AgilePlans™ by KVH

TracPhone V7IP/V7HTS Antenna and Ancillary Equipment

Reshipping Instructions
Field Service Department
If you need assistance, please contact the KVH Field Service Department.
Within the Continental U.S.A: North/South America, Australia: Europe, Middle East, Asia, Africa:
Phone: 1 866 701-7103 Phone: +1 401 851-3806 Phone: +45 45 160 180
Email: fieldservice@kvh.com Email: fieldservice@kvh.com Email: fieldservice@kvh.com

This guide explains how to prepare a TracPhone® V7-IP or V7-HTS antenna system, including the antenna,
ICM, and optional accessories (i.e., the IP-MobileCastTM Media Server, Set-top Box, and Iridium Pilot®
system) for reshipping.

Important!
These instructions assume the equipment has been removed from the vessel and that you have access to the
original packaging or the KVH reshipping kit. If all essential components are not returned, or if the
equipment is damaged and/or does not function normally, you will be billed for the cost of replacement
or repairs.

Packing Steps
The complete listing of packing steps is provided below.

1. Pack the ICM.......................................... 2 4. Pack the Set-top Box ............................12

2. Pack the Antenna................................... 4 5. Pack the Iridium System .....................14
3. Pack the Media Server ........................ 10

Tools Required
This procedure requires the following tools:
• The original packing material you • Loctite C5-A anti-seize lubricant (or equivalent)
received with the equipment
V7-HTS (silver ICM) only:
• Phillips screwdrivers
• 7/16" open-end wrench for J4 RF terminator
• 1/2" open-end wrench
• Extraction tool or equivalent for B1-to-B2 locking jumper
• 3/4" socket/ratchet or wrench cable
• 3/4" socket/torque ratchet capable of
settings between 25 and 30 ft-lbs (34 and
41 N-m) of torque

KVH, TracPhone, IP-MobileCast, CommBox, and the unique light-colored dome with dark contrasting baseplate are trademarks of KVH
Industries, Inc. All other trademarks are property of their respective companies. The information in this document is subject to change without 1
notice. No company shall be liable for errors contained herein. © 2017 KVH Industries, Inc., All rights reserved. 54-1231 Rev. B
Pack the ICM
You must return the following components:

or

Integrated CommBox Modem IEC320-C14 to IEC320-C13 IEC320-C14 to NEMA5-15P

(ICM) adapter cable, 6.5 ft (2 m) adapter cable, 7.5 ft (2.2 m)
Quantity: 1 Quantity: 1 Quantity: 1

European power cable, 8.2 ft (2.5 m) Strain-relief bracket Wi-Fi antenna

Quantity: 1 Quantity: 1 Quantity: 2

Follow the instructions below to prepare the ICM Figure 1: Foam End Caps for the ICM and Bracket
for reshipping.

a. Remove the power cable, Wifi antenna(s),

and strain-relief bracket from the ICM.
NOTE: When returning the silver ICM (see lower
ICM photo above), also remove the RF terminator
from the J4 “Rx RF” jack, and remove the locking
Ethernet jumper cable from the B1 and B2 jacks.

b. Place the strain-relief bracket in a polybag.

Then place the strain-relief bracket against
the bottom of the ICM and enclose the ICM
and bracket with foam end caps (see
Figure 13).

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c. Place the ICM and strain relief bracket into Figure 2: ICM Box Ready for Shipping
the shipping box (see Figure 14).
d. Place the power cables, Wi-Fi antenna(s), and
any other accessories in a sealed ziplock bag
and place the bag on top of the ICM (see
Figure 14).
e. Close and seal the shipping box.

The ICM is now ready to pack with the antenna

as described in the next section.

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Pack the Antenna
You must return the following components:

TracPhone antenna Diagnostics phone

Quantity: 1 Quantity: 1

Follow the instructions below to prepare the Figure 3: Radome Screws

antenna for reshipping.

Step 1 - Attach the Antenna to the Pallet

Follow the instructions below to attach the
antenna to the shipping pallet.

a. Remove the six #10-32 screws securing the

radome to the baseplate (see Figure 3).
Carefully lift the radome straight up until #10-32 Screw (x6)
clear of the antenna assembly and set it aside
in a safe place.

