DIAD 6 Charge Rack and Wireless Charge Rack Manual Models CN85-CR and CN85-WCR
Agency Information USA FCC Part 15 Subpart B Class A This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules.
Table of Contents Table of Contents 1 - Introduction.......................................................................................................................1-1 Deployment Plan ................................................................................................................1-1 Technical Support...............................................................................................................1-1 Definitions ............................................................
Table of Contents Convenient Storage .......................................................................................................5-1 Capacity .......................................................................................................................5-1 Parts and Functions.............................................................................................................5-1 Front and Side Panel ..................................................................................
Introduction Introduction This document explains how to install, use, maintain, troubleshoot and service the DIAD 6 Charge Rack. Only designated personnel with an appropriate level of technical training should attempt to repair the Charge Rack. Deployment Plan A pre-alert notice will be sent to each site prior to the manufacturer sending the DIAD 6 Charge Rack. The rack will be sent to the site approximately eight weeks prior to the first operational date of use.
Introduction How to Use this Manual The following icons are used in this manual to identify special safety and operational concerns. The WARNING icon identifies conditions or practices that could result in personal injury or loss of life. The CAUTION icon identifies conditions or practices that could result in damage to the equipment or other property. The NOTE icon is used to identify a special note or reminder. The APPROVED icon is used to identify an approved and recommended procedure.
Specifications Specifications Dimensions Height 15 1/4 inches (387 mm) Width 47 3/4 inches (1213 mm) Depth 6 3/4 inches (171 mm) Depth (with Terminals and Side Guards) 11 inches (279 mm) Weight Without DIADS 61.0 lbs (27.7 kg) With Side Guards 68.2 lbs (30.9 kg) With Side Guards and DIADS (30) 107.5 lbs (48.8 kg) Input Power Input Voltage 90 - 264 VAC; 47 - 63 Hz Current 3.5A @ 115VAC; 1.
Specifications Model and Serial Numbers A label is located on the far left side of the Charge Rack that contains the model and serial number.
Safety Safety This section identifies safety considerations involved in assembling and operating the DIAD 6 Charge Rack. Grounding • Avoid electric shock from any equipment used for the installation by supplying power from a properly grounded outlet. Hazardous Waste • Dispose of waste products properly, according to district procedure and federal, state and local regulations. Environment • This equipment is intended for installation in an area that is not normally subject to conductive dust or weather.
Safety Stability • The Charge Rack must be firmly fastened to a wall with enough room remaining to allow easy access.
Installing the Charge Rack Installing the Charge Rack Inspection of the DIAD 6 Charge Rack The DIAD 6 Charge Rack will be shipped by Honeywell Scanning and Mobility, approximately eight weeks prior to the center’s first day use of DIAD 6s. Upon arrival the shipment needs to be inspected by Site/District coordinator for any shortages or damages.
Installing the Charge Rack Receiving Replacement Parts To obtain replacement parts for defective Charge Rack components, please refer to the following web site for information regarding part numbers and costs: http://wss.inside.ups.com/sites/CRA/syse/Projects/DIAD V/Troubleshooting, FAQ, and Procedures/DIAD V Accessories and Charging Rack Part List.
Installing the Charge Rack Requirements All DIAD Charge Rack shipping containers and kits must be present. All required tools must be present. Refer to the following section for the list of required tools depending on the type of installation required. • The DCS computer MUST have all programs shut down and the computer MUST be powered off prior to disconnecting any DIAD 5 Charge Racks. • Failure to do this will result in instability in the computer and will require TSG intervention. Procedure 1.
Installing the Charge Rack • The DIAD 6 Charge Rack must be installed in an interior location or climatecontrolled environment that is not subject to excessive dust or moisture and is out of direct sunlight. • The ambient temperature of the mounting location for DIAD 6 Charge Racks must remain between 32°F and 95°F (0°C and 35°C). Charging is not guaranteed if the ambient temperature exceeds these limits.
Installing the Charge Rack plane of the back area of the Base Station at DIAD slot 4 and 12. Upon removal of screws, lift Base Station and remove. 4. With the existing Base Station removed, check the condition of existing mounting brackets. Ensure both the top and bottom u-channel brackets are level, square and properly secured to wall. Check the condition and alignment of the u-channel spring nut. Properly align the existing four u-channel spring nuts to the match hole in the new DIAD 6 Charge Rack.
Installing the Charge Rack 6. Use a Phillips screwdriver to remove the screws from the six-port charge bay on the right side of the Charge Rack and then remove the screws from the six-port charge bay on the left side of the Charge Rack. Pull the bay out and rotate it to the right to access cables.
