KVH Industries Ka Tri-Americas LNB User manual

1
KVH, TracVision, and the unique light-colored dome with dark contrasting baseplate are registered trademarks of
KVH Industries, Inc. All other trademarks are property of their respective companies. The information in this document is subject to
change without notice. No company shall be liable for errors contained herein. © 2010 KVH Industries, Inc., All rights reserved.
54-0674 Rev. A
These instructions explain how to install the Ka/Ku Tri-Americas LNB on a TracVision HD7
system. Complete instructions on how to use the system are provided in the User’s Guide.
Installation Steps
Who Should Install the LNB?
To ensure a safe and effective installation, KVH recommends that a KVH-authorized marine
technician perform this procedure. KVH-authorized technicians have the tools and electronics
expertise necessary to install the LNB. To find a technician near you, visit www.kvh.com/
wheretogetservice.
Technical Support
If you need technical assistance, please contact KVH Technical Support:
1. Remove the Antenna and Get Tools... 3
2. Remove the Radome ............................. 4
3. Disconnect the RF Cables ..................... 5
4. Remove the Lower Feed/LNB ............ 6
5. Install the New Lower Feed/LNB ...... 8
6. Mount the LNB Assembly.................. 10
7. Set the Belt Tension ............................. 12
8. Reconnect and Dress Cables .............. 13
9. Mount the Hall Effect Magnet ........... 15
10. Mount the Counterweight.................. 16
11. Replace the Radome............................ 17
12. Replace the ACU SD Card.................. 18
13. Complete the Installation ................... 20
Phone: [phone]
E-mail: [email protected]
(Mon.-Fri., 9 am - 6 pm Eastern)
(Sat., 9 am - 2 pm Eastern)
Tri-AmericasTM LNB Installation
TracVision®HD7

3
a. Before you begin, record the system’s current
network settings. You might need to be re-
enter these settings later. Refer to the
TracVision HD7 Installation Guide or User’s
Guide for complete details.
b. Remove the antenna from the vessel and
move it to a location suitable for service.
NOTE: This procedure requires handling exposed
electronic parts and components, and might take over
two hours to complete. Ensure that you take the
necessary grounding precautions before handling, and
perform this procedure in an adequate workspace.
c. Gather the tools and materials listed below.
You will need these items to complete the
installation.
• #1 Phillips screwdriver
• #2 Phillips screwdriver
• 9/32" open-end wrench
•5/16"nutdriver
•Cuttingpliers
• 2.5 mm ball-end hex wrench
(supplied)
• 9/64" ball-end hex wrench (supplied)
• 3/32" ball-end hex wrench (supplied)
• 1/16" hex wrench (supplied)
• 7/64" hex wrench (supplied)
•Needle-nosepliers
• Ruler, or equivalent
• Scribe, or equivalent
CAUTION
For your own safety, be sure to disconnect
power from all wired components before
performing this procedure.
Always lift the antenna by the baseplate and
never by the radome or any portion of the
internal antenna assembly (see Figure 1).
IMPORTANT!
Remove the Antenna and Get Tools
1
Figure 1 Antenna Radome/Baseplate
Radome
Baseplate

4
Follow the instructions below to remove the
radome.
Standard Dome Version
a. Using a #2 Phillips screwdriver, remove the
six #10-32 screws securing the radome to the
baseplate (see Figure 2).
b. Carefully lift the radome straight up off the
antenna. Then set it aside in a safe place.
TIP: If you keep the radome topside, secure it with a
lanyard to prevent it from falling overboard.
35" (90 cm) Dome Version
a. Using a #2 Phillips screwdriver, remove the
eight #10-32 screws securing the radome to
the baseplate (see Figure 3).
b. Carefully lift the radome straight up off the
antenna. Then set it aside in a safe place.
TIP: If you keep the radome topside, secure it with a
lanyard to prevent it from falling overboard.
Remove the Radome
Figure 2 Radome Screws (standard dome version)
Figure 3 Radome Screws (35" dome version)
Radome
#10-32
Screw (x6)
Baseplate
Baseplate
#10-32
Screw (x8)
Radome
2

