FLIR HS324 Commander / HM324 thermal camera teardown by Fraser

[Fraser]

I have given a good home to a FLIR HS324 Commander thermal camera. It is faulty and in need of my care 

The unit was incorrectly described as an HM324b XP+ in the auction but I can understand this error as they are a very similar specification.
The scope contains a TAU core providing the full 320 x 240 pixels resolution into a QVGA electronic viewfinder. Power is provided by four AA 2700mAh Sanyo Ni-MH cells mounted in the underside. Video output is made available via bottom mounted contacts and a dedicated 'hot shoe' that bolts on. The hot shoe also provides the battery charger function. A standard SD flash card is used to stores pictures and MP4 videos recorded with the thermal camera. A nice facility to have when observing wildlife.

The FLIR blurb claims that this unit was designed in co-operation with the police and security sector to ensure that it met their needs. The S in the HS designation means it is the security version. The M in the HM variant means it is the Maritime (Marine) version. there are minor differences between the two version firmware but they are both effectively the same unit.

FLIR made these cameras available in several version. There were lens options and the enablement of the SD card recording option. It was never a cheap camera and some users felt that the $1000 extra to enable the SD card port was greedy of FLIR.  My HS camera comes in the standard PATROL non SD card version and the Commander SD Card enabled version. I have the latter 

So what is wrong with my HS324 Commander ? Well it does power on and display it usual colour bar test screen but then it halts. Having researched the camera with FLIR, it is possible that teh TAU has crashed and needs to be reset. It is then loaded with a newer firmware that fixes the issue. If this is the case, the camera will be an easy repair as FLIR provide a special utility to reset the TAU to factory defaults.

These cameras are basically a TAU complete camera core that is controlled using RS232 from a controller board. The output of the TAU is available in analogue and digital formats and these are used to produce the EVF image and SD Card recordings via the controller board. The TAU has a colour bar mode that is deliberately selected at boot. If the TAU freezes at this point, the controller cannot instruct it to present the thermal image. This is possibly what my camera is doing. If the TAU has a more serious problem, it may not be viable to repair it and so the whole HS324 becomes an expensive paperweight.

I shall first provide some pictures of the HS324 Commander and then add the internal images when i have opened her up. Access into teh case appears to be via four screws in the bottom of the case.

Watch this space 

[Fraser]

Auxilliary lens mount. Note the classic TAU lens barrel is visible.

[Chanc3]

Looking great Fraser, let me know if you need to borrow my VPC module.

[Fraser]

OK its teardown time 

There are some surprises inside the HS324. It is a very different design to the PS/MS/LS series scopes.

Getting into the camera was more complex than expected. There are four machine screws in the bottom of the unit and four at each end of the camera securing the end plates. The end cap screws are covered by the rubber over boot that is held in place by waterproof double sided tape.

On with the show.........

[Fraser]

More pictures

[Fraser]

More Pictures

[Fraser]

The thermal camera core teardown........ not what was expected. This is effectively the majority of the HS324 functionality !

[Fraser]

More core pictures

[Fraser]

OK so there are the pictures, now a bit of a description to go with them.

The HS324 comprises a complete thermal camera module that includes a USB interface and SD card flash memory port. This module is connected to the keypad PCB that hosts the push buttons and power supply circuits. The Electronic Viewfinder driver is also present on this PCB. The EVF driver is the same KOPIN A210 used in the PS/MS and LS thermal scopes and produces a QVGA 320 x 240 pixel image on the tiny LCD display. There does not appear to be a microcontroller or processor on the PCB. This is very different to the PS/MS and LS scopes with their ARM processor.

The battery bay appeared to have to many wires connected to it for just a simple battery holder. Further investigation revealed that there are three temperature sensors installed. One on each battery linking plates. This is presumably to monitor cell temperature during charging. A surprisingly comprehensive temperature monitoring configuration that I had not expected for Ni-Mh chemistry cells.

The four bottom mounted contacts look to be decent quality. These terminals are for the charging supply input and the composite video output. A docking unit, called a 'hot shoe' by FLIR is attached the unit to connect to these bottom contacts. The hot shoe provides a conventional RCA socket for video and a standard power plug for the 12V 2A  power supply connection.

I was aware that the H series cameras do not have the neatest of interiors. i can confirm that the masses of black wires going to the battery bay, temperature sensors and I/O contacts is a little messy when compared to other cameras that use flexible ribbon cabled for such interconnections. It is functional though.

