KVH Industries TracPhone V11 User manual

KVH Industries, Inc.
TracPhone®V11
Installation Guide

TracPhone V11 Installation Guide
1
mini-VSAT Broadbandsm System with CommBox-ACU
KVH, TracPhone, CommBox, and the unique light-colored dome with dark contrasting baseplate are 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.
© 2012-2013 KVH Industries, Inc., All rights reserved. 54-0851 Rev. C
This guide explains how to install the TracPhone V11 mini-VSAT Broadband satellite
communications system. Operation instructions are provided in the Quick Start Guide.
Installation Steps
CAUTION - RF Radiation Hazard
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
1. Inspect Parts and Get Tools ................. 3
2. Plan the Antenna Installation .............. 4
3. Plan the Belowdecks Installation ........ 6
4. Prepare the Belowdecks Units............. 7
5. Prepare the Antenna Site.................... 10
6. Prepare the Antenna Cables .............. 11
7. Rig and Hoist the Antenna................. 14
8. Wire the Antenna ................................ 15
9. Mount the Antenna ............................. 18
10. Prepare the Data Cable ....................... 20
11. Wire the Belowdecks Equipment.......22
12. Connect Power......................................24
13. Turn On the System .............................26
14. Update the System Software...............27
15. Customize the Web Interface..............28
16. Set Up No-Transmit Zones .................29
17. Test the System .....................................31
18. Connect Vessel Computers .................32
19. Connect Vessel Phones & Options.....34
20. Educate the Customer..........................35
The antenna transmits radio frequency
(RF) energy that is potentially harmful.
While the system is powered on, make
sure everyone stays more than 42 feet
(13 m) away from the antenna. As
shown in the illustration, this distance
increases to 101 feet (31 m) if a person
is more than 6.5 ft (2 m) above the
plane of the antenna’s base. No hazard
exists directly below the antenna.
North/South America, Australia:
Phone: [phone] (U.S. only)
Phone: [phone]
E-mail: [email protected]
Europe, Middle East, Asia, Africa:
Phone: [phone]
E-mail: [email protected]
42 ft (13 m)
-24°
6.5 ft (2 m)
101 ft (31 m)

CE Declaration of Conformity
The undersigned of this letter declares that the following equipment complies with the
specifications of EC directive 1999/5/EC Radio & Telecommunications Terminal Equipment.
Equipment Included in this Declaration
TracPhone V11 system, consisting of:
• 02-1982-XX1TracPhone V11 Antenna
• 02-1875-02 TracPhone CommBox-ACU
• 19-0773 TracPhone Modem
1The part number is followed by two alphanumeric characters which designate non-performance-
affecting customer-specific branding.
Equipment Applicability
The TracPhone V11 system provides broadband Internet connectivity between a ship and any
destination in the world. The equipment is not intended for SOLAS applications.
Declaration and Certification
The TracPhone V11 system complies with the following harmonized standards under the
R&TTE Directive 1999/5/EC:
Manufacturer
KVH Industries, Inc.
50 Enterprise Center
Middletown, RI 02842-5279 USA
Rick Jones, Director of Corporate Quality Date
Essential Requirement Applied Standard(s)
Article 3.1(a) Health & Safety EN60950-1:2006 + A1:2009
EN60950-22:2006
Article 3.1(b) EMC EN 301 843-1 v1.2.1:2004-06,
EN 301 843-6 V1.1.1:2006-01,
EN61000-3-2:2006,
EN61000-3-3:1995, A1:2001 & A2:2005
EN60945:2002
Article 3.2 Spectrum Efficiency EN302 340 V1.1.1:2006-04
EN301 447 V1.1.1:2007-08

3
Before you begin, follow these steps to make sure
you have everything you need for installation.
a. Unpack the box and ensure it contains
everything shown in Figure 1 and on the
Kitpack Contents List. Save the packaging.
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 5/8" (16 mm) bit
• 3.75" (95 mm) hole saw (for cable access
hole, if needed)
•5/32"hexkey
• 7/16" open-end torque wrench set to
20 in.-lbs (2.25 N-m)
• 1/2" open-end wrench
• 3/4" socket/ratchet or wrench
• 1/4" socket/ratchet or nut driver
• 7/16" socket/ratchet or nut driver
• 3/4" socket/torque ratchet capable of
settings between 35 and 40 ft-lbs (47 and
54 N-m) of torque
• Light hammer and center punch
•Adhesivetape
• Eye protection
•Shoptowels
• Silicone sealant, self-vulcanizing tape, or
equivalent
•Two75RF coax cables, “F” connectors,
and termination tools (see page 11)
• Power cable (see page 13)
• Heat gun (for heat shrink)
• Wire stripper/terminal crimper
• Forehead light
Radome
Antenna
(KVH part #02-1982-01)
Baseplate
CommBox-ACU
(KVH part #02-1875-02)
Modem
(KVH part #19-0773)
Service Hatch (x2)
Figure 1: TracPhone V11 System Components
• NMEA 0183 talker and interface cable (see
page 22)
• Isolation transformer, if required (see page 24)
• Utility knife
•Flushcutters
• File
• Ruler or tape measure
•Voltmeter
• Laptop PC with the latest TracPhone V11
CommBox-ACU/antenna software (.kvh) and
modem configuration files (.sscf/.sed)
downloaded from the KVH Partner Portal
(www.kvh.com/partners)
Inspect Parts and Get Tools
1

