KVH, TracVision, and the unique light-colored dome with 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. © 2008 KVH Industries, Inc., All rights reserved. 54-0363 Rev. B 1

These instructions explain how to replace the main PCB (printed circuit board) in a TracVision C3/R5/R4 system.

Installation Steps

Tools Required

This procedure requires the following tools:

Technical Support

If you need technical assistance, please contact KVH Technical Support:

1. Replace the Main PCB...2

2. Check for Flash Wizard Updates...4

3. Flash Both Antenna Boards...4

4. Configure the Antenna...4

5. Install Satellites...6

6. Enter your GPS Position (Optional)...8

• 11/32" open-end wrench

• 7/16" open-end wrench

• Needle-nose pliers

• Phillips-head screwdriver

• PC with the latest version of the KVH Flash Update Wizard installed

NOTE: The Flash Update Wizard is available to KVH-authorized dealers through the KVH Partner Portal.

N. America, S. America, Australia:

Phone: +1 401 847-3327E-mail: techs@kvh.com

Europe, Middle East, Asia:

Phone: +45 45 160 180E-mail: support@kvh.dk

The main PCB is static-sensitive. Ensure that you take the necessary grounding precautions before handling.

IMPORTANT!

Main PCB Replacement Instructions for TracVision® C3/R5/R4

2

Step 1 - Replace the Main PCBThe following steps explain how to replace the main PCB.

a. Disconnect power from the TracVision system and any connected receivers and/or multiswitch.

b. Remove the eight screws and washers securing the radome (see Figure 1). Then remove the radome and set it aside in a safe place.

c. Locate the elevation motor shaft at the rear of the reflector (see Figure 2).

d. Using an 11/32" open-end wrench, loosen the elevation motor shaft nut, but do not remove it.

e. Rotate the elevation motor shaft counterclockwise until it is fully retracted (see Figure 3).

f. Using a Phillips-head screwdriver, remove the four screws from the main PCB cover.

g. Gently remove the main PCB cover, ensuring no cables are damaged or pinched by the edges of the cover.

CAUTION

For your own safety, be sure to disconnect power from all wired components before performing this procedure.

Figure 1 Radome Screws

Figure 2 Elevation Motor Shaft Assembly

Figure 3 Retracted Motor Shaft/PCB Cover Screws

Radome

Screw andWasher (x8)

Baseplate

Reflector

Elevation MotorShaft

Elevation MotorShaft Nut

Elevation MotorShaft

PCB CoverScrews (x4)

Main PCB Cover

h. Remove all cable connectors from the main PCB (see Figure 4).

i. Remove the four Phillips screws securing the main PCB to the rotating plate (see Figure 4).

j. Using needle-nose pliers, carefully depress the tab of the standoff located next to the RF PCB connector on the main PCB (see Figure 4 and Figure 5).

k. Carefully raise the PCB over the tab. Repeat this procedure for each of the other four standoffs (see Figure 4).

l. Remove the PCB.

m. Install the replacement main PCB. Ensure the main PCB is secured by the standoffs, then using the four screws you removed in Step h, secure the main PCB to the rotating plate (see Figure 4).

n. Reconnect all cable connectors to the main PCB (see Figure 4).

o. Gently install the main PCB cover, ensuring no cables are damaged by the edges of the cover. Then secure the main PCB cover using the four screws that you removed in Step g on page 2.

p. Extend the elevation motor shaft by rotating it clockwise until the motor shaft nut is close to the connecting rod (Figure 2 on page 2).

q. Apply a small amount of the supplied Loctite threadlocker to the threads of the elevation motor shaft, just above the motor shaft nut (see Figure 6).

3

Figure 4 Main PCB Connectors, Screws, and Standoffs

Figure 5 PCB Standoff

Figure 6 Loctite Application (motor shown unmounted for clarity purposes only)

RF PCB (J9)

Main PCB

ElevationMotor (J2)

AzimuthMotor (J1)

PowerData (J2)

= Screw (x4)

= Standoff (x5)

Gyro (R5/C3Only) (J5) Fuse (x2)

LimitSwitches (J9)

PCB

Standoff

StandoffTab

Nut

ApplyLoctite Here

ElevationMotor Shaft

4

r. Insert the motor shaft into the connecting rod by rotating the motor shaft clockwise (see Figure 7).

s. Using an 11/32" open-end wrench, tighten the elevation motor shaft nut (see Figure 7).

t. Reinstall the radome. Then reconnect power to the TracVision system.