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NOTE: The two hoisting eyelets on the antenna frame Figure 4: Antenna Hoisting Eyelets
may be used to lift the antenna, if necessary (see
Hoisting
Figure 4). Make sure they are undamaged and free of Eyelets (x2)
cracks before using them.

b. Position the antenna over the holes drilled in

the shipping pallet. Then carefully lower the
antenna onto the pallet and ensure the
mounting holes are aligned.
IMPORTANT!
You will need to rotate the antenna assembly
slowly by hand to see all four mounting
holes. You will also need to fully install the Figure 5: Mounting Bolts (Side View)
first pair of mounting bolts prior to rotating
the antenna assembly to install the second 1/2"-13 Bolt (x4)
pair of bolts. If the antenna assembly hits a Stationary
mechanical stop with excessive force, or it hits Plate
the head of a mounting bolt that wasn’t Antenna
1/2" Flat
secured in place, the limit switch might Washer (x4)
Baseplate
become damaged.
Rubber
Foot (x4)
T-Nut (x4)
CAUTION Pallet

Be sure to observe the safe handling

instructions in the Material Safety Data Sheet
(MSDS) provided with the anti-seize Figure 6: Foam Shipping Restraint and Bolts
lubricant.

c. At each of the four antenna mounting holes, Foam Notch

Restraint
place a 1/2" flat washer on a 1/2"-13 bolt and
1/2" Bolt (x4)
insert the bolt into the hole from above and a
1/2" T-nut from below (see Figure 5).
d. Secure each bolt through the shipping pallet
and into the T-nut until the T-nut bottoms
against the shipping pallet.
Pallet
e. Tighten the mounting bolts in a cross pattern
until the four rubber feet on the baseplate are
bottomed against the shipping pallet. KVH
recommends that you tighten the nuts to
between 18 and 20 ft-lbs (24 and 26 N-m) of
torque.
f. Carefully wedge the foam shipping restraint
underneath the reflector to ensure the
reflector is secure during transit. The reflector
should rest within the shipping restraint’s
notch (see Figure 6).

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Step 2 - Pack the Antenna Figure 7: Radome Bag on Antenna
Follow the instructions below to pack the
antenna and ICM together.

a. Reinstall the radome onto the antenna. Secure

it in place with the six #10-32 screws you
removed earlier (see Figure 3 on page 4).
b. Cover the antenna with a radome bag (see
Figure 7).
c. Place the shipping box over the antenna and
down onto the shipping pallet (see Figure 8).
d. Place the four triangular spacers into the
reshipping box as shown in Figure 9.

Figure 8: Reshipping Box on Antenna

Figure 9: Triangular Spacers in Reshipping Box

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e. Secure the reshipping box to the pallet using Figure 10: Bolts Securing Reshipping Box to Pallet
six #10 x 1.5" drywall screws and washers
(see Figure 10).
f. Place the pack insert tray over the radome
and triangular spacers to create a flat surface
(see Figure 11).
g. Place the diagnostic phone and any other
accessories inside the accessories box.
h. Insert the ICM box alongside the accessories
box in the insert tray (see Figure 12).
i. Fill the remaining space with bubble wrap to
secure the ICM and accessories boxes in
place. Figure 11: Insert Tray Inside the Reshipping Box

j. Close and seal the reshipping box.

k. On the outside of the reshipping box, clearly
write the RMA number and ship the antenna
and ICM to the address provided by KVH
Field Service.
NOTE: Shipments received without an RMA number
will be returned to you at your expense.

Figure 12: Identical ICM and Accessories Boxes

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Pack the ICM
You must return the following components:

or

Integrated CommBox Modem IEC320-C14 to IEC320-C13 IEC320-C14 to NEMA5-15P

(ICM) adapter cable, 6.5 ft (2 m) adapter cable, 7.5 ft (2.2 m)
Quantity: 1 Quantity: 1 Quantity: 1

European power cable, 8.2 ft (2.5 m) Strain-relief bracket Wi-Fi antenna

Quantity: 1 Quantity: 1 Quantity: 2

Follow the instructions below to prepare the ICM Figure 13: Foam End Caps for the ICM and Bracket
for reshipping.

a. Remove the power cable, Wifi antenna(s),

and strain-relief bracket from the ICM.
NOTE: When returning the silver ICM (see lower
ICM photo above), also remove the RF terminator
from the J4 “Rx RF” jack, and remove the locking
Ethernet jumper cable from the B1 and B2 jacks.

b. Place the strain-relief bracket in a polybag.

Then place the strain-relief bracket against
the bottom of the ICM and enclose the ICM
and bracket with foam end caps (see
Figure 13).

