TracPhone V3 Installation Manual

TracPhone® V3

Installation Guide

Rubber Connector Washers

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

PLEASE READ!
Important Addendum to the Installation Guide

Rubber connector washers are now provided in the kitpack to help
you protect the antenna’s RF connections from the elements.

To install these rubber washers, place them over the antenna’s “MTx”
and “MRx” connectors, as shown in Figure 1, before you connect the
RG-11 cables. Then, when you connect and tighten the RG-11 cables,
be sure the washers compress against the antenna’s baseplate.

Figure 1 RG-11 Cable Connection to the Antenna

Antenna Baseplate

Rubber Washer

Apply Silicone Grease

RG-11

54-0842 Rev. A

1

PLEASE READ!

KVH Antenna System

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

N

100-240 VAC

OR

OR

Ground

Neutral

N

100-240 VAC

Single-Phase

Power Input

Ground Fault

Monitor

(when required)

Isolation Transformer

Ground

Ground

50-120 VAC

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

1

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.

2

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.

3

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

1

RF Cable Connectors

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

54-0779 Rev. A

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.

1

TracPhone V3 Installation Guide

KVH’s Compact mini-VSAT Broadbandsm System

These instructions explain how to install the TracPhone V3 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. Remove the Shipping Restraints....... 10

7. Prepare the RF Cables......................... 11

8. Wire the Antenna ................................ 12

9. Mount the Antenna............................. 14

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 32 ft (10 m)
away from the antenna within its 7.5-75°
elevation range. No hazard exists directly
above the antenna and anywhere below the
antenna’s mounting plane.

10. Wire the Belowdecks Units.................15

11. Connect Power.................... .... ..... .........17

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..........................25

75°75°

Radiation

Hazard

ft (10

2

3

m)

7.5°

7.5°

Radiation

Hazard

3

2

ft

(

10

m

)

Antenna

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.

Technical Support

North/South America, Australia:

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

KVH, TracPhone, and the unique light-colored dome with dark contrasting baseplate are registered trademarks of KVH Industries, Inc.

mini-VSAT Broadband is a service mark 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 KVH Industries, Inc., All rights reserved. 54-0747 Rev. B

Europe, Middle East, Asia, Africa:

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

1

Radome

Baseplate

Figure 1: TracPhone V3 System Components

Antenna

Control Unit

Modem

Ethernet Switch

Multimedia Terminal
Adapter (MTA)

(KVH part #02-1860)

(KVH part #02-1601-02)

(KVH part #19-0487)

(KVH part #19-0729)

(KVH part #19-0504)

(KVH part #72-0485)

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

IMPORTANT!

1

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

Inspect Parts and Get Tools

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

• Electric drill and 5/16" (8 mm) bit

• 3.5" (89 mm) hole saw

• 1/2" socket and 7/16" socket

• 7/16" open-end wrench and 7/16" torque

• Light hammer and center punch

• Adhesive tape and scriber or pencil

• Silicone sealant or equivalent

• Wire strippers and terminal lug crimper

•Two 75RF coax cables, “F” connectors,

•Windows

• Isolation transformer, if required (see

wrench set to 20 in.-lbs

and associated installation tools (see
page 11)

®

7, Vista™, or XP laptop with
the latest version of TracPhone V-series
Flash Wizard installed (software available
to technicians on the KVH Partner Portal)

page 17)

3

Blocked!

Antenna

Mast

Look Angle

Vessel Platform

7.5° to 75°

Figure 2: Blockage from Obstruction

FWD

17.6"

(447.1 mm)

15.5"

(

393.7 mm)

9.2"

(233.7 mm)

4.6"

(116.8 mm)

5.6"

(142.2 mm)

2.8"

(71.1 mm)

4 x Ø.31"
(Ø7.9 mm)

Side View

Bottom View

Figure 3: Antenna Dimensions

Do not mount the antenna at the same level as
the radar because the radar’s energy can
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!

2

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 (25 lbs, 11.3 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.

4

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

* Dimensions may vary, as ancillary components supplied
with the system may differ from those shown in this manual.