Installing the Charge Rack 7. Pull each six-port charge bay forward and disconnect the power cord to expose the mounting holes. Be sure to retain your Phillips screws to reinstall the six-port charge bays after the rack has been mounted. Disconnect the power supply harness from the power distribution board and set the bays aside in a clean work area.
Installing the Charge Rack 8. Attach the side guard rails to each side of the DIAD 6 Charge Rack using two Phillips screws and the 3M adhesive strips supplied with each guard rail.
Installing the Charge Rack 9. Insert the four 3/8” x 1” Hex Head bolts through the 3/8” x 1 flat washers. Then place through the mounting holes in sections one and five of the Charge Rack and into the u-channel spring nut. Hand-tighten and repeat for all four locations, then torque down all bolts to 40 in lbs. with appropriate wrench or socket. Use care not to over-torque the bolts. Check to make sure the Charge Rack is level.
Installing the Charge Rack 10. Reconnect the power cables to the six-port charge bays and reinstall them with the Phillips head screws retained earlier. Screws Screws Do not pinch wires during reinstallation as this may damage the equipment. Be careful not to over-tighten the screws, which could damage the 6-Slot Bay and prevent the component from being adequately secured.
Installing the Charge Rack New Charge Rack Installation • Do not install near other equipment or machines that routinely produce conductive dust. • DIAD 6 battery charging can be negatively affected by temperature extremes. • A fully loaded DIAD 6 charge rack weighs 107.5 lbs (48.8 kg). The DIAD 6 Charge Racks must be installed in a location that will support the weight of the racks when fully loaded.
Installing the Charge Rack Item (Quantity) Part Number 4/8”x1”x14 ga. Flat Washer (10) By Local P.E. 1/4” Molly Bolt (4) By Local P.E.
Installing the Charge Rack New Installation Procedure 1. Determine the best mounting location for the installation. Check for the proper length from the Charge Rack to a power outlet. Allow sufficient space above the Charge Rack; minimum clearance between Charge Racks is 3 inches. In addition, allow sufficient space to the right of the Charge Rack to access the electrical connections. The Charge Rack will extend 2 1/4 inches past the end of the mounting frame on both ends.
Installing the Charge Rack Single Charge Rack Install Single Charge Rack Mounting Specifications Multiple Charge Rack Install Multiple Charge Rack Mounting Specifications 4-14 DIAD 6 Charge Rack Manual
Installing the Charge Rack 4. Make an indentation or small hole in the intended hole locations. Drill an appropriate hole through the wall for each of the two, or more, 3/8” lag mounting screws. Refer to the following table for the appropriate drill size for the wall materials encountered. Make sure that the holes have penetrated the structural wall supports. Hardware Mounting Recommendations Inner Wall Material Drill Sizes Hardware Washer Wood 9/32” (0.
Installing the Charge Rack 6. Insert the channel frame nut with the retainer into the channel frame where the Charge Rack mounting hardware will be inserted, (see the following figure.) Insert the right nut with retainer 6 3/4 inches from the right end of each channel. The center of the left nut with retainer is installed 30 inches from the center of the right nut. Marking the front of the channel makes installation easier.
Installing the Charge Rack 7. Use a Phillips screwdriver to remove the screws from the six-port charge bay on the right side of the Charge Rack and then remove the screws from the six-port charge bay on the left side of the Charge Rack. Pull the bay out and rotate it to the right to access cables.
Installing the Charge Rack 8. Pull each six-port charge bay forward and disconnect the power cord to expose the mounting holes. Be sure to retain your Phillips screws to reinstall the six-port charge bays after the rack has been mounted. Disconnect the power supply harness from the power distribution board and set the bays aside in a clean work area. 9. Install the side guard rails.
Installing the Charge Rack Left facing side rail/rack mounting position The Charge Rack must be fastened to the wall with the approved hardware. DO NOT use the tabs to permanently mount the Charge Rack. 10. Lift the Charge Rack into place on the mounting frame so that the tabs on the back of the Charge Rack support the weight during installation. Insert the four 3/8” x 1” Hex Head bolts through the 3/8” x 1 flat washers.
Installing the Charge Rack 11. Reconnect the power cables to the six-port charge bays and reinstall them with the Phillips head screws retained earlier. Screws Screws Do not pinch wires during reinstallation as this may damage the equipment. Be careful not to over-tighten the screws, which could damage the 6-Slot Bay and prevent the component from being adequately secured.
Using the Charge Rack Using the Charge Rack Overview You can power and charge the main battery in up to thirty DIAD 6 terminals using the Charge Rack. Charge Time The rack supplies power to the intelligent battery charging system in all DIAD 6 terminals, which senses when a full charge has been achieved and switches to a trickle charge to maintain the full charge.
