Flir ThermovisionMSeries Installation Guide

							432-0003-00-12 Rev 140 — M-Series Installation Guide 9
 Installing M-Series Systems
Camera Video Options
The M-Series gimbal assembly has either one or two video cables:
• The cable labeled IR is for the composite—also known as analog—video 
signal from the thermal (infrared) camera. This is the only cable on single 
payload cameras.
• On dual payload models, the cable labeled VIS/IR is for video from either the 
thermal camera or the DLTV camera. You use the JCU to determine which 
output displays. 
The video from dual payload models can be output on one or two video displays. 
If only a single display with a single video input is available, connect the cable 
labeled VIS/IR to the display. If the display has more than one video input, both 
video cables can be connected to the same display. In this type of installation, 
switching between the thermal and visible video channels is performed with the 
display controls, rather than the JCU.
Joystick Control Unit (JCU)
Mount the JCU in a convenient area that is close to the monitor being used to 
display the M-Series video output. Make sure the area you choose leaves enough 
room for the cable under the JCU (refer to the M-Series ICD for dimensions). The 
magnetic compass safe distance for the JCU is 55 cm (21.7 in).
The JCU can be mounted to the dash (or other surface) in any orientation, using 
four captive mounting screws that hold panel mounting clamps. When the 
mounting screws are tightened, the panel mounting clamps rotate and extend 
away from the JCU at a right angle, and come into contact with the mounting 
surface. The JCU can be mounted to dash thicknesses ranging from 0.16 – 4.45 
cm (0.063 – 1.750 in). A trim bezel snaps on top of the JCU to cover the mounting 
screws. See “Installing the Joystick Control Unit (JCU)” on page 12 for detailed 
instructions.
JCU Connection to Camera
The JCU is a Power over Ethernet (PoE) device and can be connected to the 
camera directly with the included 7.6 meter (25 feet) double-shielded Ethernet 
cable or a user-supplied cable of sufficient length. In this case, the JCU draws its 
power from the camera. 
Alternatively, the camera and the JCU can be connected together via an Ethernet 
switch; this type of configuration allows more than one JCU or camera to be used. 
The JCU draws its power through the Ethernet connection, so a PoE injector or 
PoE switch is required.
Prior to Cutting/Drilling Holes
Determine if any interior trim panels must be removed in order to gain access to 
the mounting hardware, and remove them ahead of time.
Joystick Control Unit 
						

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10432-0003-00-12 Rev 140 — M-Series Installation Guide 
When selecting a mounting location for the M-Series, consider cable lengths and 
cable routing. Ensure the cables are long enough, given the proposed mounting 
locations and cable routing requirements, and route the cables before you install 
the components. 
If you are using one of the top-down installation kits, the riser or plate should be 
used as a template for the location of the drill holes and cable access hole.
Caution: When installing the camera, do not tighten the fastener in the threaded 
hole so far that it contacts the bottom of the threaded hole. Maximum insertion 
should not exceed 6 mm (0.23 in), and torque should not exceed 12 N·m 
(8.8 lbf· ft).
Use power cables that have sufficient dimensions to ensure safety and video and 
communication cables that have sufficient dimensions to ensure adequate signal 
strength. 
To ensure a proper seal between the camera unit and the vessel, an O-ring 
should be installed in the camera base. The O-ring will seal properly with a 
surface that is flat to within 0.15 cm (0.06 in) over the diameter of the base of the 
camera. If it is necessary to install on a surface that does not meet that criteria, a 
marine-grade sealant (3M 4200 or equivalent) must be used rather than the 
O-ring.
To ensure a proper seal around the JCU, the supplied gasket must be applied to 
the JCU and the cutout opening for the JCU should precisely match the template. 
If the cutout opening is too large, the gasket around the JCU may not cover the 
opening adequately.
Multiple JCU/Camera Installations
In some installations, the system may include additional components, such as 
additional cameras or JCUs, video equipment, or network equipment. More than 
one JCU can be used to control the camera, and more than one display can be 
used to view the video. Also a single JCU can be used to control more than one 
camera and optionally you can also use a PC to control the camera.
Refer also to the M-Series ICD (FLIR Doc. # 432-0003-00) for interconnect 
diagrams showing several possible system configurations using more than one 
JCU.
The following diagram shows a possible system configuration using:
• A video amplifier (PN 4108996) supplied by FLIR that supports output to four 
video devices
• POE Injectors (PN 4113746) supplied by FLIR for DC/DC Power over 
Ethernet 
						

