ReaperSD Assembly Instructions
ReaperSD Assembly Instructions
Vigilant Solutions
Date: 08/19/2016
Version: 2.2
D3 Engineering, LLC
1057 E. Henrietta Rd
Rochester, NY 14623
p. 585.429.1550
f. 585.429.1551
www.d3engineering.com
1057 E. Henrietta Rd
Rochester, NY 14623
Phone: 585.429.1550
Fax:
585.429.1551
www.d3engineering.com
Table of Contents
Purpose............................................................................................................................................ 3
Illumination board assembly........................................................................................................... 3
IR Camera Assembly ...................................................................................................................... 4
Overview Camera Assembly .......................................................................................................... 5
POE Flex Potting Instructions ........................................................................................................ 7
Back Cover Assembly..................................................................................................................... 8
Front Cover Assembly .................................................................................................................. 12
Tray Assembly .............................................................................................................................. 14
Final Assembly ............................................................................................................................. 21
Revision History ........................................................................................................................... 25
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Purpose
This document is intended to present the instructions to assemble a complete ReaperSD unit.
Note 1: It is essential for all stainless steel screws used in this assembly that come in contact with
a thread locker be prepped with Loctite 7471 Primer and allowed to dry prior to assembly. It is
suggested that ALL hardware that comes in contact with a thread locker be prepped with the
primer.
Note 2: A table showing the torque specifications for the fasteners used in this assembly can be
found in the Appendix at the end of this document.
Illumination board assembly
Note 1: These instructions are interchangeable with the following drawings:
VSR-20-303_Assembly_Illumination_6_Degree-04
VSR-20-304_Assembly_Illumination_15_Degree-04
VSR-23-303_Assembly_Illumination_7_Degree_940nm-01
VSR-23-304_Assembly_Illumination_15_Degree_940nm-01
VSR-24-303_Assembly_Illumination_7_Degree_740nm-01
VSR-24-304_Assembly_Illumination_15_Degree_740nm-01
1.) Verify the board area around the LEDs is clean and free of any substance that would
interfere with securing Lens, LED (VSR-20-227 or similar) to Illumination Board
Assembly (VSR-24-222 or similar).
2.) Remove adhesive backer from Lens, LED (VSR-20-227)
3.) Place Lens, LED (VSR-20-227) centered over LEDs and within the silk screened Lens
guide circle.
4.) Ensure that Lens, LED (VSR-20-227) is in full contact with the PCB board.
5.) Apply Loctite 4311 UV adhesive to form a fillet between each Lens, LED (VSR-20-227)
and the PCB board in at least 2 places. In some cases it may make sense to install
multiple lens if not all lenses prior to applying the adhesive.
6.) Cure Loctite 4311 UV adhesive using the data sheets recommendations for cure time.
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IR Camera Assembly
Note 1: These instructions reference drawing:
VSR-20-305_Assembly_Camera_IR-04
VSR-23-305_Assembly_Camera_IR_940nm-01
VSR-24-305_Assembly_Camera_IR_740nm-01
Note 2: Handle the IR Filter with either soft tip or wood tweezers throughout this process to
prevent scratching.
Note 3: Ensure that any protective film that is on the IR sensor is removed before beginning this
process. The sensors may or may not have protective film.
1.) Clean IR Filter and the sensor on Assembly, IR Sensor Board (VSR-20-212) with
optical cleaner and lint free fabric.
2.) Place Assembly, IR Sensor Board (VSR-20-212) so that it lies flat, with the sensor
facing up.
3.) Place IR Filter on the sensor so that it is centered on the active imaging array.
4.) Use the tweezers to place pressure on IR Filter pushing it down on the image sensor.
Carefully place Loctite 3972 adhesive on the 4 corners of IR Filter adhering it to
Assembly, IR Sensor Board (VSR-20-212).
a. Ensure that the adhesive does not penetrate between the filter and the sensor.
5.) While maintaining the pressure on IR Filter, cure the adhesive.
a. Refer to the Loctite 3972 data sheet for curing time.
b. Do not start Step 8 before curing is complete.
