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

10
Once you have identified a suitable antenna
mounting site, follow these steps to prepare the
site for installation.
Drill the Mounting Holes
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 14).
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 on the mounting surface in the
locations indicated on the template.
c. Drill a 5/8" (16 mm) hole at the four
mounting hole locations. Later, you will
insert four 1/2"-13 bolts through these holes
to mount the antenna.
Cut Out the Cable Access Hole, If Needed
If you plan to route the antenna cables
belowdecks through a hole directly underneath
the antenna (such as examples C and D in
Figure 15), follow the steps below.
a. Using the supplied template, mark the
location of the cable access hole in the center
of the mounting hole pattern (see Figure 14).
b. Cut out the 3.75" (95 mm) cable access hole in
the location you marked in Step a. Smooth
the edges of the hole to protect the cables.
(You may also apply anti-chafe material
around the cables to prevent abrasion.)
c. Clean and dry the antenna mounting surface.
d. Peel off the paper backing from one of the
supplied foam seals 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 14).
9.74"
(247.40 mm)
Ø.63" (Ø15.88 mm)
Mounting Hole (x4)
Ø3.75" (Ø95.3mm)
Cable Access Hole
FWD
Foam Seal
(if necessary)
Good Bolt
Pattern
Poor Bolt
Pattern
Face Vessel Bow
9.74"
(247.40 mm)
Figure 14: Antenna Mounting Holes Layout
Deck
Gooseneck
Gooseneck
Foam
Seals
ABC
D
Foam
Seals
AntennaCables
Figure 15: Antenna Mounting Examples
Prepare the Antenna Site
5

11
Follow these steps to prepare and route the RF,
power, and data cables to the antenna location.
Prepare the Customer’s RF Cables
You need to connect two 75RF coax cables
from the antenna location to the belowdecks
equipment. Refer to Figure 16 to determine the
type of cables and connectors required for your
cable run. Then prepare both of them as
described below.
a. Terminate both ends of the cables with the
proper “F” connectors (see Figure 16 for
connector and tool part numbers).
b. Label both ends of the two RF cables. Label
one cable “TX,” and label the other “RX.”
Figure 16: RF Cable Requirements
Cbl f ld h
25 -100 ft (8-30 m) Cable Run
Cable LMR-400-75
(KVH part no. 32-0944-0100,
100 ft (30 m))
Loss: 0.06 dB/ft (0.195 dB/m)
Connector Times Microwave EZ-400-FMH-75*
Tools Times Microwave TK-400EZ-75
(KVH part no. 72-0374-75**)
Strip
Lengths
101-300 ft (31-90 m) Cable Run
Call KVH for lengths over 200 ft (60 m)
Cable LMR-600-75
(KVH part no. 32-0945-0200, 200 ft
(60 m))
Loss: 0.04 dB/ft (0.13 dB/m)
Connector Times Microwave EZ-600-FMH-75*
Tools Times Microwave TK-600EZ
(KVH part no. 72-0375-75**)
Strip
Lengths
0.170" (4.32 mm)
0.344" (8.74 mm)
0.065" (1.65 mm) dia.
0.610" (15.49 mm)
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
on page 36.
• Each RF cable run must not exceed 6.5 dB
of insertion loss. Keep in mind that an in-
line connector adds at least 0.2 dB of loss.
• Cables must be at least 25 ft (8 m) in
length.
• Call KVH Technical Support if you need
to use cables longer than 200 ft (60 m). An
antenna setting might need to be adjusted
over the air for the longer cable run.
• When determining cable lengths, don’t
forget to account for service loops,
approximately 8" (20 cm) at each end.
IMPORTANT!
Prepare the Antenna Cables
6