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 Installing M-Series Systems
Physical Installation
Use a thread-locking compound such as Loctite 242 or equivalent with all metal-
to-metal threaded connections.
Installing the Camera Unit
With the exception of theM-618CS model, which must be installed in the ball-up 
orientation, the M-Series camera can be mounted in an upright or upside down 
position. Two O-rings are provided for use during the camera installation. You 
should choose the one most appropriate for your configuration: 
• Part # AS568A-427 is typically used for the upright installation. Its dimensions 
(in millimeters and inches):
120 mm ID x 7 mm DIA
4.75 in ID x 0.25 in DIA
• Part # A3568A-334 is used for certain ball-down installations. Its dimension (in 
millimeters and inches):
67 mm ID x 5 mm DIA
2.63 in ID x 0.19 in DIA
Secondary Video
Primary Video
Ethernet Switch (non PoE)
M-Series CameraJCU
Video Amplifier
Remote JCU 
located with 
Remote Monitor
PoE Injectors
Video (IR)Video (VIS/IR) Ethernet
Video amplifier 
sends the video to 
up to 4 monitors In this example, the IR 
video channel is not used
Dashed lines represent 
connection to power
(PN 4108996) (PN 4113746) 
						

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As an alternative to the mounting O-ring, you can use a marine-grade sealant 
such as 3M 5200 or the equivalent.
Mounting Upright
Caution: The cable connectors terminating the pigtail cables on the camera are 
not sealed connectors; therefore, appropriate sealing steps are needed to protect 
the connections and the camera.
Caution: Before drilling holes, ensure you have first followed the steps outlined 
in the planning section (page 7). For example, it is important to test the unit at the 
planned installation location with typical vessel electronics active prior to 
mounting the camera.
Using the template supplied with the camera as a guide, mark the location of the 
holes for mounting the camera. Make sure the template is oriented properly 
relative to the bow of the vessel; observe that the forward direction is reversed for 
the ball-down installation. If the template is printed, be sure it is printed to scale 
so the dimensions are correct. If you are using one of the top-down installation 
kits, the riser or plate itself should be used as a template for the location of the 
drill holes and cable access hole.
Once the holes are drilled in the mounting surface, install the six (6) threaded 
studs into the base of the camera with thread-locking compound. Install the 
rubber O-ring in the base of the camera. Thread the power supply, video, and 
ethernet cables from the camera through the center hole, and then place the 
camera on the mounting surface so the threaded studs extend through the drilled 
holes. Then secure the camera body to the mounting surface with the supplied 
nuts and washers. As needed, the threaded studs can be replaced with studs of 
a different length or cut to a shorter length.
Mounting Upside Down
When the camera unit is mounted in an upside down orientation—with the ball 
down (select models only), you must mount the base rotated 180 degrees 
relative to the bow of the vessel, so the internal position sensors are oriented 
correctly. Refer to the arrow designation on the bottom of the camera base. A 
camera configuration setting accessible through the camera on-screen display 
(OSD) menu system is used to configure the camera for the ball-down position. 
See the M-Series Operator’s Manual for details.
When the camera is mounted upside down (ball down), the camera base must be 
rotated backwards, to point toward the stern of the vessel.
Installing the Joystick Control Unit (JCU)
The cable gland seal is designed for use with double-shielded category 5 
Ethernet cable. To ensure a good seal and to maintain compliance with EMI 
ratings, a double-shielded cable is required.
The JCU enclosure is rated IP66 above the JCU mounting surface/gasket and 
rated IP64 behind or below the gasket. 
						