Step 2 - Check for Flash Wizard UpdatesYou need to check for flash file updates to ensure you have the most current software available (see Figure 8). Follow the Flash Update Wizard’s onscreen instructions to check for updates. This procedure requires a PC with the latest version of the KVH Flash Update Wizard installed and an Internet connection.

NOTE: Refer to the Flash Update Wizard’s Help file for details on checking for updates.

Step 3 - Flash Both Antenna BoardsConnect a PC to your TracVision system, as described in the Flash Update Wizard’s Help file. Then follow the Flash Update Wizard’s onscreen instructions to flash the antenna’s main and RF boards.

NOTE: Refer to the Flash Update Wizard’s Help file for details on flashing the antenna.

Step 4 - Configure the AntennaFollow the steps below to configure the new main PCB. You will enter PC commands into the Flash Update Wizard’s “TracVision Antenna Comms” window.

a. Set the switchplate’s POWER switch to the On (up) (|) position (see Figure 9), then turn on the receiver(s). Wait one minute for system startup.

b. Type HALT then press Enter.

c. Type DEBUGON then press Enter.

Figure 7 Elevation Motor Shaft Nut

Figure 8 Check for Updates Option

Figure 9 On/Off Switch

Elevation MotorShaft Nut

ConnectingRod

OFF

ON

d. Select your TracVision model below. Type the corresponding command (shown in bold) then press Enter.

• TracVision R5: =TVR5

• TracVision R4: =TVR4

• TracVision C3: =TVC3

e. The antenna will restart. Wait one minute for system startup.

f. Type =LSTEST then press Enter to perform a limit switch test. Wait for the test to pass or fail. If the test fails, contact KVH Technical Support.

g. (C3/R5 Only) - Type =CALGYRO then press Enter to calibrate the gyro. If “scale factor out of range” appears, contact KVH Technical Support.

h. The antenna will restart. Wait one minute for system startup.

i. Type HALT then press Enter.

5

6

Step 5 - Install SatellitesNow you need set the system to track the satellites of your choice. This procedure varies according to your selected service configuration.

NOTE: If the TracVision system is equipped with service keys (see Figure ), follow the steps in the Service Key Instructions to set up the TracVision system. If the TracVision system is equipped with an HDTV Control Panel or a Multi-Sat Control Panel (see Figure 11), follow the steps in the HDTV Control Panel/Multi-Sat Control Panel’s User’s Guide to set up the TracVision system.

Option A - DIRECTV Ku-band HDTV

a. If you need to track the DIRECTV 101, 110, and 119 satellites for DIRECTV Ku-Band HDTV service, type the following Satinstall command, then press Enter.

SATINSTALL,TRISAT,DSS

b. Type ZAP then press Enter.

c. The antenna will restart.

Option B - DISH 1000

DISH 1000 setup varies by region. Refer to the map in Figure 12 to determine the appropriate DISH 1000 satellite installation for your region.

a. Type the appropriate Satinstall command for your DISH 1000 setup, then press Enter.

• To track the DISH 110, 119 and 129 satellites:

SATINSTALL,TRISAT,DISH

• To track the DISH 110, 119 and 61 satellites:

SATINSTALL,TRISAT,DISH61

b. Type ZAP then press Enter to restart the antenna.

Figure 10 Service Keys

Figure 11 Multi-Sat Control Panel (MCP)/ HDTV Control Panel

Figure 12 DISH 1000 Satellite Coverage Map

A B

= DISH 61SatelliteRecommended

Option C - Alternate/Linear Satellites

Follow the steps below to configure the system to track up to two satellites from either the circular or linear satellite library.

NOTE: In general, North American satellites require a circular LNB, while European satellites require a linear LNB. Refer to the appropriate satellite library for your geographic area.

a. Circular systems - Choose your desired satellites from the circular satellite library (see Figure 13).