6.) Evaluate Bracket, Camera Mount (VSR-20-042) for any burrs that would have an
adverse effect on camera alignment. Reject part if such a condition is found.
7.) Connect Mounting, Ring, CS (VSR-20-007) to Bracket, Camera Mount (VSR-20042) using FHMS, M1.6x5 (VSR-20-505). Apply Loctite 222MS to all three screws.
8.) Place Shield, Light, IR (VSR-20-014) over the four standoffs on Bracket, Camera
Mount (VSR-20-042).
9.) Screw Assembly, IR Sensor Board (VSR-20-212) onto Bracket, Camera Mount
(VSR-20-042) using Screw, SEMS, PHMS, M3x12 (VSR-20-513). Apply Loctite 243
to all four screws.
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Overview Camera Assembly
Note 1: These instructions reference drawing:
VSR-20-306_Assembly_Camera_Overview-04.
Note 2: Ensure that any protective film that is on the Overview sensor is removed before
beginning this process. The sensors may or may not have protective film.
1.) Clean NOTCH Filter and the sensor on Assembly, Overview Sensor Board (VSR-20214) with optical cleaner and lint free fabric.
2.) Place Assembly, Overview Sensor Board (VSR-20-214) so that it lies flat, with the
sensor facing up.
3.) Place NOTCH Filter on the sensor so that it is centered on the active imaging array.
4.) Use the tweezers to place pressure on NOTCH Filter pushing it down on the image
sensor. Carefully place Loctite 3972 adhesive on the 4 corners of NOTCH Filter
adhering it to Assembly, Overview Sensor Board (VSR-20-214).
a. Ensure that the adhesive does not penetrate between the filter and the sensor.
5.) While maintaining the pressure on NOTCH Filter, cure the adhesive.
a. Refer to the Loctite 3972 data sheet for curing time.
b. Do not start Step 10 before curing is complete.
6.) Evaluate Bracket, Camera Mount (VSR-20-042) for any burrs that would have an
adverse effect on camera alignment. Reject part if such a condition is found.
7.) Connect Mount, Ring, CS (VSR-20-007) to Bracket, Camera Mount (VSR-20-042)
using FHMS, M1.6x5 (VSR-20-505). Apply Loctite 222MS to all three screws.
8.) Place Shield, Light, Overview (VSR-20-013) Shield, Light, IR (VSR-20-014) over the
four standoffs on Bracket, Camera Mount (VSR-20-042). Make sure the angled
corners of the light shield are on the top of the bracket as shown.
9.) Screw Day Night Exchanger (VSR-20-226) onto Assembly, Overview Sensor Board
(VSR-20-214) using Screw, M2x5mm, SHCS (VSR-20-519). Do no strip the holes in
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Day Night Exchanger (VSR-20-226). Tighten screws until snug and Day Night
Exchanger (VSR-20-226) is flush with Assembly, Overview Sensor Board (VSR-20214) at both locations.
10.) Screw Assembly, Overview Sensor Board (VSR-20-214) onto Bracket, Camera
Mount (VSR-20-042) using Screw, SEMS, PHMS, M3x12 (VSR-20-513). Apply
Loctite 243 to all four screws.
11.) Apply a drop of Loctite 3972 or 4311 over the heads of each Screw, M2x5mm, SHCS
(VSR-20-519) to secure it to Assembly, Overview Sensor Board (VSR-20-214) and
cure using a UV cure station per the appropriate adhesive Data Sheet.
12.) Apply a drop of Loctite 3972 or 4311 to the back of Assembly, Overview Sensor Board
(VSR-20-214) near the serial number to secure the wire from Day Night Exchanger
(VSR-20-226) in place and cure per Data Sheet.
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POE Flex Potting Instructions
Note 1: These instructions reference drawing:
VSR-20-206_Assembly_Cable_Flex_Ethernet_POE-03
1.) Fill a syringe with Tough Seal 22 potting compound.