Component Dimensions (W x D x H)

Switch 7.5" x 4.7" x 1.5"

(19 cm x 12 cm x 3.8 cm)

MTA 4.6" x 5.12" x 1.18"

(11.7 cm x 13 cm x 3 cm)

3

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 (or an

onboard equipment rack)

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" (48.26 cm) equipment rack.

• To use the supplied power/data cable, the
control unit must be located within 100 ft
(30 m) of the antenna. However, you can
order a 150 ft (45 m) cable if a longer cable
run is necessary (KVH part #32-1031-0150).

Switch and MTA

• To use the supplied Ethernet cable, 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.

5

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

#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

4

Prepare the Belowdecks Units

If you plan to mount the control unit and modem
inside the optional 19" (48.26 cm) 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.

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.

Mounting in the Case

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

6

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.

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

4

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.

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.

7

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

4

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.

Mounting Units Separately

Contr

ol U

n

i

t

M

o

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.

8

Tie-wrap
Holes (x12)

#6-32 Screw (x4)

#6 Washer (x4)

Modem

Strain-Relief
Bracket

9.2"

(233.7 mm)

Ø5/16" (Ø8 mm)
Mounting Hole (x4)

5.6"

(142.2 mm)

Ø3.5" (Ø89 mm)
Cable Access Hole

FWD

Foam Seal

Figure 15: Antenna Mounting Holes Layout

5

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 5/16" (8 mm) hole at the four

mounting hole locations you marked in
Step b. Later, you will insert four 1/4"-20
bolts through these holes to secure the
antenna to the mounting surface.

d. Cut out the 3.5" (89 mm) cable access hole in

the location you marked in Step b. Smooth
the edges of the hole to protect the cables.
(You may also apply anti-chafe material
around the cables to protect them from
abrasion.) Later, you will route the power/
data 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.

g. Transport the antenna to the mounting site.

9

#10-32 Screw (x3)

Figure 16: Removing the Radome

#10-32 Screw (x2)

Figure 17: Shipping Restraints

Once you have removed the restraints,
handle the antenna carefully. With the
restraint removed, the internal antenna
assembly rotates freely and, if not handled
properly, can damage the limit switch.

IMPORTANT!

6

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

a. Remove the three #10-32 Phillips screws

securing the radome to the baseplate (see
Figure 16). Carefully lift the radome straight
up until clear of the antenna assembly and set
it aside in a safe place.

NOTE: Due to the snug fit, some contact between the
radome’s sealing gasket and the antenna mechanism is
normal.

b. Remove the two #10-32 Phillips shipping

restraint screws (see Figure 17). Save the
restraints for future use.

Remove the Shipping Restraints

10

Figure 18: RF Cable Requirements

* Cables from KVH include the proper connectors.

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

Cable RG-11

(KVH part #32-1087-50)

Loss: 0.084 dB/ft (0.276 dB/m)

Connector Right-angle: ICM FS11RA*

Straight: Thomas & Betts SNS11AS*

Tools Right-angle: Cable Pro PS11 and

CPLCCT-SS59/11
Straight: Thomas & Betts CST596 711
and L3011B (KVH part #72-0493)

Strip
Lengths

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

Cable LMR-400-75

(KVH part #32-0944-0100)

Loss: 0.06 dB/ft (0.195 dB/m)

Connector Times Microwave EZ-400-FMH-75*
Tools Times Microwave TK-400EZ-75

(KVH part #19-0499-0075)

Strip
Lengths

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

Cable LMR-600-75

(KVH part #32-0945-0150)

Loss: 0.04 dB/ft (0.13 dB/m)

Connector Times Microwave EZ-600-FMH-75*
Tools Times Microwave TK-600EZ

(KVH part #19-0500-0075)

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
in Appendix B on page 30.

• 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.

IMPORTANT!

7

You need to connect two 75 RF coax cables
from the antenna to the belowdecks equipment.
Refer to Figure 18 to determine the type of cables
and connectors required for your cable run. Then
prepare both of them as described below.

Prepare the RF Cables

0.064" (1.63 mm) dia.

