Flir ThermovisionMDSeries Installation Manual
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432-0010-00-12 Rev 100 — MD-Series Installation Guide 9 Installing MD-Series Systems Installation Planning Caution: The installation requires some fam iliarity with electrical connections, cabling, sealing, and proper mounting practices. If you do not have this background, consider having the MD-Series camera installed professionally. In addition, there are several choices in how the camera is mounted and cabled. If the more complex installation options are used, such as mounting from the top and creating cable connections within the ca mera dome, it is especially important to have professional assistance. Installation Options There are several options for installing and using the MD-Series camera that affect the complexity of the installation and the steps required. • One set of options relates to the posi tion of the cable connections: inside or outside the camera dome. • The other has to do with how the camera is mounted: with mounting bolts coming up from beneath or down from the top of the mounting plate. The most straightforward approach, and the one that is recommended, is to install the camera with bolts from below and the cables connected outside the dome. This configuration is ideal if the vessel has a simple cover such as a T-top. The cables can be tied back as needed. Altern atively it is possible to install the camera from above on the superstructure or hardtop of a vessel. In either location, it is also possib le to configure the cable connections within the camera dome. Doing this requires a number of additional steps. External or Internal Connections As delivered, the cables on the MD-Series camera extend through the base (shown on left). It is a simple, straightforward process to connect these cables to the supplied longer cables. Optionally, as shown in the right-hand picture, the connections can be made within the camera dome by bringing the longer cables up through the base and making the required interior cable connections. Mounting Bolt Direction Generally the MD-Series camera is secure d directly to a surface using threaded studs that extend from the base through the mounting platform and that are secured from below. If it is not possible to access the space below the mounting platform, the camera can also be mount ed in a similar top-down fashion by drilling through the base in four predetermined lo cations, mounting it directly to the surface. When using this method, it is necessary to seal around the fasteners using a marine grade sealant (3M 4200 or equivalent) to prevent leakage into the mounting structure. Internal Connections External Connections
Installing MD-Series Systems 10432-0010-00-12 Rev 100 — MD-Series Installation Guide Ball-Up and Ball-Down Installation In most installations, the MD-Series camera unit is mounted upright (ball up) on top of a mounting surface, with the base below the camera. Optionally, the unit can be hung upside down or ball down and configured to invert and revert the video output by selecting Enable Ball-Down Installation under System Settings of the camera on-screen menu system. See the MD-Series Operator’s Manual for details. Unless otherwise noted, this manual assumes an upright installation. Location Considerations It is important to determine a good location for mounting the MD-Series camera unit. The camera requires two connections: • One for power and camera control • One for the video display When determining the location, consider how the system may be expanded in the future. Optionally, either a JCU or wireless device can be used to control the camera and more than one display can be used to view the video. These are important points to consider when determining the camera location: • Make sure the mounting location is le vel and is at least as large as the footprint of the camera. To ensure a proper seal between the camera unit and the vessel, an O-ring is installed in the camera base, which will seal properly with a surface that is flat to within 0.25 mm (0.010 in) over the diameter of the base of the camera. Use a short straight edge such as a six-inch ruler to confirm the surface is flat and the edge makes contact along the entire surface. Note: 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. • Make sure the camera is placed close enough to the mounting edge that the camera field of view is not obstructed by the platform. This is especially important if the camera will be tilted downward. • Mount the MD-Series camera body 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. It is good practice to test the unit at the planned installation location with typical vessel electronics active prior to mounting the camera. • Ensure a clearance of at least double the overall height of the camera in order to allow for dome removal. • To maintain situational awareness, a good general practice is to mount the camera so that a small portion of the ve ssel is visible at the bottom of the video image as a reference point and that no more that 30% sky is visible in the video image. Upside Down (Ball Down)