5
Follow the instructions below to disconnect the
RF cables from the LNB.
a. Using cutting pliers, cut the tie-wrap securing
cables to the bottom of the LNB (see
Figure 4).
b. Using a Phillips screwdriver, remove the
screw and nut securing the P-clip on the
bottom of the LNB (see Figure 4).
c. If your LNB includes a connector plate (see
Figure 5), cut and remove the tie-wrap
securing it in place. Then remove the plate.
d. If your LNB does not include a connector
plate, using cutting pliers, cut the tie-wrap
securing the three RF cables on the top of the
LNB (see Figure 6).
e. Using 7/16" open-end wrench, disconnect the
four RF cables from the LNB (see Figure 5 or
Figure 6).
Disconnect the RF Cables
Figure 4 Tie-wrap/P-clip Removal
Figure 5 RF Cables/Connector Plate/Tie-wrap
Figure 6 RF Cables/Tie-wrap
Tie-wrap
P-clip Screw
and Nut
LNB
Connector Plate
RF Connector
(x4)
Tie-wrap
RF Connector
(x4)
Tie-wrap
3

6
Follow the instructions below to extract the LNB
assembly.
a. For reference later, depress the belt to note
the current belt tension (see Figure 8).
b. Using a 2.5 mm ball-end hex wrench, loosen
the four hex screws securing the motor in
place (see Figure 7).
c. Slide the motor to relieve belt tension. Then
unfasten the belt from the reflector’s hub and
the motor pulley (see Figure 8). Set the belt
aside in a safe place.
Remove the Lower Feed/LNB
Figure 7 Motor Screws
Figure 8 Motor Belt
Motor
Motor
Screw (x4)
Belt
Pulley
Hub
4

7
d. While holding the LNB assembly, fully
loosen the four #8 hex screws on the front of
the reflector using a 9/64" ball-end hex
wrench (see Figure 9).
e. Using needle-nose pliers, extract the four hex
screws.
f. Carefully pull the LNB assembly straight
backward.
g. Using a 3/32" ball-end hex wrench, remove
the two #4 hex screws securing the lower feed
to the motor bracket (see Figure 10).
h. Using a 7/64" ball-end hex wrench, remove
the #6 hex screw securing the lower feed/
LNB to the motor bracket (see Figure 10).
i. Remove the lower feed/LNB and the lower
feed gasket (shown in Figure 13 on page 9)
from the motor bracket.
To avoid damage, extract the bracket straight
backward; do not move the assembly from
side to side.
IMPORTANT!
Continued Remove the Lower Feed/LNB
Figure 9 Hex Screws on Reflector
Figure 10 Lower Feed Screws
#8 Hex
Screw (x4)
#4 Hex
Screw (x2)
#6 Hex
Screw
4

8
Follow the instructions below to install the new
lower feed.
a. Using a #2 Phillips screwdriver, remove the
#6-32 screw securing the lower feed cover
(see Figure 11).
NOTE: Leave the other cover screw installed for now.
To avoid damage, handle the new lower
feed/cover extremely carefully once you
remove the screw. If you exert pressure on
the cover, the cover might pivot and break the
phase cards on the lower feed.
IMPORTANT!
Install the New Lower Feed/LNB
Figure 11 Lower Feed Cover Screw
Cover
Remove this
#6-32 Screw
5

9
b. Using a 3/32" ball-end hex wrench, carefully
secure the new lower feed/LNB onto the
motor bracket with two supplied #4 hex
screws (see Figure 12).
c. Using a 7/64" ball-end hex wrench, secure
the new lower feed onto the motor bracket
with one supplied #6 hex screw (see
Figure 12).
d. Remove the second lower feed cover screw
(see Figure 11 on page 8). Then remove the
cover.
e. Press the supplied lower feed gasket into the
grooves on the lower feed (see Figure 13).
To avoid damage, handle the new lower
feed/LNB extremely carefully once you
remove the protective cover (see Figure 11 on
page 8). All three phase cards on the new
lower feed/LNB must remain intact to
complete the installation.
IMPORTANT!
Continued Install the New Lower Feed/LNB
Figure 12 Lower Feed Screws
Figure 13 Phase Cards
#4 Hex
Screw (x2)
#6 Hex
Screw
Phase
Card (x3)GrooveGasket
5

10
Follow the instructions below to mount the LNB
assembly onto the rear of the reflector.
a. Note the position of the mounting pins (see
Figure 14)and the LNB assembly’s mounting
orientation (see Figure 15).
b. Rotate the upper feed (see Figure 16) to align
the LNB mounting pin holes with the
mounting pins on the LNB assembly (see
Figure 15).
c. Place the skew belt over the reflector hub (see
Figure 15)
d. Slowly insert the motor pulley inside the belt
loop, while aligning the phase cards and
mounting pins with the mounting holes (see
Figure 15).
To avoid damage, handle the LNB assembly
extremely carefully. All three phase cards
must remain intact to complete the
installation.
IMPORTANT!
Mount the LNB Assembly
Figure 14 Mounting Pins
Figure 15 Assembly Mounting
Figure 16 Upper Feed Rotation
Mounting
Pin (x2)
RF Connectors
Gyro Bracket
Belt
6