The problem in this camera is likely to reside in the camera module. I was unable to see the camera when connecting to the USB socket so it is not presenting the USB host with its ID. The colour bar test screen is being generated so there is some life in the module. It needs to be reset but that needs the USB port to be working, so a bit of a problem at the moment. A working camera module identifies itself as a TAU when communicating with the FLIR configuration software, so it is a repackaged TAU design. Very different to the TAU in my other unit though.

I will revisit this another day as I have other priorities at the moment, namely repairing the pile of ARGUS 2 thermal cameras.

Fraser

[Fraser]

Chance3,

Thanks for the offer of the VPC module.

As you will see in the pictures of the core, my unit has an integrated VPC module. Many thanks for the offer though.

For those unaware, the FLIR VPC module attaches to a standard TAU HIROSE connector and provides a USB and composite video output.

http://www.flirshop.com/product/tau-vpc-module/Tau320-Accessories

Fraser

[Fraser]

After an evening of testing it is with regret that I must report the Tau is Toast

The fault resides in the actual Tau camera core rather than one of the ancillary boards attached to its rear. It is generating a colour bar signal from its camera board but it is unresponsive to all attempts to communicate with it and the FFC shutter does not go through its tests at power on. For a Tau core that indicates a critical fault. With Tau cores costing several thousand dollars the HS324 becomes a write off.

You win some, you lose some.

Fraser

[amyk]

Have you tried scoping the sensor? That 20-pin connector looks... familiar

[Fraser]

Hi amyk,

I will be doing a deeper investigation into the TAU core later but presently have 21 thermal cameras to repair and refurbish so they come first. More on the TAU when time permits.

Fraser

[Fraser]

The investigation into the TAU core fault is to be found here:

https://www.eevblog.com/forum/thermal-imaging/thermal-camera-teardown-the-flir-tau-320-by-fraser/msg1002542/#msg1002542

I may be able to repair it. We shall see.

Fraser

[Fraser]

I have just managed to source the FLIR 'Hot Shoe' that was not provided with my unit. A quick look inside reveals that it is not a simp,e plastic enclosure with an LED plus sockets. It contains a PCB that is populated with filters and active components. Pictures will follow.

The Hot Shoe cost me £28 so I am glad I got more than a plastic box and some connectors for my money

The spare Hot Shoe is now a discontinued item. I guess they do not break easily ?

Fraser

[Fraser]

Internal pictures of the Hot Shoe.

I was impressed to find brass screw inserts used rather than cheap self tapping screws into plastic  The camera mount thread is also spring loaded. A nice touch.

Lots of inductors and a Texas Instruments INA201AIDGK current shunt monitor on the power supply input.

Part numbers on main SMD components:

KDL       Zener diode                   AZ23C18W  18V
561H     Transistor pack
BQJ       Current Shunt Monitor  INA201AIDGK
FA         Diode Pack

Fraser

[Fraser]

Hot Shoe PCB......

[Fraser]

OK, the functionality of the Hot Shoe revealed:

1. The Power supply /charging path

The power supply is plugged into the hot shoe and the camera begins to draw charging current via its internal charger circuit.
The Hot Shoe contains a current monitor IC connected across a 1 Ohm resistor that is in series with the power rail. With adequate current flowing, the current monitor drives the bi-colour LED red element. Once charging has completed and the current draw has dropped to the 'charged' threshold, the current monitor drives the bi-colour LED green element and switches off the red element. This circuit has no effect on, or communications with, the cameras internal charger circuit.

2. Video output

The camera presents a composite video output on its lower contacts. The output is fully buffered inside the camera but the Hot Shoe converts the contacts to the user friendly RCA connector and also provides some over-voltage/transient protection across the video lines.

The Hot Shoe is in fact pretty much a simple camera flat contact to connector converter with the added value of charge current monitoring, supply filtering and video output transient protection.

I am surprised it was only £28 though. FLIR accessories tend to be somewhat expensive !
I also managed to buy a new complete lens cap/bayonet mount assembly for £12.

Fraser

[Fraser]

In case anyone needs to know the charger spec that is used with this, and similar, cameras....