12
Connect the Customer’s RF Cables to the
Supplied Pigtail Cables
a. Clean and dry the RF cables’ connectors.
b. Heat shrink is supplied with each 3 ft (90 cm)
pigtail cable to protect the connection
between the customer’s RF cables and the
pigtail cables. Slide a heat shrink sleeve onto
the end of each 3 ft (90 cm) pigtail cable
(opposite the boot end) for later use.
c. Fill half of the inner body of the customer’s
“TX” RF cable’s connector with the supplied
silicone grease to prevent moisture and
corrosion.
d. Connect and SLOWLY hand-tighten the
“TX” RF cable to the feed-thru adapter of one
of the supplied LMR-400-75 pigtail cables,
allowing the grease to diffuse and settle into
the entire space within the connector (see
Figure 17).
e. 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.
f. Seal the RF cable-to-pigtail connection using
silicone sealant, self-vulcanizing tape, or
equivalent. Then protect the connection with
the heat shrink (see step b).
g. Repeat steps c-f to connect the “RX” RF cable
to the other pigtail cable.
Use of the supplied pigtail cables is
mandatory.Do not connect the customer’s RF
cables directly to the antenna.
IMPORTANT!
To Modem
Apply Silicone Grease
P
I
G
T
A
I
L
Feed-thru Adapter
Seal connection with
silicone sealant or
self-vulcanizing tape,
then apply heat-shrink
R
F
C
A
B
L
E
Figure 17: Connecting the Pigtail Cables to the RF Cables
Continued Prepare the Antenna Cables
6

13
Prepare the Customer’s Power Cable
You will need to connect a power cable from the
antenna to the vessel’s 100-240 VAC power
supply. The cable must be a marine-grade,
3-conductor, stranded (flexible, bend radius of at
least 3" (8 cm)) power cable suitable for carrying
500 watts AC power to the antenna with less than
a 5% voltage drop across its length. Refer to
Figure 18 for the suggested cable gauge for your
cable run.
Route the Cables Belowdecks
a. Keep the ends of the data, power, and RF
cables shown in Figure 19 at the antenna
location.
b. Route the opposite ends of the cables
belowdecks through the cable access hole.
Leave an adequate service loop,
approximately 8" (20 cm) of slack, in all of the
cables at the antenna location for easy
serviceability.
c. Route the cables to the belowdecks
equipment. Be sure to always maintain the
minimum bend radius in the RF cables (see
Figure 20). Later, you will connect the data
cable to the CommBox-ACU, the power cable
to the vessel’s AC power supply, and the RF
cables to the modem.
WARNING
Do not connect the power cable to vessel AC
power yet. You will connect power in Step 12
on page 24.
Figure 18: Power Cable Recommendations
Cable Length Suggested Gauge
Up to 100 ft (30 m) 14 AWG
101-300 ft (31-90 m) 12 AWG
Be sure to comply with all applicable
electrical codes and safety standards for the
vessel’s country of origin and vessel type.
IMPORTANT!
TX
RX
Foam Seal
(if necessary)
Data Power
RF Pigtails
Figure 19: Cables Ready to Connect to Antenna
Figure 20: Minimum Bend Radius of RF Cables
Cable Type Minimum Bend Radius
LMR-400-75 4.5" (11.5 cm)
LMR-600-75 6" (15.3 cm)
Continued Prepare the Antenna Cables
6

14
Follow these steps to detach the antenna from the
pallet and safely rig the antenna for crane
hoisting.
a. Using a 7/16" socket/ratchet or nut driver,
unlock the three hex latches securing each of
the antenna’s service hatches (see Figure 21).
Then gently lower the hatches. You can now
access the four shipping bolts securing the
antenna’s baseplate to the pallet.
b. Using a 3/4" socket/ratchet or wrench,
remove the four outer 1/2"-13 bolts securing
the antenna to the pallet (see Figure 22). Do
not remove the four inner bolts that secure
the internal antenna assembly to the
baseplate.
c. Close both antenna service hatches. Secure
each hatch using the three hex latches.
d. Secure the crane rigging to the antenna’s four
lift brackets (see Figure 23). Be sure the
rigging and crane are suitably rated to safely
lift the 240 lbs (109 kg) antenna.
e. Carefully hoist the antenna to its mounting
location.
WARNING
Be sure no personnel stand underneath the
antenna at any time while it is suspended in
the air.
Take protective measures to avoid gouging or
scratching the radome during the rigging
operation.
IMPORTANT!
Hatch (x2)
1/4-turn Hex Latch (x6)
Figure 21: Service Hatches
1/2"-13 Shipping
Bolt (x4)
Do not remove the 4 inner
bolts securing the antenna
assembly to the baseplate!
Figure 22: Shipping Bolts (Antenna Bottom View)
Lift Bracket (x4)
Rope to Prevent
Tipping
Rope
Center of Gravity
Figure 23: Crane Rigging (Example)
Rig and Hoist the Antenna
7