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e. Orient the LNB assembly and upper feed to
ensure the RF connectors on the LNB will be
facing upward (approximately aligned with
the gyro bracket), while maintaining the
mounting hole alignment with the pins and
phase cards (see Figure 17).
f. Gently press the LNB assembly straight into
the rear of the reflector, ensuring the phase
cards and mounting pins remain aligned.
These cards fit snugly into the mounting
holes; some friction is expected (see
Figure 17).
g. While holding the LNB assembly in place,
insert four supplied #8 hex screws into the
mounting holes on the front of the reflector
(see Figure 18).
h. Using a 9/64" ball-end wrench, tighten the
screws in a cross pattern.
To avoid damage, be sure to press the phase
cards straight into the mounting holes. Do not
apply lateral pressure or shimmy the
assembly into place.
IMPORTANT!
Continued Mount the LNB Assembly
Figure 17 Assembly Mounting
Figure 18 Hex Screws on Reflector
RF Connectors
Gyro Bracket
Belt
#8 Hex
Screw (x4)
6

12
Follow the instructions below to set the motor
belt tension.
a. Adjust the skew motor on the bracket to
achieve moderate belt tension. Using a
2.5 mm ball-end hex wrench, tighten the
motor screws to secure the motor in place
b. Using a scribe, mark the resting location of
the belt against the reflector midway between
the hub and the pulley (see Figure 19).
c. Using a scribe and ruler, measure 1/8"
outward from the scribe mark you just
created (see Figure 19). This marks the
desired belt deflection distance.
d. Using the supplied tension meter, secure the
belt at the midway point. Then pull the belt
outward using 2 lbs of force (see Figure 20).
e. Reference the scribe marks in relation to the
belt position. Adjust the motor position, as
required, to ensure the belt deflection is 1/8"
using 2 lbs of force.
f. Using a 2.5 mm ball-end hex wrench, fully
tighten the four motor screws (see Figure 21).
Set the Belt Tension
Figure 19 Belt Tension Adjustment
Figure 20 Belt Tension Measurement
Figure 21 Motor Screws
Scribe Mark
(Deflected)
Midway
Point
Reflector
Pulley
Hub
Scribe Mark
(Resting)
Motor
Motor
Screw (x4)
7

13
Follow the instructions below to reconnect and
dress the cables.
a. Using a 7/16" open-end wrench, connect and
tighten the RF1, RF2, RF3, and RF4 cables to
the LNB exactly as shown in Figure 22 and
Figure 23. Tighten the RF1 cable first. Then
tighten each of the remaining connectors,
ensuring the wire of each connector contacts
the flat of the previous connector when
tightened.
b. Place the supplied connector plate onto the
LNB, as shown in Figure 24.
c. Firmly secure the connector plate onto the
LNB by inserting a supplied thin tie-wrap
through the LNB mounting holes (shown in
Figure 23).
d. Rotate the LNB assembly to ensure there is no
contact between the connector plate and the
limit switch cable (see Figure 24). If there is
contact, adjust the RF cables and connector
plate to maximize clearance. Then retighten
the tie-wrap to resecure the connector plate.
e. Trim and remove the excess tie-wrap length.
Reconnect and Dress Cables
Figure 22 RF Connector Orientation
Figure 23 LNB Cables/Mounting Holes
Figure 24 Connector Plate Mounting
RF1
RF2 RF3 RF4 RF1
Mounting
Hole (x2)
Thin
Tie-wrap
Limit Switch
Cable
Connector
Plate
8