432-0010-00-12 Rev 100 — MD-Series Installation Guide 11 Installing MD-Series Systems • Ensure the camera mount is suitable for the camera mass and that potential vibration and mechanical shock is mini mized. The camera is tested to hold position for mechanical shock up to 9g transverse and 15g vertical. Improper mounts that are loose and/or resonate can magnify vessel impacts causing the camera to be unable to maintain pointing direction. • Consider the camera’s location relative to other navigation devices. If a magnetic compass is used for navigation and direction, establish a “compass safe distance” for any object placed in its vicinity, especially any electronic equipment. The magnetic compass safe distance for the camera is 7 cm (2.75 in) and for the PoE inject or is 11 cm (4.33 in). • Verify that both sides of the mounting surface are accessible. • Consider the thickness of the mounting platform. With the supplied hardware, the camera can be mounted to a platform that is up to 41 mm (1.6”) thick. Depending on the thickness of the mounting platform, it may be necessary to provide other mounting hardware, rather than using the supplied threaded studs and nylock nuts and acorn nuts. • Ensure the supplied coaxial and Ethernet cables are long enough, given the proposed mounting locations and cable routing requirements. It is a good idea to route the cables before beginning the physical installation to verify correct length. Camera Settings The MD-Series has a number of settings that can be tailored using on-screen menus. These settings are fully described in the MD-Series Operator’s Manual. To change the system settings requires the use of a wireless device, a direct connection with a PC, or the installation of an optional JCU. If one of these is not available on the vessel when the came ra will be used, consider setting up the camera at the time of installation. For example, connect a PC or laptop to the camera’s Ethernet connection 1. Then it will be possible to make any setup changes from the PC a web browser. Proper Grounding As part of the installation, ensure the ca mera is properly grounded. Following best grounding practices, the camera chassis gr ound should use the lowest resistance path possible. A dedicated stud located on the bottom of the MD-Series near the cable egress points provides chassis ground for a hi gh conductivity path to vessel ground (maximum 0.25 Ohm). The installer must provide the grounding strap and ring terminal for the connection. A nylock nut is provided to secure the strap. The ring terminal is typically sized for #6 or M3 stud and 14 to 16 gauge wire. If using a 1 Connect the camera to the end of the PoE injector with the warning and then connect an Ethernet cable from the othe r end of the PoE injector to a PC or laptop. Connect DC power to the PoE injector’s terminal block.
Installing MD-Series Systems 12432-0010-00-12 Rev 100 — MD-Series Installation Guide different ring terminal, make sure that its size does not interfere with the camera mounting. Failure to provide this connection may result in electrical interference between the camera and other shipboard electr onic 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. Physical Installation When shipped from the factory, the MD-Series camera has two cables that extend through the base. • The teal cable is to be connected to the supplied 25-foot Ethernet cable using the supplied RJ45 waterproof coupler. • The black cable is to be connected to the 25-foot coaxial cable using the suppled F-type female-to-female connector. 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. The complete installation of the MD-Ser ies camera follows a series of steps: 1.Remove the camera dome so that the camera is accessible 2.Attach the grounding strap and mount the camera in the chosen location 3.Route the camera cables without tighteni ng the cable glands in the base. This can be done with the connections ou tside the camera dome (simpler approach) or inside the dome. The MD-Series ICD contains a drawing representing the two approaches 4.Complete the electrical connections using the supplied PoE injector and observe the video on a monitor Dedicated grounding stud with nut
432-0010-00-12 Rev 100 — MD-Series Installation Guide 13 Installing MD-Series Systems 5.Adjust the pan/tilt position of the camera if needed and tighten the cable glands in the base 6.Replace the camera dome Important : Use a thread-locking compound such as Loctite 242 or equivalent with all metal-to-metal threaded connections. Remove the Camera Unit Dome 1.Place both thumbs on the ball front near th e top of the opening and grip firmly around the dome 2.Push down on the ball front with both thumbs while pulling up on the dome 3.Once the dome is detached, gently slide it up and off the camera Mount the Camera Unit The camera unit can be mounted from the bottom, which is the recommended approach because it is the most straightforward. If necessary, it is possible to mount it from above by drilling holes in the base plate. Both approaches are described in this section. Prior to cutting or 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. Caution: Please be aware of these cautions: • When installing the camera, do not tighten fasteners in the threaded holes so far that they contact the bottom of the threaded hole. Maximum insertion should not exceed 6 mm (0.24 in), and torque should not exceed 9.5 N·m (7 lbf· ft). • The F-type connector terminating the video cable on the camera is not a sealed connection; therefore, appropriate sealing steps are needed to protect the connection and the camera. • Before drilling holes, ensure the steps out lined in the planning section (starting on page 10) have been followed. For example, it is important to test the unit at the planned installation location, with the typical vessel electronics active, prior to mounting the camera. Mounting the Camera from the Bottom 1.Using the mounting templa te supplied with the camera (and part of the MD-Series ICD) as a guide, mark the location of the holes for mounting the camera. Also mark the location for the cable port holes. Make sure the template is oriented proper ly relative to the bow of the vessel. If the template is printed, be sure it is printed to scale so the dimensions are correct.