0.25" (6.35 mm)

0.5" (12.7 mm)

a. Terminate both ends of the cables with the

proper “F” connectors (see Figure 18 for
connector and tool part numbers).

NOTE: If you only need to run RG-11 RF cables, you
may terminate one end of each with a right-angle
connector, or use pre-terminated 50 ft (15 m) RG-11
cables from KVH (KVH part #32-1087-50), and omit
the pigtail cables described in the next section.

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

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

0.065" (1.65 mm) dia.

0.170" (4.32 mm)

0.344" (8.74 mm)

0.610" (15.49 mm)

11

Figure 19: Minimum Bend Radius of RF Cables

Cable Type Minimum Bend Radius

RG-11 4.5" (11.5 cm)
LMR-400-75 4.5" (11.5 cm)
LMR-600-75 6" (15.3 cm)

Figure 20: Antenna Cable Connections
Figure 21: Connecting RF Cables to the Antenna

Do not connect LMR-400-75 or LMR-600-75
cables directly to the antenna’s RF connectors.

IMPORTANT!

8

Follow these steps to connect the power/data
and RF cables to the antenna.

NOTE: An optional 150 ft (45 m) power/data cable is
available from KVH (KVH part #32-1031-0150).

a. Route the power/data and RF cables

belowdecks through the 3.5" (89 mm) cable
access hole. Leave an adequate service loop,
approximately 8" (20 cm) of slack, in the
cables for easy serviceability. Also be sure to
always maintain the minimum bend radius in
the RF cables (see Figure 19).

b. Connect the power/data cable to the

“Power/Data” jack on the bottom of the
antenna (see Figure 20). Hand-tighten until
the connector locks in place; do not use
excessive force.

c. Using the supplied 3 mm Allen hex key,

remove the connector cover from the
antenna’s baseplate. Save the cover and the
four M4 cap screws for later use.

Wire the Antenna

MTX MRX

d. Clean and dry the antenna’s two RF

connectors and the RF cables’ connectors.

e. Fill half of the inner body of the “TX” RF

cable’s connector with the supplied silicone
grease (to prevent moisture and corrosion).

f. Connect and SLOWLY hand-tighten the

“TX” RF cable to the feed-thru adapter of one
of the supplied RG-11 pigtail cables, allowing
the grease to diffuse and settle into the entire
space within the connector (see Figure 21).

g. 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.

h. Fill half of the inner body of the “TX” pigtail

cable’s right-angle connector with silicone
grease.

M4 Cap
Screw (x4)

(supplied in kitpack)

Feed-thru Adapters

(supplied in kitpack)

(supplied by customer)

Cover

Right-Angle Connectors

(type “F”)

RG-11 Pigtails

RF Cables

Power/Data Cable
RF Cables

Straight
Connectors

(type “F”)

To Modem

12

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.

IMPORTANT!

8

i. Connect and SLOWLY hand-tighten the

“TX” pigtail cable to the“MTx” jack on the
bottom of the antenna, allowing the grease to
diffuse and settle into the entire space within
the connector.

j. Make sure the “TX” pigtail cable’s connector

is tightened all the way into the antenna’s
connector. Then tighten it with a 7/16" torque
wrench set to 20 in.-lbs.

k. Repeat steps e-j to connect the “RX” RF cable

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

l. Wipe off any excess grease from the outside

of all RF cable connectors.

m. Seal all above deck RF cable connections with

silicone sealant or equivalent.

n. Reattach the cover over the antenna’s

connectors and secure in place with the M4
cap screws.

Continued Wire the Antenna

o. Secure the cables near the antenna connectors

to prevent stress, then weatherproof and seal
the cable access hole as required.

13

Figure 22: Forward Arrow in Antenna Baseplate

Be sure to insert the mounting bolts from
above and use the supplied hardware for a
secure connection.

IMPORTANT!

