #10-32 screws you removed in Step 6b, along with the six #10-32 screws supplied in the kitpack (see Figure 17 on page 10).

f. Reattach the service hatch to the antenna’s

baseplate using the M4 screws you removed in Step 6a (see Figure 16 on page 10).

g. Install a protective plastic cap (supplied in

the kitpack) over each radome screw.

Tie-wrap

IMPORTANT

REMOVE THIS SHIPPING

RESTRAINT BEFORE OPERATING

Wire

IMPORTANT

Page 21

12 1110987612543

Data

Power

Antenna

Blue/White

White/Blue

Brown/White

White/Gray

Gray/White

White/Orange

Orange/White

White/Brown

Red

Black

Terminal Strip Connector

Figure 25: Antenna Power and Data Wiring

The diagram refers to wires by body color/ stripe color. For example, “Brown/White”

means the brown wire with the white stripe.

IMPORTANT!

1211

Control Unit

Terminal Strip Connector

Antenna

Figure 26: Antenna Power and Data Wiring

Antenna

MRx

J1 AC PWRJ3Rx RFJ2Tx RF

ACU

CONSOLE

BUC PWR

J8 USER ENET

J7 ACU ENET

MODEL: VMBR-1510 ArcLight PART: 1234567 REV XXX SERIAL: XX-XXXXXX CAGE CODE: 12345

Modem

MTx

TxRFRxRF

Figure 27: Antenna RF Transmit and Receive Wiring

Be sure to terminate RF cables properly with type “F” connectors.

IMPORTANT!

Wire the Belowdecks Units

Wire the Antenna Cables

Follow these steps to connect the antenna to the control unit and the modem.

NOTE: A system wiring diagram is provided in Appendix A on page 29.

a. First dress the data and power cables from

the antenna. Strip back the insulat i on of each wire approximately 1/4" (6 mm) and gently twist each wire to ensure a good electrical connection.

b. Find the terminal strip connector in the

kitpack. Connect the antenna data cable to the terminal strip connector as shown in Figure 25.

c. Connect the power cable from the antenna to

the terminal strip connector as shown in Figure 25.

d. Plug the terminal strip connector into the rear

panel of the control unit (see Figure 26).

e. Connect the RF coax cable labeled “RX”

(connected to the antenna’s MRx jack) to the “Rx RF” jack on the back of the modem (see Figure 27).

f. Connect the RF coax cable labeled “TX”

(connected to the antenna’s MTx jack) to the “Tx RF” jack on the back of the modem.

Page 22

MODEM

RS422

BUC POWER

20V 2.5A

J1 AC PWRJ3Rx RFJ2Tx RF

ACU

CONSOLE

BUC PWR

J8 USER ENET

J7 ACU ENET

NO OPERATOR SERVICEABLE PARTS INSIDE, DO NOT OPEN

CAUTION

MODEL: VMBR-1510 ArcLight PART: 1234567 REV XXX SERIAL: XX-XXXXXX CAGE CODE: 12345

Wire Colors:

Body/Stripe

Control Unit

Modem

ACU

BUC Power

BUC Pwr

Figure 28: Modem Data and BUC Power Wiring

SerialGP10

Antenna On/Off Audio

SIM

Power

Control Unit

Remote Service

& Support Module

Cellular

Antenna

Maintenance Port

Serial

Antenna

Figure 29: Remote Service & Support Module Wiring

ACU

CONSOLE

BUC PWR

J8 USER ENET

J7 ACU ENET

NO OPERATOR SERVICEABLE PARTS INSIDE, DO NOT OPEN

CAUTION

Modem

MTA

4 3 2 18 7 6 5

POE

48V

Switch

12V DC RSTR WAN LAN PHONE 2 PHONE 1

Laptop

Phone1

User ENet

WAN

Analog

Phone

PoE ports for optional devices

Figure 30: Switch and MTA Wiring

Continued Wire the Belowdecks Units

Wire the Control Unit to the Modem

Follow these steps to connect the control unit to the modem.

a. Connect a serial data cable from the

“Modem” jack on the control unit to the “ACU” jack on the modem (see Figure 28).

b. Connect the BUC power cable from the “BUC

Power” jack on the control unit to the “BUC Pwr” jack on the modem.

Wire the Remote Service Module

Follow these steps to connect the remote service & support module to the control unit.

a. Connect a serial data cable from the

“Maintenance Port” jack on the control unit to the “Serial” jack on the remote service & support module. (see Figure 29).

b. Make sure the cellular antenna is connected

to the “Antenna” jack on the remote service & support module.