From the FLIR Support pages:

Can I use a car adaptor or external battery power pack to charge my handheld camera (Scout TS-Series, Scout BTS-Series, First Mate, H-Series, HF-Series, HS-Series, Guardsman, HG-Series, BH-Series, BHF-Series)?

The H-Series and BH-Series family of cameras come with an AC-to-DC power supply that connects to the camera through the hot-shoe and charges the included NiMH batteries.

An alternative power supply can be used as long as it meets the following specifications:

Output: 12 VDC, ~800 to 1000 mA

Connector Size: 5.5mm (Outside barrel) x 2.5mm (Inside Barrel)

Center: Positive.

[Fraser]

Just in case anyone finds this thread in the future and is looking for a replacement or spare Hot Shoe for their H series (HS HM TS) camera....

The Hot Shoe is now discontinued by FLIR as a spare part. I searched Europe for one and all dealers I contacted reported that they order them direct from FLIR on an as needed basis. I tried ordering through that route and the part was never despatched from FLIR. The order was cancelled after some months of waiting. It appears FLIR have no remaining stock.

Now the good news. I tracked down the last remaining stock of these Hot Shoes in the UK. I am now the holder of all that stock. I have just 3 spare Hot Shoes and they are available to buy from me, but sadly they will not be cheap. Obsolete items rarely are ! They are possibly the only stock to be found in Europe.

If you need one. PM me and we can discuss price and postage.

Fraser
11 March 2017

[Worsdier]

I own a FLIR HS324 without the SD card recording function enabled. Is there a known hack that allows this option to be enabled?

[Fraser]

Not that I am aware of

[Worsdier]

Cool, thanks for the reply.

[ir.ukrm]

Which batteries can I use here?

[Worsdier]

4x AA

[ir.ukrm]

What is the voltage?

[Worsdier]

What is the voltage?

4x 1.5V Alkaline or 4x 1.2V NiMH works

[ir.ukrm]

What is the voltage?

4x 1.5V Alkaline or 4x 1.2V NiMH works

What is the voltage for charging batteries?

[Fraser]

The camera is designed to accept standard Alkaline 1.5V cells or Ni-Mh 1.2V cells.

Alkaline cells are quickly consumed !

Fraser

[ir.ukrm]

The camera is designed to accept standard Alkaline 1.5V cells or Ni-Mh 1.2V cells.

Alkaline cells are quickly consumed !

Fraser

And then what is included in the connector near the video output?

[Worsdier]

And then what is included in the connector near the video output?

That's just a 12V DC input, but obviously not used to charge the batteries directly... there is a circuit in-between which does the charge controlling stuff and temperature monitoring as required for NiMH cells.

[ir.ukrm]

And then what is included in the connector near the video output?

That's just a 12V DC input, but obviously not used to charge the batteries directly... there is a circuit in-between which does the charge controlling stuff and temperature monitoring as required for NiMH cells.

That is, if I connect 12 volts, can the thermal imager work without an accumulator? And where should there be plus 12 volts?

[Worsdier]

From the manual: https://www.manualslib.com/manual/829646/Flir-H-Series.html?page=24#manual

Your H-Series camera is equipped with a sophisticated power systemthat accommodates a wide variety of AA battery types. This includesrechargeable and non-rechargeable batteries.The camera is optimized for operation with the 2700 mAhrechargeable NiMh batteries that were supplied with your camera. Itis recommended that you use these batteries in all but emergencysituations.

Battery Status Indicator–While the camerais On, a battery status indicator is alwaysshown in the corner of the display image. Thisindicator provides an estimation of theremaining battery charge.

Using Non-Rechargeable Batteries –The H-Series camera allowsAlkaline non-rechargeable batteries to be used. When non-rechargeable batteries are installed, connecting the Hot Shoe to apower source will power the camera from the power source and thebattery charging circuitry will be disabled.

[mikasa]

I got a same device. where to get the software and USB driver. the video timestamp on HS-324 can't adjust

[cos.cirstea]

Hello Fraser,

     I have come across a Flir Hs 323 camera with a defect. At a first inspection it seems that an IC from the TAU is defective. Do you have any idea what it is, I would like to replace it.

Thank you kindly,

[Miek]

It's probably a TPS61027, from the pinout/package and what looks like a "BDU" marking.

[Fraser]

I believe I have all IC’s listed in my archive. I will. Heck and confirm the identity. That is a Buck converter IC.