1/4"-20 Bolt (x4)

1/4" Flat Washer (x4)

(5/8" diameter)

Rubber

Foot (x4)

Foam Seal

Mounting

Surface

1/4"-20 Lock Nut (x4)

Antenna

Baseplate

1/4" Flat Washer (x4)

(1" diameter)

IMPORTANT! Apply
anti-seize to threads

Figure 23: Mounting the Antenna (Side View)

Use caution if you’re using power tools. High
installation speeds can damage the threads.

IMPORTANT!

9

Follow these steps to mount the antenna.
a. Place the antenna over the holes drilled in the

mounting surface and make sure the f orward
arrow inside the baseplate points toward the
bow and is parallel to the vessel’s centerline
(see Figure 22). The antenna’s baseplate
should rest squarely atop the foam seal.

Mount the Antenna

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.”

b. Apply a thin layer of the supplied anti-seize

lubricant to the threads of the four 1/4"-20
bolts to prevent galling.

c. At each of the four baseplate mounting holes,

place a 5/8" diameter flat washer on a
1/4"-20 bolt and insert the bolt into the hole
from above (see Figure 23).

®

anti-seize lubricant:

d. Secure each mounting bolt to the mounting

surface using a 1" diameter flat washer and a
1/4"-20 lock nut from below. Tighten all four

14

bolts until the four rubber feet on the
baseplate are bottomed against the mounting
surface and the foam seal is fully compressed.

e. Reinstall the radome onto the antenna. Secure

in place with the three #10-32 screws you
removed earlier (see Figure 16 on page 10).
Then install a protective plastic cap (supplied
in the kitpack) over each radome screw.

Control Unit

Antenna

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

N/C N/C

Figure 24: Antenna Power/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!

Antenna

MRx

J1
AC PWRJ3Rx RFJ2Tx RF

J4

ACU

J5

CONSOLE

J6

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 25: Antenna RF Transmit and Receive Wiring

Be sure the RF cables are terminated properly
with type “F” connectors.

IMPORTANT!

MODEM

RS422

BUC POWER

20V 2.5A

J1
AC PWRJ3Rx RFJ2Tx RF

J4

ACU

J5

CONSOLE

J6

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

Modem

ACU

BUC Power

BUC Pwr

Figure 26: Modem Data and BUC Power Wiring

10

Wire the Belowdecks Units

Wire the Antenna Cables

Follow these steps to connect the antenna to the
belowdecks equipment (see page 29 for a
complete system wiring diagram).

a. First dress the power/data cable from the

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

b. Connect the antenna power/data cable to the

supplied terminal strip connector as shown in
Figure 24.

c. Plug the terminal strip connector into the rear

panel of the control unit.

d. 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 25). Hand-tighten, then tighten with a
7/16" torque wrench set to 20 in.-lbs.

e. 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.
Hand-tighten, then tighten with a 7/16"
torque wrench set to 20 in.-lbs.

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

b. Connect the BUC power cable from the “BUC

“Modem” jack on the control unit to the
“ACU” jack on the modem (see Figure 26).

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

15

J4

ACU

J5

CONSOLE

J6

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

PC

Phone1

User ENet

WAN

5

Analog

Phone

67

PoE ports
for optional
devices

Figure 27: Switch and MTA Wiring

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

Be sure to connect the customer’s phone to
the “Phone 1” jack on the MTA, and not to t he
“Phone 2” jack. Only the “Phone 1” jack is
enabled for use.

IMPORTANT!

10

Continued Wire the Belowdecks Units

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 non-PoE port on the
switch (see Figure 27).

b. Connect a second straight-through Ethernet

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

c. Connect the customer’s analog (not digital)

phone or PABX to the “Phone 1” jack on the
MTA. This jack is linked to a unique phone
line.

d. For a wired Ethernet network, connect the

customer’s computer(s) to any non-PoE
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).

Wiring Optional Accessories

KVH offers optional accessories that extend the
capabilities of the TracPhone system. For
example, the UCH-250 Fax Server (KVH part
#19-0520) is an enterprise-grade fax solution that
provides a dedicated fax line using a fully
managed, store-and-forward fax service.

Before you install any accessory, complete the
basic system installation as described in the rest
of this manual. After you have tested the system
and verified proper operation, refer to the
separate instructions provided with the
accessory to connect the device to the system.