Installing MD-Series Systems 14432-0010-00-12 Rev 100 — MD-Series Installation Guide 2.Drill the 4 holes for the mounting studs using a 6.4-mm diameter drill. Also drill the appropriate cable port holes. 3.After the holes are drilled in the mounting surface, install the four threaded studs into the base of the camera with thread-locking compound. 4.Install the rubber O-ring in the groove in the base of the camera. 5.Pull the supplied grounding cable up through the cable access port and attach it to the grounding stud on the base of the camera using a user- supplied ring terminal. 6.The next step depends on whether the cables are connected externally or internally: External Connection : Thread the video and Ethernet cables from the camera through the cable port. Internal Connection: Loosen the light grey capture nuts on both of the cable glands in the base.Use a wr ench if they are tight. Pull the rubber glands and clamping claws out of the threaded counter bores. Pull both cables completely up through the base. Slip the rubber gland, clamping claw and capture nut off each cable and set them aside. 7.Place the camera on the mounting surface so the threaded studs extend through the drilled holes. 8.Secure the camera body to the mounting surface with the supplied nuts and washers. Install stud in 4 locations Insert 0-ring in the groove Attach grounding cable 2 capture nuts on base Capture nut Rubber gland Clamping Claw
432-0010-00-12 Rev 100 — MD-Series Installation Guide 15 Installing MD-Series Systems Note:As needed, the threaded studs can be replaced with studs of a different length or cut to a shorter length. Continue with “Route Camera Cables” on page 16. Mounting the Camera from the Top 1.Loosen the light grey capture nuts on both of the cable glands in the base, using a wrench to loosen them if necessary. Pull the rubber glands and clamping claws out of the threaded counte r bores, leaving them on the cable. Pull both cables completely up through the base. (See the picture for step 6. in the previous section.) 2.Using a 10-mm wrench, comp letely loosen the self-locking M6 bolt in the center of the camera bracket in order to detach the base from the rest of the camera assembly. Make sure to place the bolt, washer, and thrust washer in a safe place for reuse once the base is properly mounted. Caution : Do not detach the grounding c able since doing so will adversely affect its seal. 3.Use the pilot locations in the base to drill clearance holes for the 4 required mounting fasteners. The ex act fasteners to use will vary depending on the mounting surface. Maximum major diameter is 6.5 mm. Maximum head diameter is 13 mm. Loosen this bolt to remove camera from base Drill holes using the 4 pilot locations in the top of the base
Installing MD-Series Systems 16432-0010-00-12 Rev 100 — MD-Series Installation Guide Ensure that the size of the clearance holes accommodates the tolerance associated with hand drilling, bolt patterns, and fastener tolerances. 4.Using the mounting template supplied with the camera (and part of the MD-Series ICD) as a guide, mark the location of the holes for mounting the camera. The base itself can also be used as a guide. Make sure the template is oriented properly relative to the bow of the vessel. If the template is printed, be sure it is printed to scale so the dimensions are correct. 5.In addition to the four mounting holes, drill the appropriate cable port holes using the template as a guide. 6.Install the rubber O-ring in the base of the camera. 7.After the holes are drilled in the mounting surface, secure the base to the mounting surface with the required fasteners. Seal around fastener heads using marine grade sealant (3M 4200 or equivalent). 8.Using the M6 bolt, washer, and thrust washer, reattach the camera to the base. 9.If connecting cables externally, rethread the video and Ethernet cables through the counter bores and through the cable port, making sure the rubber cable gland and clamping claw fit properly. If connecting cables internally, leave the cables as they are, refer to “Connect Cables Internally” on page 19 and skip the next step. 10.Loosely tighten the light grey capture nuts at the base. Make sure to support the cable so it is perpendicular to the base. The nuts will be tightened completely after any needed mechanical adjustments are made to the camera pan and tilt (see page 24). Route Camera Cables There are two options for routing the camera cables: • The simplest and most straightforward is to route the cables through the two cable glands in the base and connect the camera cables externally to the extended 25-foot cables. In this case the connections are visible. • Optionally make the connections withi n the camera by routing the longer cables through the two base cable glands. In this case the connections are hidden inside the dome cover. Caution: It is recommended that any built-up triboelectric charge on the Ethernet cable be discharged before connecting it to the camera. This can be accomplished simply by pressing an ungl oved finger across the Ethernet RJ45 coupler of the cable for a few seconds.