2.) Attach a dispensing needle to the syringe.
3.) Stick the tip of the dispensing needle into the bottom of one of the “quadrants” in the
opening in the back of Assembly, POE Flex (VSR-20-206).
4.) Slowly dispense the potting compound into the quadrant until you see the compound
reach the top of the opening.
5.) Remove the dispensing needle and repeat steps 3 and 4 for the remaining three quadrants.
6.) Once all four openings have been filled with the potting compound set the connector
upright to allow the compound to cure.
7.) After 5 minutes flip the connector over and place it in an oven set at 70˚C for an hour.
After an hour the compound has reached 90-95% of its maximum hardness.
8.) Remove from the oven and let cool.
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Back Cover Assembly
Note 1: These instructions reference drawing:
VSR-2N-9ab_ReaperSD-07.
Note: An alternate STOP Valve (VSR-20-535) has been approved for use in ReaperSD systems.
This valve is an manufactured to accurately fit the ¼” NPT hole in the rear end cap without the
use of supplemental Teflon tape (the threads are precoated with Teflon). For further information,
see the approved alternates list.
1.) When using STOP, VALVE (VVR-10-514) it is required to apply Teflon tape to the
threads. VVR-10-514 comes with a coating on the thread already, but that has shown to
be insufficient at times. Apply the tape over the same area as the coated threads.
Standard plumbers Teflon tape is adequate. When reinstalling either STOP, VALVE it is
suggested to apply Teflon tape.
2.) Screw STOP, VALVE (VVR-10-514) or STOP, VALVE (VSR-20-535) into REAR,
ENDCAP, PV (VVR-10-017) by first tightening with finger and then tightening with
wrench three full turns. Do not over tighten. Also, take care not to scratch the black
coating of the end cap.
3.) Place Tubing, Shrink, .75 x 19mm L (VSR-20-029) over STOP, VALVE (VVR-10514). Apply heat to shrink tubing over the valve.
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4.) Place CONN, GASKET (VVR-10-028) into the slot on REAR, ENDCAP, PV (VVR10-017) and screw in Plate, Connector Mount (VSR-20-040) using
M3x6_SEMS_PHMS (VVR-10-503).
a. DO NOT fully tighten the screws. This will compress the gasket and will cause
issues later when mounting Assembly, POE Flex (VSR-20-206).
5.) Remove the nut from Assembly, POE Flex (VSR-20-206), if not done already. Ensure
that the O-ring gasket on Assembly, POE Flex (VSR-20-206) does not fall off and is
seated at the base of the connector.
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6.) Push Assembly, POE Flex (VSR-20-206) through the opening on the Back Cover
Assembly. Make sure the contacts point up in the direction shown below. Apply Loctite
243 to threads and screw on the nut to 22-26 in-lbs.
7.) Place EXTRUSION, SEAL (VVR-10-014) over REAR, ENDCAP, PV (VVR-10-017)
around the inside edge.
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Front Cover Assembly
Note 1: These instructions reference drawing VSR-2N-9ab_ReaperSD-07.
1.) Lay FRONT, ENDCAP (VVR-10-002) on a flat surface, face down.
2.) If using VVR-10-004-13, install VSR-20-070 into FRONT, ENDCAP (VVR-10-002).
Do not install if using VVR-10-004-12.
3.) Place WINDOW, SEAL (VVR-10-005) into FRONT, ENDCAP (VVR-10-002).
4.) Remove the film from both sides of WINDOW (VVR-10-004) and place it inside
FRONT, ENDCAP (VVR-10-002)/ WINDOW, SEAL (VVR-10-005). Take care to
make sure no debris is stuck to the side of the window that will be inside the enclosure.
Blow off debris with compressed air if necessary.
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5.) Place EXTRUSION, SEAL (VVR-10-014) over FRONT, ENDCAP (VVR-10-002)
and WINDOW (VVR-10-004) around the edge.
a. Make sure the seal is pushed down fully around the window, especially in the
corners.