Wire the Switch and MTA

Follow these steps to connect all LAN devices. a. Connect the supplied straight-through

Ethernet cable from the “User ENet” jack on the modem to any port on the switch (see Figure 30).

b. Connect a second straight-through Ethernet

cable from any port on the switch to the “WAN” jack on the MTA.

c. Connec t the customer’s analog (not digital)

phone(s), fax machine, and/or PABX to the desired RJ-11 “Phone” jack(s) on the MTA. Each jack is linked to a unique phone line.

NOTE: If the customer requires an enterprise-grade fax solution, install KVH’s optional UCH-250 Fax Server (KVH part #19-0520).

d. For a wired Ethernet network, connect the

customer’s computer(s) to any port(s) on the switch. For a wireless network, connect an access point (customer-supplied) to the switch (ports 1-4 support IEEE 802.3af devices).

NOTE: The Ethernet and VoIP equipment supplied with the system might differ from those shown in this diagram.

Page 23

Ground

Neutral

100-240 V AC

TracPhone V7 Equipment Isolation T r ansformer

60-220 V AC

Ground

Shipboard

Two-Phase,

Split-Phase,

or Delta Power

Single-Phase

Power Input

Figure 31: Single-Phase AC Power Input

NOTE: Ground fault protection devices cannot detect faults behind an isolation transformer.

Vessel AC Power

115 or 230 V AC

Single-Phase

J1 AC PWRJ3Rx RFJ2Tx RF

ACU

CONSOLE

BUC PWR

J8 USER ENET

J7 ACU ENET

NO OPERATOR

SERVICEABLE PARTS INSIDE, DO NOT OPEN

CAUTION

MODEL: VMBR-1510 ArcLight PART: 1234567 REV XXX SERIAL: XX-XXXXXX CAGE CODE: 12345

Antenna On/Off Audio

SIM

Power

Strip

AC/DC

Adapter

4 3 2 18 7 6 5

POE

48V

12V DC RSTR WAN LAN PHONE 2 PHONE 1

Control Unit

Modem

Remote Service Module

MTA

AC/DC

Adapter

Switch

AC/DC

Adapter

AC Input

12 VDC

48V

AC Pwr

Power

Figure 32: Power Wiring

Connect Power

Follow these steps to connect power to the TracPhone V7 system.

WARNING

The TracPhone system requires 3-wire singlephase AC power (hot, neutral, and ground). Voltage between hot-neutral and hot-ground should each measure between 100-240 VAC.

Some 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). The TracPhone system cannot operate on this type of power. Attempting to run the

TracPhone system directly on two-phase, split-phase, or delta power 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, if the vessel is limited to twophase, split-phase, or delta AC power, or if there is a floating ground condition, you MUST use a suitable isolation transformer to supply single-phase power to the TracPhone system (see Figure 31).

a. Before you begin, disconnect vessel power. b. Be sure the vessel is properly grounded in

accordance with marine standards.

c. Connect the control unit and modem to the

supplied AC power strip using the adapter cables provided in the kitpack (see Figure 32).

d. Strain-relieve all wires at the back of the

control unit and modem by securing them to the attached strain-relief bracket(s) using tiewraps. Leave enough slack for serviceability.

Page 24

e. Connect the appropriate power cord (US or

European) to the power strip. Then plug it into the vessel’s 115 or 230 VAC supply.

f. Connect the MTA, switch, and remot e service

& support module to AC power via their AC/DC adapters (see Figure 32 on page 16).

Continued Connect Power

Page 25

Establishing a wireless connection onboard a steel vessel might require a special WAP and advanced networking expertise.

IMPORTANT!

When setting up a wireless network, apply security settings, such as encryption, to protect the network from outside intrusion.

IMPORTANT!

Figure 33: Windows 7/Vista - Local Area Connection Properties

Figure 34: Windows 7/Vista - Internet Protocol Properties

Follow these steps to configure the user’s computer(s) for a wired connection to the TracPhone V7. Once you have set up and tested a wired connection, you can configure a wireless connection (wireless access point not supplied).

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.

Configure the Computer(s)

Windows 7 or Vista

a. Turn on the networked computer. b. From the Windows Control Panel, navigate

to the Network and Sharing Center. You can find the control panel either through the Start menu or “My Computer.”

c. 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 for TracPhone V7.

d. At the Local Area Connection Status window,

click Properties. This screen only displays if the

computer is currently connected to a network.

e. At the Local Area Connection Properties

window, select the Networking tab. Then select Internet Protocol Version 4 and click

Properties (see Figure 33).

f. At the Internet Protocol Properties window,

select Obtain an IP address automatically and Obtain DNS server address

automatically (see Figure 34). Then click OK.

g. At the Local Area Connection Properties

window, click OK.