432-0010-00-12 Rev 100 — MD-Series Installation Guide 17 Installing MD-Series Systems Connect Cables Externally Leave the cables as installed from the factory and make connections outside the camera unit, as shown in this diagram. This is the simplest way to install the camera and is the recommended approach. Step 1 : Connect the Ethernet Cables (Teal and Grey) In this step, connect the camera’s Ethern et cable to one end of the supplied RJ45 coupler. Then connect the supplied 25-foot Ethernet cable to the other end. The two ends of the RJ45 coupler are different, but if using the supplied cable, connect either of the cables to either ends. The complete coupler is shown below on the left. On the right, the coupler is fully disassembled showing all components. Caution: The Ethernet clamping claw is delicate; treat it gently so that no prongs are broken 1.Connect the teal Ethernet cable to the RJ45 coupler using these steps: a.Remove the dark grey capture nut, gland, and claw from one end of the RJ45 coupler. b.Thread the teal cable through the dark grey capture nut, followed by the dark grey claw. Then wrap the cable gland around the cable. Seat the clamping claw over the gland. c.Insert the end of the cable into the end receptor in the coupler. This picture shows the sequence of pieces on the cable. d.Bring the capture nut up to the coupler and tighten it. 2.Then connect the 25-foot Ethernet cabl e to the other end of RJ45 coupler: Capture nut Rubber gland Clamping ClawCircular gasket Assembled RJ45 Coupler
Installing MD-Series Systems 18432-0010-00-12 Rev 100 — MD-Series Installation Guide a.Remove the rubber boot from the end of the Ethernet cable using a cutter. It will not seal correctly with the rubber boot in place. Caution: Be careful not to cut any part of the Ethernet cable when removing the rubber boot to ensure the enclosure seal is not compromised. b.Remove the dark grey capture nut, clamping claw, and gland from the other end of the RJ45 coupler. c.Thread the 25-foot Ethernet cable through dark grey capture nut, followed by the dark grey claw. Then wrap the cable gland around the cable. Seat the clamping claw over the gland. d.Insert the end of the 25-foot Ethernet cable into the receptor in the coupler until it snaps into place. Caution : Be careful to minimize any tw isting in the cable to prevent communication failure. e.Bring the capture nut up to the coupler and tighten it. f.Pull down on the cable at the camera base to reduce slack for dome clearance. g.Loosely tighten the light grey capture nut at the base. Make sure to support the cable so it is perp endicular to the base. The nut will be tightened completely after any needed mechanical adjustments are made to the camera pan and tilt (see page 24). If no further adjustments are needed, hand tighten the capture nut and then make an additional 1/4 turn with a wrench. Step 2 : Connect the Video Cables (Black) Connect the video cable from the camera to the 25-foot video cable using the supplied female-to-female connector. Then seal the connection with marine grade sealing tape and electrical tape. 1.Thread the female-to-female connector into the end of the camera’s video cable with a 7/16 inch wrench. Important : Be sure to apply thread locker to the F-type connectors. 2.Attach the 25-foot coaxial cable to the other end of the connector after applying thread locker so that it looks like the picture below. Female-to-Female Connector