Flir ThermovisionVoyager II Installation Guide

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VOYAGER II
INSTALL ATION GUIDE 
						

							2 © FLIR Systems, Inc., 2010. All rights reserved worldwide. No parts of this manual, in whole or in part, 
may be copied, photocopied, translated, or transmitted to any electronic medium or machine readable 
form without the prior written permission of FLIR Systems, Inc.
Names and marks appearing on the products herein are either registered trademarks or
trademarks of FLIR Systems, Inc. and/or its subsidiaries. All other trademarks, trade names, or 
company names referenced herein are used for identifi cation only and are the property of their 
respective owners.
This product is protected by patents, design patents, patents pending, or design patents pending.
The Voyager II imaging system is controlled by US export laws. There are special versions of this system 
that are approved for international distribution and travel. Please contact FLIR Systems if you have any 
questions.
FLIR Systems, Inc. 
70 Castilian Drive 
Goleta, CA 93117 
Phone: +1.888.747.FLIR (+1.888.747.3547) 
www.fl ir.com
Document Number: 432-0002-00-11, rev 120
Document History
Revision Date Comment
100 Feb 2008 Initial Release
110 Jan 2009 Voyager II: includes NMEA interface, updated drawings, added TOC 
and page numbers, other minor changes
120 Jul 2010 Updated NMEA section and various minor enhancements
This document is controlled to FLIR Technology Level 1.  The information contained in this document 
pertains to a dual use product controlled for export by the Export Administration Regulations (EAR).  
FLIR trade secrets contained herein are subject to disclosure restrictions as a matter of law. Diversion 
contrary to US law is prohibited.  US Department of Commerce authorization is not required prior to 
export or transfer to foreign persons or parties unless otherwise prohibited. 
						

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Contents
VOYAGER II INSTALL ATION   4
Introduction  4
Installation Preparation  4
Prior to Cutting / Drilling Holes   4
PHYSICAL INSTALLATION   5
Voyager II Camera Body   5
Voyager II Bulkhead Box   5
Voyager II Joystick Control Unit (JCU)   5
ELECTRICAL INTERCONNECT   6
Main Sensor Cable  6
Installation Steps 6
NMEA INTERFACE 14
References 14
NMEA INTERFACE INSTALL ATION  14
NMEA Interface Installation  14
Connector Slot 16
RS-232 CONNECTIONS (WITH NMEA INTERFACE CARD)  15
Spare JCU Slot (1 or 2 JCUs in use)  15
Pigtail Connection (3 JCUs in use)  16
RS-422 CONNECTIONS (NO NMEA INTERFACE CARD)  17
Electrical Checkout 17
Testing the NMEA Interface  17
MFD as NMEA Talker  18
NMEA Multiplexer as NMEA Talker  18
CONNECTIONS QUICK REFERENCE  20
DRAWINGS & INSTALLATION TEMPLATES   20 
						

							4 VOYAGER II INSTALLATION 
Introduction 
Thank you for buying your new Voyager II! This manual describes the physical mounting and electrical 
connection of the Voyager II camera. If you need help during the installation process, call 888.747.3547 
to speak with one of FLIR’s applications experts. The Voyager II should be installed by a qualifi ed  marine 
electronics technician, as incorrect installation could void the warranty. 
The Voyager II comes with these standard components: 
• Camera Body 
• Bulkhead Box
•  NMEA Interface Board (in a separate bag inside the Bulkhead Box)
•  50’ or 100’ main sensor cable (depending on what you ordered) - connects 
  the Camera Body to the Bulkhead Box 
•  Joystick Control Unit (JCU) with 100’ cable that connects to the Bulkhead Box 
•  System Power cable (10’)
•  Voyager Documentation Package
You may need to supply: 
•  16- gauge electrical wire; up to 100’ (3-conductor, for system power) 
•  One 3/8x16 and six 1/4-20 stainless steel bolts for attaching the Voyager II Camera Body
Note that bolt length may be dependant on mounting platform thickness 
•  Four (4) bolts or screws for attaching the Bulkhead Box as required 
•  Miscellaneous electrical hardware, connectors and tools 
If using the NMEA interface features, refer to the NMEA Interface chapter.
Installation Preparation
•  Find a good place to mount the Voyager II’s components: 
o  Mount the Voyager II as high as practical, but without interfering with any radar, 
  navigational or communications electronics, and minimizing the degree to which 
  vessel structures block the camera’s view. 
o  Mount the Voyager II as close to the vessel’s centerline as possible so you will have 
  a symmetrical view of on-coming traffi c. 
o  Voyager II should be mounted on a fl at surface with the base on the bottom and the 
  camera on top. Do not hang the Voyager II upside down; the picture will display 
  upside down, and you may damage the Voyager II. 
Prior to Cutting / Drilling Holes 
•  Once the mounting location has been selected, verif y both sides of the mounting surface are  
 accessible. 
•  Determine if any interior trim panels must be removed in order to gain access to the mounting 
  hardware, and remove them ahead of time. 
•  When selecting a mounting location for the Voyager II, consider cable lengths and routing. Ensure 
the cables are long enough, given the proposed mounting locations and cable routing require-
ments, and route the cables before you install the components.  
						