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Tray Assembly
Note 1: These instructions reference drawing:
VSR-2N-9ab_ReaperSD-07.
1.) Place Thermal Pad, Illuminator (VSR-20-020) on to the back of the Assembly,
Illumination X Degree (VSR-20-303/4). Align holes in the thermal pad with holes in
Assembly, Illumination X Degree (VSR-20-303/4).
2.) Connect Cable, LED Control (VSR-20-208) and Cable, Power, Illuminator (VSR-20224) to Assembly, Illumination X Degree (VSR-20-303/4).
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3.) Attach Assembly, Illumination X Degree (VSR-20-303/4) to the Tray, Electronics
(VSR-20-041) with the M2x10 PPMS Screws (VSR-20-527). Apply Loctite 243 to the
two screws before assembly. Route the connected cables through the openings in the tray.
a. Use calipers or reference object to measure the distance from the front of the tray
to the top surface of the illumination board at both lower corners. Adjust to
4.7mm +/- 0.1.
4.) Secure LIGHT, SHIELD (VVR-10-021) to Tray, Electronics (VSR-20-041) on the
inside of both lens openings as shown below, using Loctite 454 Ensure that the curve fits
into the profile established by the tray. The light shields should protrude out 1mm PAST
the front of the LED lenses to ensure that light does not leak into the lens and produce the
“halo” effect.
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5.) Place IR, Cut, Filter (VVR-10-029) inside IR, FILTER, HOLDER (VVR-10-027).
6.) Slide SENSOR, HOUSING (VVR-10-511) retaining ring over Harness, ALS (VSR-20230).
7.) Route sensor end of Harness, ALS (VSR-20-230) through the opening in Tray,
Electronics (VSR-20-041) from the back side.
8.) Slide SENSOR, HOUSING (VVR-10-511) over sensor end of Harness, ALS (VSR-20230).
9.) Push assembled SENSOR, HOUSING (VVR-10-511) through the opening in Tray,
Electronics (VSR-20-041) from the front of tray and install SENSOR, HOUSING
(VVR-10-511) ring on the backside.
10.) Install assembled IR, FILTER, HOLDER (VVR-10-027) into opening in Tray,
Electronics (VSR-20-041).
11.) Attach Lens to Camera Assemblies referencing the System Configuration table, apply
Loctite 243 to the threads of the Overview Len and IR Len and screw them into the
Mount, Ring, CS (VSR-20-007) on each camera assembly.
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12.) Once the lenses have had their apertures set and have been focused, apply a line of
Loctite 4311 between the lens barrel and the Mount, Ring, CS (VSR-20-007) on both the
top and bottom to lock them into the correct position. Cure per data sheet.
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13.) Attach assembled cameras (IR Camera Assembly, IR Lens and Assembly, Overview
Camera (VSR-20-306), Overview Lens) to Tray, Electronics (VSR-20-041) using
Washer, Flat, M3 (VSR-20-305) and Screw, M3x4, SHCS per the
REAPER_SD_SYSTEM_CONFIGURATION_TABLE_(9ab Series) for the model
being assembled. Reference the picture below for camera positioning.
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a. Do not secure the screws completely. The camera positions will need to be
adjusted during the alignment process. Wait to apply Loctite until ready to
perform alignment.
14.) Attach Thermal Pad (VSR-20-015) to the processor on Processor Board (VSR-20204). The sticky side of Thermal Pad (VSR-20-015) should be placed on the processor.
15.) Mate Interface Board (VSR-20-202) to Processor Board (VSR-20-204).
16.) Attach the mated board stack (Interface Board (VSR-20-202) and Processor Board
(VSR-20-204) to Tray, Electronics (VSR-20-041) using Washer, M3, External Tooth
(VSR-20-517) and PPHS, M3x0.5 x 20 (VSR-20-502). Apply Loctite 243 to all six
threads on the tray.
a. Tighten the six screws down to the appropriate torque specification by following a
crisscross pattern. Don’t tighten adjacent screws in order to prevent deformation
of the tray.
b. Suggested method would be to tighten the screws in the following order: Upper
right, lower left, middle right, middle left, lower right, upper left.
