Flir ThermovisionVoyager III Installation Guide

							432-0005-00-12 Rev 100 — Voyager III Installation Guide 9
Physical Installation
Voyager III Bulkhead Box 
• Provide room for adequate service loops as depicted in the installation drawings supplied.
• Using customer-supplied hardware, moun t the Voyager III bulkhead box. Refer 
to the bulkhead box drawings in the Voyager III ICD for detailed instructions.
203.20 mm (8.00 in.)
203.20 mm (8.00 in.)
174.61 mm
(6.87 in.)
110.49 mm
Recommended
(4.35 in.)
323.85 mm
(12.75 in.) 8X 7.92 mm (0.31 in.)
Bulkhead Box Mounting Dimensions 
						

							Physical Installation
10432-0005-00-12 Rev 100 — Voyager III Installation Guide 
Voyager III 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.
Caution : An installation template is provided in the JCU ICD (Doc. # 500-0385-
19). If you print the te mplate 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 ga sket 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 5/16  inches (0.31 in, 0.79 cm; 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 mounti ng 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 0.31 – 1.750 inches (0.79  – 4.45 cm). 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. 
						

							432-0005-00-12 Rev 100 — Voyager III Installation Guide 11
Electrical Connections
If you intend to mount the JCU to a panel of 0.31 inches (0.79 cm) 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 rear of the mounting surface and a llows the clamp to contact thinner panel 
surfaces while still allowing for proper co mpression of the JCU mounting gasket to 
form a watertight seal. 
Electrical Connections
The following sections describe the connec tions to the Voyager III system. Refer 
to the NMEA 0183 Standard for details on interconnecting the Voyager III with 
other marine electronic devices.
Caution : During installation, ensure the main sensor cable exiting the Voyager III 
camera body maintains a minimum bend radi us of five inches, is not in contact 
with sharp edges, and is not pinched be tween any mounting surface. Do not pull 
on the cables. 
Caution:  It is recommended that any built-up triboelectric charge on the Ethernet 
cable should be discharged  before connecting it to the bulkhead box and JCU. 
This can be accomplished simply by pressing an ungloved finger across the 
Ethernet RJ45 connector of the cable for a few seconds.
JCU Clamp reversed for mounting JCU to thin panel 
						

							Electrical Connections
12432-0005-00-12 Rev 100 — Voyager III Installation Guide 
Proper Grounding
Caution: Ensure the Voyager III system is properly grounded. The camera body 
and bulkhead box chassis grounding studs are provided for implementing the 
grounding scheme applicable to the vessel.
Caution:  If multiple analog video displays are installed, to minimize ground loops 
FLIR recommends using a video distribution panel for each video channel 
(primary and secondary) specific to the installation environment and then 
attaching the multiple display to the distribution panels.
Main Sensor Cable 
After routing the main sensor cable between the Voyager III camera body and the 
bulkhead box, prepare it for termination inside the bulkhead box as described in 
the following procedures.
The following tools and documents are recommended to complete the job: 
• The bulkhead box drawing in the Voyager III ICD (Doc. # 500-0483-19)
• Ruler or measuring tape 
• Exacto knife 
• Scissors 
• Wire cutter 
• Wire stripper for 20 gauge wires 
• Crimping tool for BNC connector (RG-179) 
M5 ground stud
M5 ground stud
Main sensor
cable connector 
						

							432-0005-00-12 Rev 100 — Voyager III Installation Guide 13
Electrical Connections
• Channel locks 
• 2 mm flathead screw driver 
Install the Main Sensor Cable Gland Seal
Step 1.Remove the main sensor cable feed-through gland seal (A) by 
unscrewing the lock nut (B) on the inside of the bulkhead box.
Step 2.Unscrew the squeeze nut (C) from the gland body (D), as shown above, 
to expose the gland barrel (E).
Step 3.Remove the gland barrel from the gland body by inserting a finger and 
pulling it out.
Step 4.Slide the squeeze nut (C), gland barrel (E), and gland body (D) over the 
cable and out of the way of preparing the main cable for attachment to the 
bulkhead box.
Step 5.As shipped, the standard cables have flying leads that are labeled and 
grouped for additional preparation. Refer to the Voyager III bulkhead box 
description in the ICD. 
ABCD
E
M5 ground stud
DCE 
						