							5 PHYSICAL INSTALLATION 
Voyager II Camera Body 
Using the template supplied with this Installation Manual as a guide, mark the location of the 
holes for mounting the Voyager II. Make sure the template is aligned so that the Voyager II will 
point straight ahead, and that the cable will exit towards the stern of the vessel. 
Using stainless steel hardware, mount the Voyager II’s camera body with 6 1/4x20 bolts and washers 
and a 3/8x16 bolt in the center for added support. All the bolts are required due to the weight of the 
Voyager II camera.
Voyager II Bulkhead Box 
NOTE:
    FLIR recommends that you terminate all cable ends inside the Bulkhead Box BEFORE you mount 
    it. Refer to the section on detailed cable preparation and termination for these instructions. 
Mount the Bulkhead Box in an area that: 
  •  Is sheltered from the weather 
  •  Has good airfl ow 
  •  Is not exposed to direct sunlight 
  •  Is within easy reach of all required cables 
  •  Provides room for adequate service loops as depicted in the installation drawings supplied 
Voyager II Joystick Control Unit (JCU) 
Mount the JCU in a convenient area that is close 
to the monitor that will display the Voyager II video 
output. Make sure the area you choose will leave 
enough room for the connector and cable under 
the JCU (refer to the drawing package supplied for 
dimensions).
Using the template supplied with the Installation 
Manual as a guide, mark the locations of the holes to 
be cut and drilled for the JCU. 
Cut the hole that will allow the JCU to be recessed 
in the vessel’s control console per the installation 
drawings supplied, and drill the holes for the four 
mounting studs.
Route the JCU  cable through the JCU munting hole. 
Connect the terminated end of the cable to the JCU, 
insert the JCU into its mounting location and secure 
with the supplied mounting studs.  
						

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Step 1: 
Remove the main sensor cable feed 
through grommet 
(A) by unscrewing it 
from the lock nuts 
(B) and (C) on the 
Bulkhead Box.
Step 2: 
Unscrew the grommet cap 
(A) from the cable 
gland 
(B) to expose the grommet seal
The following sections (Electrical Interconnect and NMEA Interface) describe the connections 
to the Voyager. Refer to the NMEA 0183 Standard for details on interconnecting the 
Voyager II with other marine electronic devices.
ELECTRICAL INTERCONNECT 
Main Sensor Cable 
After routing the main sensor cable between the Camera Body and the Bulkhead Box, install 
the Camera Body and connect the terminated end of the main sensor cable to the connector 
on the back of the Camera Body’s base. 
This section describes the procedures required to prepare the main sensor cable, JCU cable 
and main power cable for termination inside the Bulkhead Box. The following tools and docu-
ments are recommended to complete the job: 
•  The installation drawings and templates (FLIR p/n 432-0002-00-19) at the end of this 
manual 
•  Ruler or measuring tape 
• Exacto knife 
• Scissors 
• Wire cutter 
•  Wire stripper for 20 gauge wires 
•  Crimping tool for BNC connector (RG 179) 
• Channel locks 
• 2mm fl athead screw driver 
Installation Steps
A A
B
BC
Caution: 
A non-isolated connection to ex-
ternal electronics may result in 
damage to the Voyager Camera 
System. Use electro-optical iso-
lators when needed in accordance 
with sound marine electronics 
practices 
						

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Step 3: 
Remove the grommet seal from the cable 
gland by inserting a fi nger and pulling it out.
Step 4:
Now that the grommet cap
 (A), seal (B), 
and cable gland 
(C) have been disassembled, 
remove the other sections of the grommet
from the front of the Breakout Box, 
including the 1” reducer 
(D), and the inner lock 
nut 
(E).
Step 5:
Now prepare the main cable ends for attach-
ment to the inside of the Bulkhead Box. Refer 
to the drawings at the end of this manual for 
more information. As shipped, the standard 
cables have fl ying leads that are stripped to 
the appropriate length, labeled and require no 
additional preparation. Some of the instruc-
tions that follow apply only if the cable is short-
ened to a custom length.
Step 6: 
Slide the black outer jacket of f the cable, 
exposing the inner metal braid. Measure 13.5” 
from the end of the cable, carefully cut around 
the outer black cable jacket until you can slide 
it of f, and remove it. Be careful not to cut into 
the metal braid beneath the outer jacket.
AB C D E 
						

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Step 10:
Slide the grommet seal up the cable so that 
the front edge just lines up with the end of the 
black outer cable jacket as shown
Step 9:
Slide the grommet cap 
(A – not shown), seal 
(B), and cable gland (C) over the cable
Step 7:
Push the braid back over the black outer jack-
et an inch or two, creating an area of slack in 
the braid. Carefully insert scissor tips into the 
braid, and cut all the way around it as shown. 
Slide the excess braid of f the cable and dis-
card it
Step 8:
Working with the shorter length of braid, trim 
i t so t ha t onl y 1” ex t ends bey ond t he black ou t -
er jacket as shown. 
A
B
C 
						

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Step 11:
Carefully fold the metal braid back over the 
grommet seal as shown 
Step 12:
Trim the metal braid as shown, so that the 
black o-ring seal is clear of the metal braid. 
Step 13:
Slide the cable gland over the grommet seal 
as shown, capturing the metal braid between 
the two
Step 14:
Screw the grommet cap onto the cable gland 
as shown. 
You are now ready to prepare the cable ends 
for connection to the Bulkhead Box’s internal 
termination blocks 
						

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Step 16:
Prepare the video cable by securing the crim-
pable 75-ohm BNC connector (provided) onto 
the RG-179 cable. If you are unsure how to ter-
minatet this type of connector, contact FLIR 
for additional information.
Step 17:
The rest of the wires will need to be 
prepared in a fashion similar to the following 
progression. 
Carefully cut around the outer insulation as 
shown. 
Step 15:
Trim the clear Mylar sheath back so the 
individual wire bundles can be spread 
apart as shown. This will make them 
easier to identify and work with. 
Cut the blue Ethernet cable to 12.5” long, 
measured from the end of the cable 
gland. 
Cut the wire bundle inside a clear jacket 
and steel braid to measure 11.5” long. 
Cut the bundle of 4 twisted pairs inside a 
white outer jacket to measure 11.5” long. 
The video cable should be cut to 9.5”