Page 26

Figure 35: Windows XP - Local Area Connection Properties

Figure 36: Windows XP - Internet Protocol (TCP/IP) Properties

Continued Configure the Computer(s)

Windows XP

a. Turn on the networked computer. b. At the Windows Contol Panel, double-click

Network Connections. You can fi nd the control

panel either through the Start menu or “My Computer.”

c. At the Network Connections window,

double-click the Local Area Connection icon for the Ethernet connection you are using for TracPhone V7.

d. At the Local Area Connection Status window,

select the General tab. Then click Properties.

This screen only displays if the computer is currently connected to a network.

e. At the Local Area Connection Properties

window, select the General tab. Then select

Internet Protocol (TCP/IP) and click Properties (see Figure 35).

f. At the Internet Protocol (TCP/IP) Properties

window, select the General tab. Then select Obtain an IP address automatically and Obtain DNS server address automatically (see Figure 36). Then click OK.

g. At the Local Area Connection Properties

window, click OK.

h. Restart the computer.

Page 27

Figure 37: Macintosh OS X - Network Preferences

Macintosh OS X

a. Turn on the networked computer. b. At System Preferences, click the Network

c. At the Network window (see Figure 37),

d. Network: Click Apply Now. e. Restart the computer.

Continued Configure the Computer(s)

icon.

select the following:

•Show: Built-in Ethernet

•Configure: Using DHCP

• Leave all text boxes blank

Page 28

Double-check all of your wiring before continuing. If wiring is incomplete or incorrect, electronics may become damaged when you apply power.

IMPORTANT!

STATUS

Power Switch

Figure 38: Power Switches

Power Switch

Modem

Control Unit

Figure 39: Status Lights

Follow these steps to turn on the TracPhone V7 system for the first time.

a. Ensure the antenna has a clear, unobstructed

view of the sky.

b. Apply vessel power to the TracPhone system,

including the switch, MTA, and remote service & support module.

c. Turn on the power switch on the front of the

the modem (see Figure 38). The button’s light should illuminate green.

d. Turn on the power switch on the front of the

control unit (see Figure 38). The button’s light should illuminate green.

Turn On the System

Control Unit

e. Wait 5 minutes for system startup. f. Verify that the status lights on the control

unit and modem (see Figure 39) exhibit the following conditions:

• Control Unit: Lit green

• Antenna: Lit or flashing green

• Modem: Lit or flashing green

• Status: Any condition except off If any of these lights exhibit a different

condition, refer to the Troubleshooting section of the User’s Guide.

g. Verify that the status lights on the MTA and

switch indicate a normal condition. Refer to the MTA and switch manuals for details.

Modem

STATUS

Page 29

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

CTRL UNIT SW VERSION 2.14

ANTENNA STATUS NEXT MENU ACCEPT

Press ACCEPT

Press MENUS twice

PRESS TO VIEW EACH ANTENNA ITEM

Press MENUS to scroll through the status screens

Figure 40: Software Versions Displayed on the Control Unit

Figure 41: TPV7 Flash Update Wizard Help Menu

Update the System Software

Follow these steps to ensure the latest software is installed in the TracPhone V7 system.

a. At the control unit, press MENUS until the

display shows “ANTENNA STATUS” (see Figure 40). 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 TPV7 Flash Update Wizard’s Release Notes.

NOTE: Before using the TPV7 Flash Update Wizard, be sure to check for updates to ensure it has all of the latest software files (Internet access required).

If Necessary

e. Use the TPV7 Flash Update Wizard to update

any older versions of software in the TracPhone V7 system. Refer to the Wizard’s Help menu for complete details (see Figure 41).

Page 30

Figure 42: Example of an RF Radiation Hazard Zone

Antenna

000

180

090270

135

225

315

Forward

015

080

RF Radiation Hazard Zone (Example)

Beginning

Azimuth

Ending

Azimuth

Figure 43: Azimuths Relative to Antenna’s Forward Arrow

ZONE 1= 015-080 CHANGE ACCEPT

Step 1:

Set Zone 1 Azimuth Range

ZONE 2= 999-999 NEXT ITEM CHANGE

Step 2:

Set Zone 2 Azimuth Range

XMT IN ZONES= NO NEXT ITEM CHANGE

Step 3:

Set to “NO”

Figure 44: Setup Process for RF Hazard Zones

Set Up RF Hazard Zones

To prevent exposure to RF energy, which might be harmful to people who stand within 36 feet (11 meters) of the antenna, you can configure up to two RF radiation hazard zones for areas where crew and/or passengers frequent (see Figure 42). The system will disable the transmitter whenever the antenna is pointing within one of these zones.