15
Follow these steps to connect the antenna cables.
Attach the Second Foam Seal, If Needed
If you routed the cables belowdecks through a
hole directly underneath the antenna location
(see “Cut Out the Cable Access Hole, If Needed”
on page 10), follow these steps to attach the
second foam seal to the base of the antenna.
a. Clean and dry the bottom of the antenna.
b. Peel off the paper backing from the second
foam seal to expose the adhesive. Align the
foam seal so it is centered on the antenna (see
Figure 24). Then press the foam seal firmly
onto the underside of the antenna.
Connect the RF Pigtail Cables
a. Clean and dry the antenna’s two RF
connectors, labeled “MTX” and “MRX” (see
Figure 24).
b. Place one of the supplied rubber connector
washers over the “MTX” jack on the bottom
of the antenna, as shown in Figure 25.
c. Fill half of the inner body of the “TX” pigtail
cable’s male connector with silicone grease.
d. Connect and SLOWLY hand-tighten the
“TX” pigtail cable to the antenna’s “MTX”
jack, allowing the grease to diffuse and settle
into the entire space within the connector.
e. Make sure the “TX” pigtail cable’s connector
is tightened all the way into the antenna’s
connector and the rubber washer is
compressed against the antenna’s base. Then
tighten the connector with a 7/16" torque
wrench set to 20 in.-lbs.
f. Apply a thin layer of silicone grease to the
jacket of the “TX” pigtail cable, along the
wider segment at the base of the connector.
g. Slide the rubber boot up the cable until it
covers the entire connector and mates with
the rubber washer. This will protect the
connection from the elements.
h. Wipe off any excess grease from the cable.
i. Repeat steps b-h to connect the “RX” pigtail
cable to the antenna.
Foam Seal
(if necessary)
MTX MRX
Data Power
Figure 24: Foam Seal and Connectors on Base of Antenna
Antenna Baseplate
Rubber Washer
Rubber Boot
Apply Silicone Grease
To Modem
P
I
G
T
A
I
L
R
F
C
A
B
L
E
Figure 25: Connecting the Pigtail Cables to the Antenna
Wire the Antenna
8

16
Connect the Data Cable
Connect the data cable to the “Data” jack on the
base of the antenna (see Figure 24 on page 15).
Hand-tighten until the connector locks in place;
do not use excessive force.
Connect the Power Cable
a. Using a 7/16" socket/ratchet or nut driver,
unlock the three hex latches securing each of
the antenna’s service hatches (see Figure 21
on page 14). Then gently lower the hatches.
b. Loosen the four captive screws securing the
cover to the connector module (see
Figure 26). Detach the cover.
c. Pass the power cable through the sealing
gland on the antenna baseplate then through
the vacant access hole in the connector
module (see Figure 24 on page 15 and
Figure 27).
d. Strip the jacket from the end of the power
cable. Then strip back the insulation of all
three wires approximately 1/4" (6 mm) and
gently twist each wire to ensure a good
connection.
e. Crimp a ring terminal (supplied in the
kitpack) onto the end of each power wire.
f. Connect the wires to the terminal block as
shown in Figure 27.
g. Reattach the connector module’s cover.
h. Make sure the On/Off switch on the side of
the connector module is set to On (|).
i. Extract any excess cable through the sealing
gland, then tighten the gland by twisting its
nut onto the cable.
WARNING
Do not connect the power cable to vessel AC
power yet. You will connect power in Step 12
on page 24.
Captive Screw (x4)
Connector Module
Cover
Figure 26: Connector Module Cover
Insert AC Power Cable
Through Sealing Gland
Pass Wires Through Access Hole
and Wire to Terminal Block
On/Off Switch
Line
(100-240 VAC)
Neutral
Ground
L2
L1
GRD
Figure 27: Power Cable Wiring
Continued Wire the Antenna
8