16

Ground

Neutral

N

100-240 V AC

TracPhone Equipment

Shipboard
3-Wire
Single-Phase
AC Power

Ground

Neutral

N

100-240 V AC

TracPhone Equipment Isolation Transformer

60-220 V AC

60-220 V AC

Ground

Shipboard

Two-Phase,

Split-Phase,

or Delta Power

Single-Phase

Power Input

OR

Ground Fault

Monitor

(when required)

Figure 28: Single-Phase AC Power Input

NOTE: Since ground fault protection devices cannot detect
faults behind a transformer, install a ground fault
monitoring device between the isolation transformer and the
TracPhone system if ground fault protection is required on
the vessel.

Vessel AC Power

115 or 230 V AC

Single-Phase

J1
AC PWRJ3Rx RFJ2Tx RF

J4

ACU

J5

CONSOLE

J6

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

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

MTA

Switch

AC/DC

Adapter

AC Input

12 VDC

48V

AC Pwr

Figure 29: Power Wiring

11

Connect Power

Follow these steps to connect power to the
TracPhone 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 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 28).

a. Before you begin, disconnect vessel power

and be sure the vessel is properly grounded
in accordance with marine standards.

b. Connect the control unit and modem to the

supplied AC power strip using the adapter
cables provided in the kitpack (see Figure 29).

c. Strain-rel ieve 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.

d. Connect the appropriate power cord (US or

European) to the power strip. Then plug it
into the vessel’s 115 or 230 VAC supply. Also
connect the MTA and switch to AC power via
their AC/DC adapters (see Figure 29).

17

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 30: Windows 7/Vista - Local Area Connection Properties

Figure 31: Windows 7/Vista - Internet Protocol Properties

12

Follow these steps to configure the user’s
computer(s) for a wired connection to the
TracPhone V3. Once you have set up and tested a
wired connection, you can configure a wireless
connection (wireless access point (WAP) 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

18

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 V3.

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 30).

f. At the Internet Protocol Properties window,

select Obtain an IP address automatically
and Obtain DNS server address

automatically (see Figure 31). Then click OK.

g. At the Local Area Connection Properties

window, click OK.

Figure 32: Windows XP - Local Area Connection Properties

Figure 33: Windows XP - Internet Protocol (TCP/IP) Properties

12

Continued Configure the Computer(s)

Windows XP

a. Turn on the networked computer.
b. At the Windows Control 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 V3.

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 32).

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 33). Then click OK.

g. At the Local Area Connection Properties

window, click OK.

h. Restart the computer.

19

Figure 34: Macintosh OS X - Network Preferences

12

Continued Configure the Computer(s)

Macintosh OS X

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

icon.

c. At the Network window (see Figure 34),

select the following:

•Show: Built-in Ethernet

•Configure: Using DHCP

• Leave all text boxes blank

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

20

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 35: Power Switches

Power Switch

Modem

Control Unit

Figure 36: Status Lights

13

Follow these steps to turn on the TracPhone V3
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 and MTA.

Turn On the System

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

modem (see Figure 35). The button’s light
should illuminate green.

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

control unit (see Figure 35). The button’s light
should illuminate green.

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

unit and modem (see Figure 36) 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.

Control Unit

Modem

STATUS

g. Verify that the status lights on the MTA and

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

21

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 37: Software Versions Displayed on the Control Unit

Figure 38: TracPhone V-series Flash Wizard Help Menu

14

Update the System Software

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

a. At the control unit, press MENUS until the

display shows “ANTENNA STATUS” (see
Figure 37). 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).

If Necessary

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 38).

22

Figure 39: 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 40: 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 41: Setup Process for RF Hazard Zones

15

Set Up RF Hazard Zones

To prevent exposure to RF energy, which may be
harmful to people who stand within 32 ft (10 m)
of the antenna within its 7.5-75° elevation range
(see Figure 45 on page 25), you can configure up
to two RF radiation hazard zones for areas where
crew and/or passengers frequent. The system
will disable the transmitter when 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 39 and Figure 40).