Follow these steps to set up an RF hazard zone. a. Determine the necessary azimuth range for

the RF hazard zone(s). You will need to enter, in clockwise order, beginning and ending azimuths (>4° apart) relative to the antenna’s forward arrow, which should be pointing toward the bow (see Figure 43).

b. At the control unit, press MENUS until the

display shows “CONFIGURATION.” Then press ACCEPT.

c. Press MENUS until the display shows “SET

HAZARD ZONE.”

Optional

Hazard Zone

080

015

d. Press CHANGE until the display shows “SET

HAZARD ZONE = YES.” Then press ACCEPT.

e. At “ZONE 1,” press CHANGE. A cursor

appears under the first number in the azimuth range for RF hazard zone #1.

f. Press CHANGE until the number is set to the

first digit of the beginning azimuth for the first hazard zone (enter a zero if < 100°).

g. Press ACCEPT. The cursor moves to the next

number.

h. Repeat steps f and g to set the remaining

digits of the desired RF radiation hazard zone. Then press ACCEPT.

i. At “Zone 2,” repeat steps e-h to set the range

for the second RF hazard zone, if desired.

j. At “XMT IN ZONES,” verify that the display

shows “XMT IN ZONES = NO.” Then press MENUS.

k. Press EXIT to exit the menu.

NOTE: For more details, refer to the Configuration section of the User’s Guide.

Page 31

Figure 45: Good Service Connection Indicated on Control Unit LCD

NOTE: Satellites will vary depending on your location.

Once the system is online, do not turn it off for 30 minutes to allow the modem to download the latest 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.

IMPORTANT!

POWER

RUN

WAN

LAN

VOIP

PHONE 2

PHONE 1

POWER

RUN

WAN

LAN

VOIP

PHONE 2

PHONE 1

Figure 46: MTA Status Lights

Figure 47: Welcome Page for Testing

Test the System

Now that you have installed the system, you can test the system to verify it is ready for customer delivery. Follow these steps to test the system for proper operation.

a. Ensure the antenna has a clear, unobstructed

view of the sky.

b. With the TracPhone system powered on,

restart the networked computer(s).

c. Verify that the antenna is tracking the service

satellite and the modem is connected to the mini-VSAT Broadband service, as indicated by the control unit screen shown in Figure 45. If an error appears, refer to the Troubleshooting section of the User’s Guide.

ONLINE TRACKING 22.0W

d. If the customer has activated the TracPhone

system for mini-VSAT Broadband service, verify that the system can access the Internet by entering any common website address (URL) into the browser.

e. If the customer has activated the TracPhone

system, also verify that you can place a voice call. First make sure the MTA’s “VOIP” light is lit green (see Figure 46). Then, using any telephone connected to the MTA, place a call to someone on a terrestrial or cell u la r network and ask that person to call you back at the customer’s number.

f. Even if the customer has not yet activated the

TracPhone system for mini-VSAT Broadband

service, you can still check the modem’s communications to the land-based hub. Open the web browser on any networked computer and enter the following address to access the Welcome page: http://208.83.165.11/mbbtest. Verify that the Welcome page appears in the browser (see Figure 47).

Page 32

Figure 48: General Status Page Via Modem Web Interface

g. Open the web browser on any wired (not

wireless) networked computer and enter the following address to access the modem’s web interface: http://192.168.0.1

h. Under “Forward Link” on the General Status

page, make sure Eb/No is at least 2 dB (see Figure 48).

NOTE: Refer to the User’s Guide for details about the other status information that is available on this web page.

Continued Test the System

Page 33

Figure 49: Customer Welcome Kit

Antenna

Radiation

Hazard

Radiation

Hazard

Figure 50: Safe Distance to Avoid Risk of RF Radiation Exposure

Figure 51: Example of Satellite Blockage

Educate the Customer

The installation is complete! Before you leav e the vessel, enter the system serial numbers on the first page of the User’s Guide, give the Welcome Kit to the customer, and review the following with the customer:

• Advertised data speeds and reasons why speeds may decrease at times (refer to Section 15 of the End User Agreement)

• Voice service and all associated long-distance charges (refer to the Airtime Rate Sheet)

• Fair Access Policy: streaming video and peerto-peer file sharing are prohibited (refer to Sections 44-45 of the End User Agreement)

Also explain how to use the system and be sure the customer understands the follow ing:

• The antenna transmits RF energy that is potentially harmful. Whenever the system is powered on, make sure everyone stays more than 36 feet (11 meters) away from the antenna within its 5-80° look angle (see Figure 50). No hazard exists directly above the antenna and anywhere below the antenna’s mounting plane.