17
Protect the Cables
a. Position the cable cover (supplied in the
kitpack) over the antenna’s cable connectors
and secure in place with the six #6-32 captive
screws and washers (see Figure 28).
b. Secure the cables near the antenna connectors
to relieve stress (such as the example in
Figure 29). The cable cover is designed for
aesthetics only – it does not provide any
support for the cables and may become
damaged if cables are not properly strain-
relieved.
c. Weatherproof and seal the cable access hole,
as required.
13V/22KHz
18V/22KHz
Power/Data
13V
18V
Label Label Label Label Label
#6-32 Captive
Screw and
Washer (x6)
Cable
Cover
Foam
Seals
(if needed)
Figure 28: Cable Cover
Figure 29: Strain-relief Example
Strain-relief and
Service Loops
(cutaway view)
Seal Access Hole
Deck
Maintain minimum
bend radius!
Gooseneck
To Belowdecks
Equipment
The integrity and reliability of the RF cables is
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!
Continued Wire the Antenna
8

18
Follow these steps to mount the antenna to the
mounting surface.
a. Position the antenna over the holes drilled in
the mounting surface and make sure the
forward arrow inside the baseplate points
toward the bow and is parallel to the vessel’s
centerline (see Figure 30).
b. Carefully lower the antenna onto the
mounting surface and ensure the mounting
holes (and foam seals, if used) are aligned.
c. Apply a thin layer of the supplied anti-seize
lubricant to the threads of the four supplied
1/2"-13 mounting bolts to prevent galling.
d. At each of the four antenna mounting holes,
place a 1/2" flat washer on a 1/2"-13 bolt and
insert the bolt into the hole from above (see
Figure 31).
e. Secure each mounting bolt to the mounting
surface using a 1/2" flat washer and a 1/2"-13
lock nut from below (see Figure 31).
f. Tighten the mounting bolts in a cross pattern
until the four rubber feet on the baseplate are
bottomed against the mounting surface. KVH
recommends that you tighten the nuts to
between 35 and 40 ft-lbs (47 and 54 N-m) of
torque.
CAUTION
Observe the safety warnings printed on the
tube of Loctite®anti-seize lubricant:
“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.”
Cable Connectors
(Face Stern)
Forward Arrow
Inside Baseplate
(Point Toward Bow)
Hatch
Hatch
FORWARD
Antenna
(Top View)
Figure 30: Forward Arrow in Antenna Baseplate
If the foam seals are used, do not reposition
the antenna laterally once the antenna’s foam
seal has made contact with the foam seal on
the mounting surface. If you need to
reposition the antenna, lift the antenna first to
avoid damage to the foam seals.
IMPORTANT!
1/2"-13 Bolt (x4)
1/2" Flat
Washer (x4)
Rubber
Foot (x4)
Mounting
Surface 1/2" Flat
Washer (x4)
1/2"-13 Lock
Nut (x4)
Antenna
Baseplate
Isolation
Bushing (x4)
(preinstalled)
IMPORTANT!
Apply anti-seize
to threads
Foam Seals
(if used)
Stationary
Plate
Figure 31: Mounting the Antenna (Side View)
Mount the Antenna
9

19
g. Disconnect the crane rigging.
h. Remove the eight screws, flat washers, and
lock nuts securing the four lift brackets to the
antenna (see Figure 32). Use a 5/32" hex key
to keep the screws from turning, and use a
1/2" open-end wrench to loosen and remove
the nuts. Remove the lift brackets and
hardware and set them aside.
NOTE: Save the brackets and bracket hardware in
case the antenna needs to be moved in the future.
i. Install eight 1/4"-20 screws and washers
(supplied in the kitpack) in place of the
longer mounting bracket screws you
removed in the previous step (see Figure 33).
j. Close both antenna service hatches. Secure
each service hatch using the three hex latches.
Lift Bracket
(x4)
1/4"-20 x 1.5"
Screw (x8)
Counter-sun
k
Washer (x8)
1/4"-20 Flat
Washer (x8)
1/4"-20 Lock
Nut (x8)
Figure 32: Removing the Lift Brackets
1/4"-20 x 7/8"
Screw (x8)
Counter-sun
k
Washer (x8)
Figure 33: Reinstalling the Radome Hardware
Continued Mount the Antenna
9