17.) Route Cable, LED Control (VSR-20-208) such that it can be brought up between the
board stack and the overview camera with minimal stress.
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18.) Make the following cable connections to Interface Board (VSR-20-202) (reference
connection diagram):
c. Cable, LED Control (VSR-20-208) → Interface Board (VSR-20-202) J11
d. Cable, Power, Illuminator (VSR-20-224) → Interface Board (VSR-20-202)
J10
e. DNE Cable (from Assembly, Overview Camera (VSR-20-306) → Interface
Board (VSR-20-202) J16
f. Harness, ALS (VSR-20-230) → Interface Board (VSR-20-202) J8.
19.) Use Cable, Flex, 40 Cond. (VSR-20-232) to connect IR Camera Assembly and
Assembly, Overview Camera (VSR-20-306) to Interface Board (VSR-20-202) J6 and
J7 respectively. Reference the photos below for the orientation of the cable contacts, and
reference the connection diagram for further information.
20.) Go through the alignment procedure for the cameras. Apply Loctite 243 to screws just
before beginning the alignment process. Tighten down the screws (Screw, M3x4, SHCS
(VSR-20-515)) to secure the cameras to the tray once aligned.
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Final Assembly
Note 1: These instructions reference drawing VSR-2N-9ab_ReaperSD-07.
1.) Place Wedge-Lock, Retainer (VSR-20-044) onto each side of Tray, Electronics (VSR20-041)
NOTE: If substitute wedge-locks are being used that do not have the –P option in the
manufacturer part number (meaning the wedge locks do not have included locator pins),
you must locate the wedge locks on the holes on the tray and hold them in place. A
suggested method is to use tape and adhesive as shown in steps a-c below. These steps
can be skipped if the –P wedge locks specified in the BOM are used in this assembly.
a. Apply a few drops of Loctite 454 to the edges of the wedge locks to secure them
to the tray.
b. Ensure that the wedge locks are unscrewed enough to be placed completely flat
on the tray and the socket head end of the wedge lock is facing the back of the
tray as shown.
c. Remove tape and locator pins once adhesive begins to set.
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2.) Slide the tray into Extrusion, ReaperSD (VSR-20-038) until the tabs on the tray make
contact with the rails inside the enclosure and it can’t be moved any further.
a. Slide the back of the tray into the front of the enclosure. The front of the
enclosure is the end with the most gap between the ends of the rails and the outer
surface of the enclosure.
3.) Secure the tray inside the enclosure by tightening the screws on the wedge locks. Make
sure the lenses are flush with the front of the enclosure. Tighten evenly on each side by
switching back and forth between the two wedge locks. Be sure to tighten to the torque
spec provided in the appendix.
4.) Place the front of the assembled enclosure onto the Front Cover Assembly, ensuring that
the seal sits properly along the outer edge.
5.) Secure the Front Cover Assembly to Extrusion, ReaperSD (VSR-20-038) using M4SPLIT_LOCK_WASHER (VVR-10-506) and M4x12_SHCS (VVR-10-507).
a. Tighten screws incrementally in a circular pattern around the front cover to allow
the seal to compress evenly.
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6.) Carefully connect Assembly, POE Flex (VSR-20-206) to Interface Board (VSR-20202). The cable gets inserted with the tab fully up at 90 degrees, contacts down, until the
“T” shape in the cable gets past the catch points on the connector. Push the tab INWARD
(backwards) towards the center of the board to secure the cable. Handle back cover with
care through the next steps to ensure the cable does not twist or bend awkwardly.
Correct Seating of Cable
Incorrect Seating of Cable
7.) Place the Back Cover Assembly onto the back of the assembled enclosure ensuring that
the seal sits properly along the outer edge.