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f. Tuck the motor cable and gyro wires between
the LNB and the motor (see Figure 25).
g. While aligning the end of the cable braid with
the right edge of the motor, tuck the cable
harness between the LNB and motor (see
Figure 25)
h. Secure the cable harness to the LNB with the
P-clip you removed earlier, and a supplied
#8-32 screw, washer, and nut (see Figure 25).
Ensure the P-clip is mounted on the inside of
the LNB (facing the reflector).
i. Using a supplied tie-wrap, secure the cable
harness and gyro wires to the LNB, as shown
in Figure 25
j. Route the cables around the LNB, as shown
in Figure 26.
k. Loosely secure the RF cables to the LNB plate,
as shown in Figure 27.
l. Rotate the LNB assembly and ensure the
cables do not contact the limit switch.
m. Tighten the tie-wrap securing the RF cables to
the LNB plate (see Figure 27).
Continued Reconnect and Dress Cables
Figure 25 P-clip/Tie-wrap Mounting
Figure 26 Cable Harness/Cable Routing
Figure 27 LNB Plate Tie-wrap
Cable
Braid End
#8-32 Screw,
Washer & Nut
Tie-wrap
P-clip
P-clip
Tie-wrap
Routed
Cables Cable
Harness
LNB Plate
Tie-wrap
Cables
Limit
Switch
8

15
Follow the instructions below to mount the Hall
Effect magnet fixture.
a. Mount the supplied magnet fixture onto the
gyro bracket by inserting the fixture studs
from underneath and through the gyro
bracket mounting holes, as shown in
Figure 28.
b. Insert and hand-tighten two supplied nuts
and washers onto the fixture studs, as shown
in Figure 28.
c. Using a ruler, or equivalent, distance the
magnet, located on the magnet fixture,
approximately 1/8" - 1/4" from the LNB (see
Figure 28).
d. While holding the fixture in place, tighten the
nuts and washers using a 5/16" nut driver
(see Figure 28).
e. Remeasure the gap between the magnet and
the LNB. Readjust and retighten the fixture,
as necessary, to achieve a 1/8" - 1/4" gap (see
Figure 28).
Mount the Hall Effect Magnet
Figure 28 Hall Effect Magnet Fixture Mounting
Magnet
1/8"-1/4"
Gap
Nut and
Washer (x2)
Gyro
Bracket
9

16
Follow the instructions below to mount the
counterweight and reinstall the radome.
a. Slowly tilt the reflector so that it points nearly
straight upwards (see Figure 29).
b. Peel off the release liner from the double-
sided adhesive tape on the underside of the
counterweight.
c. Mount the supplied counterweight onto the
subreflector, as shown in Figure 29.
d. Using a 1/16" hex wrench, tighten the two set
screws to secure the counterweight in place
(see Figure 29).
Mount the Counterweight
Figure 29 Counterweight/Set Screws
Subreflector
Counterweight
Set Screw
(x2)
10

17
Standard Dome Version
Reinstall the radome. Then secure it in place
using the six #10-32 screws you removed earlier
(see Figure 30).
35" (90 cm) Dome Version
Reinstall the radome. Then secure it in place
using the eight #10-32 screws you removed
earlier (see Figure 31).
Figure 30 Radome Screws (standard dome version)
Figure 31 Radome Screws (35" dome version)
Radome
#10-32
Screw (x6)
Baseplate
Baseplate
#10-32
Screw (x8)
Radome
11 Replace the Radome

18
Follow the instructions below to replace the SD
card inside the ACU.
NOTE: This procedure requires handling exposed
electronic parts and components. Ensure that you take
the necessary grounding precautions before handling.
a. Using a #1 Phillips screwdriver, remove the
eight Phillips screws securing the ACU cover
(see Figure 32). Then remove the cover and
set it aside in a safe place.
b. Locate the SD card (see Figure 33).
c. Gently press and slide the locking tab to
unlock it (see Figure 34).
CAUTION
For your own safety, be sure to disconnect
power from all wired components before
performing this procedure.
Figure 32 ACU Cover Screws
Figure 33 SD Card Location
Figure 34 Locking Tab/SD Card
Screw (x8)
SD Card
Location
Locking
Tab
Lock Unlock
SD Card
12 Replace the ACU SD Card

19
d. Gently remove the SD card (see Figure 35).
e. Insert the supplied SD card (see Figure 35).
f. Gently close and slide the SD card locking tab
(see Figure 34 on page 18).
g. Reinstall the ACU cover.
h. Using a #1 Phillips screwdriver, secure the
ACU cover with the eight Phillips screws you
removed earlier.
Continued Replace the ACU SD Card
Figure 35 SD Card Removal/Installation
SD Card
12

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Follow the steps below to complete the
installation.
NOTE: For additional information on any of the
following steps, please refer to the TracVision HD7
User’s Guide or the TracVision HD7 Installation
Guide.
a. Using the supplied USB drive, update the
TracVision HD7 software.
b. Re-enter the network settings, if required.
c. Set the satellite service to DIRECTV L.A. to
enable DIRECTV Latin American service.
Complete the Installation
13