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 Installing M-Series Systems
Caution: An installation template is provided in the JCU ICD. If you print the 
template from the PDF file, ensure that it was printed to the correct scale by 
checking the dimensions prior to cutting any holes.
Standard JCU Mounting Instructions
1.Using the JCU template supplied as a guide in Doc. # 500-0385-19, mark the 
location of the rectangular opening that will allow the JCU to be recessed in the 
vessel’s control console. Ensure the corners are marked precisely and cut 
square. 
2.Apply the adhesive side of the rubber gasket to the back of the JCU on the 
surface that faces the mounting platform. The JCU comes with 4 panel 
mounting clamps that can be reversed when the thickness of the panel 
material is less than 0.79 cm (5/16 or 0.31 in); see instructions below. Ensure 
the mounting clamps are rotated inward and are recessed so the entire JCU 
fits into the hole
3.Remove boots from both ends of the Ethernet cable, as it may interfere with 
the coupling gland. The boot may cause the RJ45 connector tab to depress, 
which can lead to intermittent connections.
4.Loosen or remove the cable gland nut on the JCU, and insert the Ethernet 
cable RJ45 connector through the gland nut. Once the Ethernet cable is 
connected to the JCU, replace the gland nut and turn the nut 1/4 turn beyond 
hand tight.
5.Insert the JCU into the hole and secure by turning the 4 corner screws 
clockwise. Rotate each screw one full turn and ensure the mounting clamps 
are rotated outward from the JCU housing. Tighten the screws to draw the 
mounting clamps up against the mounting surface and then tighten another 
quarter or half turn. Do not overtighten the screws.
Mounting the JCU to a Thin Panel 
As shipped from the factory, the JCU can be mounted to dash thicknesses 
ranging from 0.79 – 4.45 cm (0.31 – 1.75 in). The clamps are set with the small 
foot on the clamp facing away from the panel and toward the front of the JCU, as 
shown below.
If you intend to mount the JCU to a panel of 0.79 cm (0.31 in) thickness or less, 
remove the clamps from the mounting screws, turn them around and thread them 
back onto each of the four screws. In this configuration, the clamp foot faces the  
						

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rear of the mounting surface and allows the clamp to contact thinner panel 
surfaces while still allowing for proper compression of the JCU mounting gasket 
to form a watertight seal.
Electrical Connections
Watertight connectors/enclosures should be used on each of the electrical 
connections. Table 1.1 shows the connections for the cables attached to the 
camera.
*VIS/IR cable is only available on dual payload models.
Caution: During installation, ensure the cables exiting the bottom of the camera 
are not in contact with sharp edges, do not bend at sharp angles, and are not 
pinched between the bottom of the camera and the mounting surface. Do not pull 
on the cables with excessive force. 
Caution: It is recommended that any built-up triboelectric charge on the Ethernet 
cable should be discharged before connecting it to the JCU and camera. This 
can be accomplished simply by pressing an ungloved finger across the Ethernet 
RJ45 connector of the cable for a few seconds.
TABLE 1.1  Connections Quick Reference
Cable Label Wire Comment
Power Red Nominal 12V DC / 24V DC 
Absolute range 10V to 32V DC 
5 AMP maximum
Black DC return 
Green Chassis ground
IR F-Style Coax Thermal camera video only
VIS/IR * F-Style Coax Use if only one display
JCU RJ45 Use shielded Ethernet cable 
						

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 Installing M-Series Systems
Proper Grounding
Caution: Ensure the camera is properly grounded. Following best grounding 
practices, the camera chassis ground should use the lowest resistance path 
possible. 
The green wire in the camera cable can be used to provide chassis ground for 
cable lengths under 2 m (6 ft). For longer cabling, the camera must be connected 
to a vessel ground using a low-resistance grounding strap connected directly to 
one of the M6 mounting bolts on the camera base as shown in the M-Series ICD 
(432-0003-00). 
Failure to provide this connection may result in electrical interference between 
camera and other shipboard electronic systems. Furthermore, it is recommended 
that a bonded grounding scheme is used with a common ground between the 
chassis ground and electrical return, with the connection made as close as 
possible to the negative terminal of the battery. 
Connecting Power
The camera itself does not have an on/off switch. Generally the M-Series camera 
will be connected to a circuit breaker and the circuit breaker will be used to apply 
or remove power to the camera. When power is supplied, the camera will be in 
one of three modes: Booting Up. Standby, or Powered On. The M-Series 
Operator’s Manual has detailed information about powering and operating the 
camera.
Consider installing a fuse in line with the power connection to protect the camera 
from power surge or short circuit. Table 1.2 applies to both 12V and 24V 
operation.
The installer must use power cable wires that are sufficient size gauge or 
diameter for the supply voltage and total load (camera and length of cable run), to 
ensure proper supply voltage at the camera and adequate current carrying 
capacity. Table 1.3 lists recommended wire size for various cable lengths. 
TABLE 1.2  Fuse Recommendations
Model Fuse
M-324L, M-625L, M-612L, M-618CS 5 amp
M-324XP, M-625XP 3 amp
TABLE 1.3  Power Cable Wire Gauge Recommendation
Length in Meters (Feet)Wire Gauge (AWG) 
for 12V SupplyWire Gauge (AWG) 
for 24V Supply
8 (25) 16  18
16 (50) 14  18 
						