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8.) Secure the Back Cover Assembly onto Extrusion, ReaperSD (VSR-20-038) using M4SPLIT_LOCK_WASHER (VVR-10-506) and M4x12_SHCS (VVR-10-507).
a. Tighten screws incrementally in a crisscross pattern around the back cover to
allow the seal to compress evenly.
9.) Tighten all exterior nuts and screws to their torque specs.
10.) Place Label, Serial Number (VSR-20-046) and Label, Vigilant Logo (VSR-20-053)
onto the assembly with the top of the logo facing the back of the enclosure as shown
below.
11.) With camera securely in both hands vigorously shake camera for a few seconds.
a. If there is an audible sound coming from the camera then it needs to be checked
for loose parts.
b. Check the front window for any debris on the inside. If there is then the unit needs
to be opened and cleaned.
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Revision History
Rev 0.1 – Pre-Release 1
Rev 0.2 – Pre-Release, removed picture showing incorrect ALS connection
Rev 1.0 – 1/10/2014 significantly updated all sections after mini-production build. Added
several pictures
Rev 1.1 – Minor update to reflect current drawing revisions, changed spec on illumination
board screws from 4.6mm to 4.7mm +/- 0.1, added heat sink compound P/N, and changed
P/N for illumination board to tray screws.
Rev 1.2 – Added step of applying Teflon tape to VSR-10-514 in Back Cover Assembly
Rev 1.3 – Added photo of good/bad flex connection and optional method of gluing IR filter
Rev 1.4 – Updated instruction for light shield installation to extend 1mm past LEDs to reduce
halo effect.
Rev 1.5 – Removed steps for adding heat sink compound
Rev 1.6 – Added lens configuration information for VSR-20-xxx and VSR-21-xxx
Rev 1.7 – Fixed configuration information for VSR-21-xxx series
Rev 1.8 – Added information to match updated mechanical files (shims & tray rev 05)
Rev 1.9 – Made some references generic so they apply to all variants of the product.
Updated configuration table to add VSR-24 series.
Rev 2.0 – Pulled out lens configuration table and added a reference instead.
Rev 2.1 – Updated adhesives. Added illumination board assembly. Added shake test. Defined
cable connections more precisely. Added more detail and steps to the ALS assembly. Added
VSR-23 series.
Rev 2.2 – Remove all instructions for installation of Day Night Exchanger (VSR-20-226)
Add instructions for installation of NOTCH FILTER (VSR-20-033). Substituted Shield,
Light, IR (VSR-20-014) for Shield, Light, Overview (VSR-20-013) in VSR-20306_Assembly_Camera_Overview.
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APPENDIX
ReaperSD Fastener Torques
Screw
Torque (in-lbs)
M4x12mm SHCS
23-25
M1.6x5mm FHMS
0.5 (±0.01)
M2x5mm SHCS
Snug (See
instructions)
M3x12mm SEMS,
PHMS
7-8
M2x10mm PPMS
N/A (See
instructions)
M3x0.5 x 20mm
7-8
M3x4mm SHCS
7-8
Wedge Locks
Stop Valve
Nut on VSR-20-206
(PoE Flex Assembly)
M3x6 SEMS, PHMS
CONFIDENTIAL
6-8
N/A (Finger tighten,
then 3 full turns)
22-26
7-8
Thread
locker?
N/A
Loctite 7471
Loctite 222MS
Loctite 3972
or 4311
Loctite 7471
Loctite 243
Loctite 7471
Loctite 243
Loctite 7471
Loctite 243
Loctite 7471
Loctite 243
N/A
N/A
Loctite 7471
Loctite 243
N/A
- 26 Define • Design • Deploy
Location
Front and Rear end cap
CS Mount Ring to Camera Mount
Bracket
Overview sensor to DNE
IR, Overview sensors to Camera Mount
Bracket
Illumination board to Tray
Board stack to Tray
Camera Mount Bracket to Tray
Between Tray and Enclosure rails
Threaded hole in Rear End cap
Nut on PoE Flex Assembly that secures
VSR-20-206 to the Rear End cap
Connector Mount Plate to Rear End cap
CONFIDENTIAL
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