4
Before you begin, consider the following antenna
installation guidelines.
Choose a Suitable Mounting Surface
• Make sure the mounting surface is wide
enough to accommodate the antenna’s base
(see Figure 2).
• Make sure the mounting surface is flat, level
(within ±1º), rigid enough to withstand heavy
vibration, and strong enough to support the
antenna. The antenna weighs 240 lbs (109 kg),
excluding cables.
• Select a location that is as close as possible to
the intersection of the vessel’s centerline and
midships.
• If available, install the antenna on a platform
or pedestal, rather than on a deck, and ensure
the diameter of the mounting surface matches
the diameter of the antenna’s base (19.01"
(48.29 cm)). Both service hatches should be
fully accessible for installation and service.
• Avoid placing the antenna near any magnetic
compasses or other onboard antennas to
prevent potential interference.
Prevent RF Radiation Exposure
Select a location that is well above any areas
accessible to passengers and crew to reduce the
risk of RF radiation exposure. (See page 1 for an
illustration of the hazard area.)
If mounting the antenna near an accessible area is
unavoidable, you may configure one or two no-
transmit zones to prevent transmissions in
hazardous directions. (See “Set Up No-Transmit
Zones” on page 29 for details.)
57.28"
(145.50 cm)
19.01"
(48.29 cm)
Ø51.30"
(130.31 cm)
9.74"
(24.74 cm)
9.74"
(24.74 cm)
Mounting Hole
4x Ø0.63" (1.59 cm)
Ø13.78"
(35.00 cm) Cable Connectors
(cable cover not shown)
Service
Hatch
Side View
Bottom View
Service
Hatch
FWD
Figure 2: Antenna Dimensions
Plan the Antenna Installation
2

5
Minimize Satellite Blockage
The antenna requires a clear view of the sky to
transmit and receive satellite signals (see
Figure 3). The fewer obstructions, the better the
system will perform.
Avoid RF Interference
Although many variables determine the exact
distance required between the antenna and
radar/high-power radio transmitters, including
transmitter beam properties and the reflective
properties of nearby surfaces, consider the
following general guidelines when selecting a
safe antenna location:
• Mount the antenna as far away as possible
from the radar and any high-power radio
transmitters.
• The minimum distance between the antenna
and the radar varies depending on the power
level of the radar and the vertical separation
you maintain between them. Using the
guidelines provided in Figure 4, mount the
antenna at least the minimum distance away
from the radar.
Blocked!
Antenna
Vessel Platform
-24° to 119°
Look Angle
Mast
Figure 3: Blockage from Obstruction
RF emissions from radars and high-power
radio transmitters may damage the antenna
or impair its performance if it’s improperly
positioned within the beam path.
IMPORTANT!
Figure 4: Minimum Distances from Radar
* Not permitted
Radar
Type
Radar
Power
Min. distance (d) at ±xxº
vertical separation
15º 40º 60º
X-band Up to
50 KW
3 ft
(0.9 m)
3 ft
(0.9 m)
3 ft
(0.9 m)
S-band Up to
10 KW
N/P* 6.6 ft
(2 m)
6.6 ft
(2 m)
30 KW N/P* N/P* 9.8 ft
(3 m)
50 KW N/P* N/P* 16.4 ft
(5 m)
d
+xx°
Antenna
Antenna
-xx°
d
Radar
Continued Plan the Antenna Installation
2