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 the azimuth

value is less than 100°.

g. Press ACCEPT. The cursor moves to the next

number.

h. Repeat steps f and g to set the remaining

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

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

k. Press EXIT to exit the menu.

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

for the second RF hazard zone, if desired.

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

23

Figure 42: 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!

Figure 43: Welcome Page for Testing

Submission of the Installation Checklist is
required to certify the quality of your
installation.

IMPORTANT!

16

Follow these steps to test the system to verify it is
ready for customer delivery.

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 42.
If an error appears, refer to the
Troubleshooting section of the User’s Guide.

Test the System

ONLINE
TRACKING 22.0W

d. Open the web browser on any networked

computer and enter http://208.83.165.11/
mbbtest. Verify that the Welcome page
appears in the browser, indicating good
communications between the modem and the
land-based hub (see Figure 43).

e. Fill out the Installation Checklist (provided in

the Customer Welcome Kit) and return it to
KVH. Refer to the instructions on the form.

24

Figure 44: Customer Welcome Kit

Radiation

Hazard

3

2

ft (1

0

m)

7.5°

Radiation

Hazard

3

2

ft

(

10

m

)

75°75°

7.5°

Antenna

Figure 45: Safe Distance to Avoid Risk of RF Radiation Exposure

Figure 46: Example of Satellite Blockage

17

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 explain how to use the
system. Be sure the customer understands the
following:

• The antenna transmits RF energy that is
potentially harmful. Whenever the system is
powered on, make sure everyone stays more
than 32 ft (10 m) away from the antenna
within its 7.5-75° elevation range (see
Figure 45). 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 46).

• 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,
visit www.kvh.com/mvbservice.

25

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 Cable ........ 30

27

Power

Not Used

J1
AC PWRJ3Rx RFJ2Tx RF

J4

ACU

J5

CONSOLE

J6

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

Power

Power

Power

4 3 2 18 7 6 5

POE

48V

+

12V DC RSTR WAN LAN PHONE 2 PHONE 1

12 1110987612543

Antenna

Control Unit

MTx

MRx

Modem

Blue/White

White/Blue

Brown/White

White/Gray

Gray/White
White/Orange
Orange/White

White/Brown

Red

Black

Terminal Strip Connector

Laptop

PC

Analog

Phone

MTA

Switch

Power/Data

N/C

N/C

Not Used

A

Wiring Diagram

Appendix

29

Figure 47: Cutting the Cable

Figure 48: Reshaping the Cable

Figure 49: Placing the Heat Shrink Tubing and Ferrule

Figure 50: Stripping the End to Expose the Center Conductor

B

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 47).

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 48). 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 49).

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

the ST-400EZ stripping tool (see Figure 50).
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

30

Figure 51: Removing Plastic Residue
Figure 52: Stripping the Cable Jacket

Figure 53: Cable Stripped, Exposing Dielectric

Figure 54: Deburring the Center Conductor

B

5. Using a utility knife, carefully remove any

residual plastic from the center conductor, if
necessary (see Figure 51).

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

the ST-400EZ stripping tool (see Figure 52).
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 53).

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

the center conductor (see Figure 54). Avoid
nicking the aluminum tape covering the
dielectric.

Continued Terminating LMR-400-75 Cable

31

Figure 55: Flaring the Braid

Figure 56: Pushing On the Connector

Figure 57: Trimming the Braid

Figure 58: Sliding the Ferrule Over the Braid

B

8. Gently flare the braid with your fingers (see

Figure 55).

9. Insert the end of the cable into the connector

body until the dielectric is firmly seated
inside the connector (see Figure 56). Be sure
all braid wires remain on the outside of the
connector.

10. Trim any excess braid (see Figure 57), 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 58).

Continued Terminating LMR-400-75 Cable

32

Figure 59: Crimping the Ferrule onto the Cable

Figure 60: Applying the Heat Shrink Tubing

Figure 61: Proper Center Conductor Pin Length

B

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 59).
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 60). 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 61).

Continued Terminating LMR-400-75 Cable

Center Conductor

1/4" (5-7 mm)

33

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