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c. Place the ICM and strain relief bracket into Figure 14: ICM Box Ready for Shipping
the shipping box (see Figure 14).
d. Place the power cables, Wi-Fi antenna(s), and
any other accessories in a sealed ziplock bag
and place the bag on top of the ICM (see
Figure 14).
e. Close and seal the shipping box.

The ICM is now ready to pack with the antenna

as described in step h on page 5.

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Pack the Media Server
(If Equipped)
You must return the following components:

IP-MobileCast Media Server European power cable, 8.2 ft (2.5 m) IEC320-C14 to NEMA5-15P
Quantity: 1 Quantity: 1 adapter cable, 7.5 ft (2.2 m)
Quantity: 1

Follow the instructions below to prepare the Figure 15: Foam End Caps on the Media Server
IP-MobileCast Media Server for reshipping.

a. Enclose the media server in foam end caps

(see Figure 15).
b. Place the media server into the reshipping
box and secure it in place with the foam
spacer (see Figure 17).

Figure 16: Media Server and Foam Spacer in Reshipping Box

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c. Place the power cables and any other Figure 17: Packed Power Cables and Accessories
accessories in a sealed ziplock bag and place
the bag on top of the Media Server (see
Figure 18).
d. Close and seal the reshipping box.
e. On the outside of the reshipping box, clearly
write the RMA number and ship the media
server to the address provided by KVH Field
Service.
Shipments received without an RMA number will be
returned to you at your expense.

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Pack the Set-top Box
(If Equipped)
You must return the following components:

IP-MobileCast Set-top Box AC adapter and power cable HDMI cable

Quantity: 1 Quantity: 1 Quantity: 1

Remote control
Quantity: 1

Follow the instructions below to prepare the Figure 18: Set-top Box and Accessories
IP-MobileCast Set-top Box for reshipping.

a. Remove and discard the batteries from the

Set-top Box remote control.
b. Place the Set-top Box, remote control, AC
adapter, and power cable in polybags or
ziplock bags and place the bags within the
inner shipping box (see Figure 18).

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c. Close and seal the inner shipping box (see Figure 19: Sealed Inner Shipping Box
Figure 19).
d. Place the HDMI cable and any other
accessories in a sealed ziplock bag and place
the bag on top of the inner shipping box (see
Figure 20).
e. Close and seal the reshipping box.
f. On the outside of the reshipping box, clearly
write the RMA number and ship the Set-top
Box to the address provided by KVH Field
Service.
NOTE: Shipments received without an RMA number
will be returned to you at your expense.

Figure 20: HDMI Cable and Set-top Box

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Pack the Iridium System
(If Equipped)
You must return the following components:

Iridium Pilot Above Decks Iridium Pilot Below Decks Iridium OpenPort Captain
Equipment (ADE) Equipment (BDE) Handset
Quantity: 1 Quantity: 1 Quantity: 1

BDE power module BDE power adapter cable

Quantity: 1 Quantity: 1

Follow the instructions below to prepare the Figure 21: ADE in Box (Foam Cap Shown)
Iridium Pilot system for reshipping.

Step 1 - Pack the ADE

Follow the instructions below to pack the ADE.

a. Place the ADE in the ADE box.

b. Enclose the ADE with the protective foam
cap (see Figure 21).
c. Close and seal the box.

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Step 2 - Pack the BDE Figure 22: Iridium System Component in Foam Bag (Example)
Follow the instructions below to pack the BDE,
Captain handset, and power module.

a. Place the BDE, power module, and handset

into individual polybags, foam bags, or
ziplock bags (see Figure 22).
b. Pack the BDE, power module, and handset
into their individually labeled boxes. Then
arrange all four boxes in the Below Decks Kit
box and secure the boxes in place with bubble
wrap (see Figure 23).
c. Close and seal the box.

Figure 23: Below Decks Kit Box

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Step 3 - Pack All Components Together Figure 24: ADE Box Placed in Reshipping Box
Follow the instructions below to pack the ADE,
BDE, and all remaining accessories together.

a. Place the ADE box in the bottom of the

reshipping box (see Figure 24).
b. If you are returning the mounting bracket,
place it in the Mounting Kit box.
c. Place the BDE power adapter cable and any
other accessories in the accessories box (see
Figure 25).
d. Arrange the Mounting Kit box, Below Decks
Kit box, and accessories box in the reshipping
box so that they are secure during transit.
e. Close and seal the reshipping box.
f. On the outside of the reshipping box, clearly
Figure 25: Belowdecks Components
write the RMA number and ship the Iridium
system to the address provided by KVH Field
Service.
NOTE: Shipments received without an RMA number
will be returned to you at your expense.

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