• Keep the radome installed on the antenna at all times. The radome protects the antenna’s moving parts from wind, rain, and debris.

• 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 51).

• Clean the antenna regularly. Dirt buildup on the radome can affect communications. Heavy rain or snow may also temporarily interrupt communications.

• The vessel must be located within the coverage area of the satellite. To view a coverage map, visit www.kvh.com/

minivsatmap.

• The system must be activated for mini-VSAT Broadband service. For activation details,

refer to the Activation Checklist located in the Welcome Kit or on the web at www.kvh.com/

mvbservice.

Page 34

Appendices

This section provides a system wiring diagram and supplemental instructions for terminating an LMR-400-75 cable.

Contents

A. Wiring Diagram................................... 29

B. Terminating LMR-400-75 Cables....... 30

Page 35

SerialGP10

Power

J1 AC PWRJ3Rx RFJ2Tx RF

ACU

CONSOLE

BUC PWR

J8 USER ENET

J7 ACU ENET

NO OPERATOR SERVICEABLE PARTS INSIDE, DO NOT OPEN

CAUTION

MODEL: VMBR-1510 ArcLight PART: 1234567 REV XXX SERIAL: XX-XXXXXX CAGE CODE: 12345

Antenna On/Off Audio

SIM

Power

12 1110987612543

Data

Power

Antenna

Control Unit

MTx

MRx

Modem

Service Module

Blue/White

White/Blue

Brown/White

White/Gray

Gray/White White/Orange Orange/White

White/Brown

Red

Black

Terminal Strip Connector

Note: Terminals #3

and #8 are not used

Power

Not Used

Power

4 3 2 18 7 6 5

POE

48V

12V DC RSTR WAN LAN PHONE 2 PHONE 1

Laptop

Analog

Phone

MTA

Switch

Wiring Diagram

Appendix

Page 36

Figure 52: Cutting the Cable

Figure 53: Reshaping the Cable

Figure 54: Placing the Heat Shrink Tubing and Ferrule

Figure 55: Stripping the End to Expose the Center Conductor

Terminating LMR-400-75 Cables

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 52).

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 53). 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 54).

4. Insert the end of the cable into the #1 end of

the ST-400EZ stripping tool (see Figure 55). 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.

Appendix

Page 37

Figure 56: Removing Plastic Residue Figure 57: Stripping the Cable Jacket

Figure 58: Cable Stripped, Exposing Dielectric

Figure 59: Deburring the Center Conductor

5. Using a utility knife, carefully remove any

residual plastic from the center conductor, if necessary (see Figure 56).

6. Insert the end of the cable into the #2 end of

the ST-400EZ stripping tool (see Figure 57). 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 58).

7. Using the DBT-02 tool, deburr and chamfer

the center conductor (see Figure 59). Avoid nicking the aluminum tape covering the dielectric.

Continued Terminating LMR-400-75 Cables

Page 38

Figure 60: Flaring the Braid

Figure 61: Pushing On the Connector

Figure 62: Trimming the Braid

Figure 63: Sliding the Ferrule Over the Braid

8. Gently flare the braid with your fingers (see

Figure 60).

9. Insert the end of the cable into the connector

body until the dielectric is firmly seated inside the connector (see Figure 61). Be sure all braid wires remain on the outside of the connector.

10. Trim any excess braid (see Figure 62), 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 63).

Continued Terminating LMR-400-75 Cables

Page 39

Figure 64: Crimping the Ferrule onto the Cable

Figure 65: Applying the Heat Shrink Tubing

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 64). 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 65). 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.

Continued Terminating LMR-400-75 Cables

Page 40

www.kvh.com

KVH Industries, Inc.

World Headquarters

Middletown, RI U.S.A.

Tel: +1 401 847 3327 Fax: +1 401 849 0045

E-mail: info@kvh.com

KVH Industries A/S

EMEA Headquarters

Kokkedal, Denmark

Tel: +45 45 160 180 Fax: +45 45 160 181

E-mail: info@emea.kvh.com

KVH Industries Pte Ltd.

Asia-Pacific Headquarters

Singapore

Tel: +65 6513 0290 Fax: +65 6472 3469

E-mail: info@apac.kvh.com