							Electrical Connections
14432-0005-00-12 Rev 100 — Voyager III Installation Guide 
Step 6.Measure a minimum of 15.75 in. (40 cm) from the end of the cable, 
carefully cut around the outer black cable jacket until you can slide it off, 
and remove it. Be careful not to cut into the metal braid beneath the outer 
jacket.
Step 7.Slide the black outer jacket off the c able, exposing the inner metal braid. 
Step 8.Push the braid back over the black outer jacket an inch or two, creating 
an area of slack in the braid. 
Step 9.Carefully insert scissor tips into the braid, and cut all the way around it. 
Slide the excess braid off the cable and discard it.
Step 10.Working with the shorter length of braid, trim it so that only 1inch extends 
beyond the black outer jacket. 
Step 11.Slide the gland barrel up the cable so that the front edge just lines up 
with the end of the black outer cable jacket as shown below.
Step 12.Carefully fold the metal braid back over the gland barrel as shown. 
Step 13.Trim the metal braid so that the braid is 2 mm past the black O-ring. 
2 mm 
						

							432-0005-00-12 Rev 100 — Voyager III Installation Guide 15
Electrical Connections
Step 14.Slide the gland body over the gland barrel; capturing the metal braid 
between the two.
Step 15.Screw and tighten the squeeze nut  onto the gland body as shown. 
You are now ready to prepare the cable ends for connection to the bulkhead box’s 
internal terminal blocks and connectors. Refer to the Voyager III bulkhead box 
description in the ICD.
Note: All trim lengths are terminated wire lengths—the wire and the specific 
termination are included in the length. 
Install the Main Sensor Cable
Step 1.Spread apart the individual wire bundles to make them easier to identify 
and work with. Cut and terminate the cables to the lengths as defined in 
the Voyager III bulkhead box description in the ICD.
Step 2.Ethernet cable —Terminate to RJ45 connector per TIA/EIA-568B 
standard. If you are unsure how to terminate this type of connector, 
contact FLIR for additional information.
Step 3.Video cables —Two RG-179 video cables terminate to crimpable 75 ohm 
BNC connectors (provided). If you are unsure how to terminate this type 
of connector, contact FLIR  for additional information.
Step 4.Relabel the video cables using flag-type labels: 
Video 1 becomes Primary Video In
Video 2 becomes  Secondary Video In
Step 5.System power and pan/tilt power —Four twisted pairs terminate to 
terminal block J5. 
Step 6.Communication ports —Six conductor (five are used) with braid 
terminate to terminal block J6. 
						

							Electrical Connections
16432-0005-00-12 Rev 100 — Voyager III Installation Guide 
Step 7.The wires for J5 and J6 will need to be prepared in a fashion similar to 
the following progression. Carefully meas ure, cut, and strip each wire as 
described in the Voyager III bulkhead box description in the ICD. 
Slide the outer insulation off. 
Separate the inner wires.
When this is done, they are ready for termination to the terminal block 
plugs for J5 and J6.
Note: You can terminate the wires at J5 and J6 after the cable is installed into 
the bulkhead box to increase the clearance around the cable leads while 
inserting them into the bulkhead box. 
						

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Electrical Connections
Step 8.The finished cable, shown below, has the RJ45 connector, two BNC video 
connectors, and all other leads termi nated at the terminal block plugs.
Step 9.Carefully slide all of the prepared 
wires and the video cables through 
the hole in the bulkhead box. 
Step 10.Slide the locknut over the wires 
and tighten to secure the cable 
gland seal to the bulkhead box.
Step 11.If you have not done so already, 
connect the wires from the main 
sensor cable to the terminal block plugs at J5 and J6. 
Step 12.Make the following connections: 
The Ethernet plug to E1
Primary Video In to J9
Secondary Video In to J10
Refer to the ICD for details of the bulkhead box connections or review the 
following graphic (also inside the cover door of the bulkhead box) for a 
color-coded guide.
Terminated Main Sensor Cable
J5
J6
BNC VideoRJ45
Install heat shrink tubing as shown.  
						

							Electrical Connections
18432-0005-00-12 Rev 100 — Voyager III Installation Guide 
Note:Use the Video Tracker PCB, PN 250-0404-00, at connector J7 if the 
Video Tracker module is removed from the bulkhead box for service or repair and 
you want to continue using the camera system without it. The PCB is provided in 
a separate bag in the bulkhead box.