Fraser

[cos.cirstea]

Thank you for your response Miek and Fraser! I would be most grateful if you could check your archive Fraser and let me know the IC type.

Best regards

[Fraser]

Hi,

I checked and then realised that this is not actually part of the TAU core. The PCB is is part of the HS series host processing system for the TAU and sadly I could not quickly lay my hands on my high resolution pictures of those PCB's. Thankfully I have a disassembled HS so took a picture of the IC for you. It is indeed marked as "BDU" and that is, as Miek stated,  the Texas Instruments TPS61027DRCR and described as a Boost converter.

Datasheet is here:

https://www.ti.com/lit/ds/symlink/tps61020.pdf?ts=1613399693177&ref_url=https%253A%252F%252Fwww.google.com%252F

and attached to this post.

Check all of the Tantalum capacitors on your HS unit, including on the power distribution PCB as they are a weak point and are a common failure. The ones on the power distribution PCB like to burn up !

Fraser

[cos.cirstea]

Hello Fraser,

    Thank you for your help. Just checking to be 100% sure. The board in the your image has a different code than mine. Also the Boost converter in mine has BDU 04W ZJ9L on it while yours is BDU 01W ZL5N. Is there any chance that by replacing the Boost with the recommended Texas Instruments TPS61027DRCR may mess something up?

Thank you,

[Fraser]

You will be fine with the TPS61027DRCR. Board numbers change a lot so do not worry about that. The other codes on the IC are involved with production date etc and are of no concern in this case.

Do remember that Buck/Boost converters can fail spontaneously or due to a fault elsewhere in a circuit. Check for a short on its output rail after removing the faulty IC and then monitor the IC closely for overheating when you have fitted a new one.

Fraser

[cos.cirstea]

Thank you very much! I will get back when I have changed it!

[svgurus]

Hello, Fraser! Did you try putting this rear board on TAU, containing SD slot and usb port on other tau 1-2? Does it let use Fir gui and save pictures somehow?

[Malone]

Just stumbled across this thread while doing some Googling, I've had an HS324 Command for a couple of years with a viewfinder display issue which I'm fairly sure is caused by a fault in the LCD screen. For the first 10 minutes or so of being powered on, the screen has noise in the form of horizontal white lines that progressively get better and eventually disappear. When plugging in an external display to the hotshoe port, these lines aren't present. Hence my thinking that it's a fault with the LCD screen itself.

Does that sound sensible, or do you think the issue could be more serious? My hope is that it's just a quick fix to replace the QVGA LCD screen with a generic one.

I'd really appreciate any advice you might be able to give - hopefully you're still around and I'm not being too rude by replying to such an old thread!

[Fraser]

Malone,

It may be worth getting a can of electronics freezer spray and applying it to the Kopin LCD driver IC and surrounding components. You could have an issue with a component that has a fault when cool and settles when warmed up. I personally would investigate the EVF circuit before declaring the LCD panel as the faulty component. Sadly the A210 Kopin driver is a possible candidate for causing this fault and it is not the easiest component to source. Cooling and heating the Kopin A210 IC and its associated passive components may provide useful information on the fault. Replacement EVF parts for the scope are very expensive due to rarity so finding a suitable alternative EVF module may be a financially viable option but be warned, grafting such into the scopes casing may take a lot of effort. Repairing what is already there is the simplest solution if parts can be sourced. I do hold spares for the HS324 but much depends upon how much you want to spend on your unit and I tend to carry out the repairs rather than supply just parts. The A210 IC is a BGA component so care is needed to change it to avoid damage to the PCB and components.

The HS324 is infamous for its poor power supply reliability and that is another area that you should investigate. If there is noise on a power rail that supplies the EVF circuit, it could explain the noise introduced into the image. Check the quality of the power supply rails and I also recommend fitting new Tantalum capacitors to the power supply board as they have a habit of failing, sometimes in a catastrophic manner that burns the PCB.

Fraser

[Fraser]

A thread containing useful information on the Kopin EVF display series…..

https://www.eevblog.com/forum/projects/kopin-kd040922k-k-micro-sized-lcd-display/

Fraser

[Malone]

Thank you very much Fraser, that's really helpful. I'll have a look into the EVF circuit and power supply.

If you have the availability I would certainly consider hiring you to attempt a repair - something tells me you might have more luck with it than me! I will have a look myself first and see what I can find out.

Many thanks again.