Linear systems - Choose your desired satellites from the linear satellite library (see Appendix A on page 9).

b. Type the following command then press Enter. Be sure to use your selected satellites’ Install Names. Examples are provided in Figure 14 and Figure 15.

SATINSTALL,<SAT_A_NAME>,<SAT_B_NAME>

NOTE: Select the satellite you want to track first as “SAT_A”. Once the procedure is complete, the TracVision system will begin tracking that satellite.

c. Type ZAP then press Enter to restart the antenna.

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Figure 13 Circular Satellite Library

Figure 14 Example of Circular Satellite Installation

Figure 15 Example of Linear Satellite Installation

Satellite Install Name

DIRECTV 72° W DSS_72

DIRECTV 101° W DSS_101

DIRECTV 110° W DSS_110

DIRECTV 119° W DSS_119

DISH Network 61° W ECHO_61

DISH Network 110° W ECHO_110

DISH Network 119° W ECHO_119

DISH Network 129° W ECHO_129

ExpresssVu 82° W EXPRESSVU

ExpressVu 91° W EXPRESSTV

None None

Installing DIRECTV 101 and DIRECTV 119

HALTSATINSTALL,DSS_101,DSS_119ZAP

Installing Astra 2S and Hotbird

HALTSATINSTALL,ASTRA2S,HOTBIRDZAP

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Step 6 - Enter your GPS Position (Optional)If you wish to speed up how quickly the antenna will track the satellite the first time after this procedure is completed, you can enter your GPS coordinates into the antenna. The TracVision system will use this data to speed up initial satellite acquisition.

a. Determine your latitude and longitude.

NOTE: For your convenience, Appendix A on page 8 lists approximate latitude and longitude values for North America. For European latitude and longitude values, refer to Appendix A on page 9.

b. Using the table below, type the following command to enter your latitude and longitude.

GPS,XX,D,YYY,F

The procedure is complete!

Variable Value

XX latitude (0-90)

D (Enter N or S)N (North)

S (South)

YYY longitude (0-180)

F (Enter W or E)W (West)

E (East)

Figure 16 North American Position Grid

Grid # Latitude Longitude

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

125° W

110° W

90° W

70° W

55° W

125° W

110° W

90° W

70° W

50° W

125° W

110° W

90° W

70° W

125° W

110° W

90° W

75° W

83° W

78° W

55° N

55° N

55° N

55° N

55° N

45° N

45° N

45° N

45° N

45° N

40° N

40° N

40° N

40° N

32° N

32° N

32° N

32° N

27° N

27° N

Appendix A - Linear Satellite Library & Approximate European Latitude and Longitude ValuesThis section includes the linear satellite library and a European position grid and table for determining the approximate latitude and longitude values for your location.

Linear Satellite Library

Satellite Install Name

Arabsat 26° E ARABSAT

Astra 1 19° E ASTRA1

Astra 2N 28° E ASTRA2N

Astra 2S 28° W ASTRA2S

Eutelsat W3A 7° E EUTEL_W3A

Hispasat 30° W HISPASAT

Hotbird 13° E HOTBIRD

HotbirdWB 13° E HOTBIRDWB

Nilesat 101 7° W NILESAT

PAS9 58° W PAS_9

Sirius 5° E SIRIUS

Thor 8° W THOR

Turksat 1C 42° E TURKSAT1C

None None

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Figure 17 European Position Grid

1 2 3 4

11

765

8 9 10

12 13 14

1615

17 18 19 20

21 22 23 24

Grid # Latitude Longitude

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

7° W

7° E

22° E

45° E

7° W

7° E

22° E

7° W

7° E

22° E

40° E

7° W

7° E

22° E

7° W

7° E

7° W

7° E

22° E

37° E

7° W

7° E

22° E

37° E

67° N

67° N

67° N

65° N

63° N

63° N

63° N

57° N

57° N

57° N

55° N

53° N

53° N

50° N

47° N

47° N

43° N

43° N

43° N

43° N

36° N

36° N

36° N

36° N