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Warning: Use of insufficient wire gauge can result in fire. Suggested gauge 
depends on supply voltage shown. For lower supply voltages, lower gauge wire 
must be used.
Video Connections
The video cables from the camera are terminated with F-type male connectors. 
Video cables of various lengths with F-type female connectors at one end and 
BNC-connectors at the other end are available from FLIR. The video cable used 
should be rated as RG59/U or better to ensure an adequate quality video signal. 
Another alternative is to interconnect the camera video cable to a longer video 
cable using an optional F-type female-to-female adaptor (FLIR PN 4115330). For 
cable runs in excess of 100’, a video amplifier should be used.
Ethernet Connections
The Ethernet cable from the camera can be connected to another Ethernet cable 
with the included RJ45 waterproof enclosure connector (FLIR PN 4115028).
The Ethernet network cable should be rated for use with PoE devices 
(IEEE802.3af) and should be 8-conductor T568B, Ethernet, double-shielded for 
EMI considerations (FLIR PN 308-0163-25 or equivalent).
24 (75) 12  16
32 (100) 10  16
TABLE 1.3  Power Cable Wire Gauge Recommendation
Length in Meters (Feet)Wire Gauge (AWG) 
for 12V SupplyWire Gauge (AWG) 
for 24V Supply 
						

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CHAPTER 2M-Series Reference 
Introduction
This chapter includes the following reference information:
• A summary of maintenance procedures
• A table of camera specifications
• Information about standards referenced during the installation procedure
• A glossary of acronyms 
• A table comparing features of various M-Series models
M-Series Maintenance
The M-Series components are designed for years of rugged, trouble-free use. 
When the system is not in use, keep the JCU cover in place for additional 
protection.
Cleaning the JCU
To clean the JCU, use a soft cloth and clean water. Mild household cleaner such 
as Windex can also be used to remove tougher stains or spots. Do not use 
alcohol based cleaners or any type of solvents as this may discolor or damage the 
unit.
Cleaning the Camera Optics
Great care should be used with your cameras optics. They are delicate and can 
be damaged by improper cleaning. The M-Series thermal camera lenses are  
						

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designed for the harsh outdoor environment and have a coating for durability and 
anti-reflection, but may require cleaning occasionally. FLIR Systems Inc. 
suggests that you clean the lens when image quality degradation is noticed or 
excessive contaminant build-up is seen on the lens. 
Rinse the camera housing and optics with low pressure fresh water to remove 
any salt deposits and to keep it clean. If the front window of the camera gets 
water spots, wipe it with a clean soft cotton cloth dampened with fresh water. If 
the window requires further cleaning, use a soft moist cotton-based cloth with 
isopropyl alcohol or dish soap.
Do not use abrasive materials, such as paper or scrub brushes as this will 
possibly damage the lens by scratching it. Only wipe the lens clean when you 
can visually see contamination on the surface.
Cleaning the Camera Body
Do not pressure wash the camera, especially around the FLIR logos, as that 
could force water through the camera seals. Clean the interface between the 
yoke and base often to prevent accumulation of debris or salt deposits.
If you have a problem with your thermal camera, do not attempt to repair it 
yourself. The M-Series camera is a sealed unit and can not be opened or 
serviced in the field. Consult your installation dealer or FLIR Systems Inc. for 
repair information.
Caution: The M-Series is sealed at the factory against liquid water, suspended 
particulates, and other contaminants. It is important that you not open the camera 
for any reason, as it will compromise this seal and possibly damage the unit. 
Opening the M-Series camera will void the manufacturer’s warranty.
Specifications
Table 2.1 lists details about physical characteristics, power usage, and 
environmental features of your M-Series camera. 
TABLE 2.1  Specifications
Physical Characteristics
Camera Size  17.8 cm (7 in) diameter by under 29.2 cm (11.5 in) tall
Camera Weight Under 5.4 kg (12 lb), depending on the camera model
Joystick Size 9.1 X 14.2 X 8.13 cm (3.6 X 5.6 X 3.2 in)
3.17 cm (1.25 in) above platform including joystick
Joystick Weight .45 kg (1 lb)
Base Ball
Side 
Cover
Bezel
Yoke