6
Before you begin, consider the following
installation guidelines for the belowdecks units.
• Select a mounting location in a dry, well-
ventilated 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 panels to
accommodate the connecting cables.
• You have three options for mounting the
belowdecks equipment:
Option 1 - In the optional case
Option 2 - In an onboard equipment rack
Option 3 - To a horizontal surface
NOTE: The CommBox-ACU and modem are sized to
fit a standard 19" (482.6 mm) rack, occupying 3U of
space.
• To use the supplied data cable, the
CommBox-ACU must be located close
enough to the antenna to allow a 100 ft (30 m)
cable run between them. However, you can
order a longer data cable, if necessary:
150 ft (45 m): KVH part no. 32-1157-0150
300 ft (90 m): KVH part no. 32-1157-0300.
• Be sure the location provides adequate Wi-Fi
reception. Do not install it in an area
surrounded by metal or near any electrical
devices that emit RF noise.
Side View
Front View
19.00"
(48.26 cm)
16.75"
(42.55 cm)
2.63"
(6.68 cm)
18.31"
(46.51 cm)
1.75"
(4.45 cm)
11.18"
(28.40 cm)
16.31"
(41.43 cm)
1.30"
(3.30 cm)
4.90"
(12.45 cm)
4 x ø.25"
(0.64 cm)
Strain-Relief Bracket
(Modem Only)
Top View
0.44"
(1.12 cm)
Figure 5: CommBox-ACU or Modem Dimensions (Identical)
20.5"
(52.1 cm)
11.3"
(28.7 cm)
20.5"
(52.1 cm)
Figure 6: Case Dimensions
Plan the Belowdecks Installation
3

7
If you plan to use the optional 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): no. 2, no. 5,
no. 9, and no. 12.
e. At the back of the case, insert four cage nuts
into the following locations on the frame (two
on each side): no. 1 and no. 3.
f. Remove the four #6-32 screws and washers
securing the two retaining straps to the sides
of the modem. Do not remove the top screws
securing the straps to the CommBox-ACU.
g. Attach the supplied strain-relief bracket to
the retaining straps and modem using the
screws and washers you removed in Step f
(see Figure 8).
h. At the top 3U section of the case, insert the
CommBox-ACU/modem assembly and
secure the front mounting brackets to the case
using four M6 screws and washers (see
Figure 9).
i. Secure the back of the CommBox-ACU 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
CommBox-ACU using four #6-32 screws and
washers (see Figure 9).
j. At the bottom 3U section of the case, attach
the supplied blank panel using four M6
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.
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 (x42)
Retaining
Strap (x2)
CommBox-ACU
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 CommBox-AC
U
M6 Screw (x8)
Plastic Washer (x8)
Cage Nut (x8)
Blank Panel
CommBox-ACU
and Modem
Case
Figure 9: Securing the CommBox-ACU/Modem in the Case
Prepare the Belowdecks Units
4
Case Mount

8
If you plan to use an existing equipment rack,
follow these steps to secure the equipment in the
rack.
a. Remove the four #6-32 screws and washers
securing the two retaining straps to the sides
of the modem. Do not remove the top screws
securing the straps to the CommBox-ACU.
b. Attach the supplied strain-relief bracket to
the retaining straps and modem using the
screws and washers you removed in Step a
(see Figure 10).
c. Insert the CommBox-ACU/modem assembly
into the rack and secure the front mounting
brackets to the rack using four M6 screws and
washers (see Figure 11).
#6 Washer (x4)
#6-32 Screw (x4)
Strain-Relief
Bracket
Tie-Wrap
Holes (x42)
Retaining
Strap (x2)
CommBox-ACU
Modem
Figure 10: Attaching the Strain-Relief Bracket
M6 Screw (x4)
Plastic Washer (x4)
CommBox-ACU
Modem
Attach to Rack
Figure 11: Securing the CommBox-ACU/Modem in the Rack
Prepare the Belowdecks Units
4
Rack Mount

9
If you plan to mount the CommBox-ACU and
modem to a horizontal surface, 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 sides
of the modem. Do not remove the top screws
securing the straps to the CommBox-ACU.
b. Attach the strain-relief bracket to the
retaining straps and the modem using the
screws and washers you removed in Step a
(see Figure 12).
c. Attach the supplied “L” mounting brackets to
the sides of the modem using four #6-32
screws and washers (see Figure 13).
d. Once you have completed all system wiring,
mount the modem/CommBox-ACU
assembly to the vessel using fasteners
appropriate for the mounting surface.
#6 Washer (x4)
#6-32 Screw (x4)
Strain-Relief
Bracket
Tie-Wrap
Holes (x42)
Retaining
Strap (x2)
CommBox-ACU
Modem
Figure 12: Attaching the Strain-Relief Bracket
Figure 13: Attaching the Mounting Brackets
#6 Washer (x4)
#6-32 Screw (x4)
Bracket (x2)
CommBox-ACU
Modem
Ø.156" (Ø3.96 mm)
Mounting Hole (x4)
Prepare the Belowdecks Units
4
Horizontal Surface Mount