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.