Using the Charge Rack Side Guard Power Supply End Non-Power Supply End Terminal Wells The rack contains thirty terminal wells. Place the DIAD 6 terminal in any one of the thirty wells to power the terminal and charge the installed battery pack. The rack completely charges the main battery in a DIAD 6 terminal in 6 hours. AC Power Jack Use the AC power cable that comes with the rack to supply power to this power jack. For more information, see Power on page 5-2.
Using the Charge Rack Charging the Main Battery The rack provides power to the DIAD 6 terminals and allows the charging of the main batteries in the terminal. The intelligent battery charging system incorporated into all DIAD 6 terminals prevents overcharging, which means that DIAD 6 terminals may be stored in the rack indefinitely without damage to the terminals, battery packs, or the rack.
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Part Replacement Procedures Big Harness - 200004056CNRKIT Part Replacement Procedures Big Harness - 200004056CNRKIT Part Name: Big Harness Part #: 200004056CNRKIT Tools Required: 1 medium #2 Phillips head screw driver Before working on the Charge Rack, always disconnect the AC cord from the power supply. After removing power, wait 15 minutes before servicing the unit to avoid shock. Isolate screws by size as you remove them to ensure proper placement when reinstalling. 1.
Part Replacement Procedures Big Harness - 200004056CNRKIT 2. Remove the two screws from the power supply. Retain the screws for installation. Screws 3. Pull the power supply straight out by holding onto the heat sink.
Part Replacement Procedures Big Harness - 200004056CNRKIT 4. Support the power supply with one hand and disconnect the main plug. Set the unit aside in a clean work area. Main Plug Support the power supply with one hand 5. Remove each of the six-slot terminal bays (there are five bays). Begin by removing the four mounting screws that hold the bay to the sheet metal enclosure. Retain the screws for installation.
Part Replacement Procedures Big Harness - 200004056CNRKIT 6. Pull the bay out and rotate it to the right to access the cables.
Part Replacement Procedures Big Harness - 200004056CNRKIT 7. Disconnect the power supply harness from the power distribution board. 8. Repeat steps 5-7 for the four remaining bays. 9. To remove the big harness, begin by cutting the zip ties holding the harness to the sheet metal frame.
Part Replacement Procedures Big Harness - 200004056CNRKIT 10. Place the new harness into the wiring channel in the rear of the enclosure and add the zip ties that were provided in the kit.
Part Replacement Procedures Big Harness - 200004056CNRKIT Don’t forget to pull each lead out for each bay.
Part Replacement Procedures Big Harness - 200004056CNRKIT 11. Take the bay to the rack.
Part Replacement Procedures Big Harness - 200004056CNRKIT 12. Connect the power cable. Do not pinch wires during reinstallation as this may damage the equipment 13. Re-install the bay using the four mounting screws. Screws Screws Be careful not to over-tighten the screws, which could damage the 6-Slot Bay and prevent the component from being adequately secured. 14. Repeat steps 11-13 for the other four bays.
Part Replacement Procedures Big Harness - 200004056CNRKIT 15. Take the power supply to the Charge Rack and connect the main plug. Do not pinch wires during reinstallation as this may damage the equipment.
Part Replacement Procedures Big Harness - 200004056CNRKIT 16. Remount the power supply into place.
Part Replacement Procedures Big Harness - 200004056CNRKIT 17. Using the heat sink, place the power supply back into the main unit. Heat Sink 18. Re-install the two screws.
Part Replacement Procedures Big Harness - 200004056CNRKIT 19. The installation should be complete. Re-install the AC cord and test for functionality.
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Part Replacement Procedures NyoGel® 760G Lubricant Procedure NyoGel® 760G Lubricant Procedure 1. Remove power from the Charge Rack. 2. Remove all screws of the six-slot terminal bay. Retain the screws for installation. Screws Screws 3. Disassemble the cable from the power distribution board. by pulling the bay out and rotating it to the right to access the cables.
Part Replacement Procedures NyoGel® 760G Lubricant Procedure CN85-CR (Wired) 4. Disconnect the power supply harness from the power distribution board.
Part Replacement Procedures NyoGel® 760G Lubricant Procedure 5. Fully fill the first and fourth positions of the connector with NyoGel lubricant. 6. Insert the wire harness into the board connector.
Part Replacement Procedures NyoGel® 760G Lubricant Procedure 7. Re-install the bay using the four mounting screws. Screws Screws 8. Stick the “Lubricant Applied” label on the rack as indicated below.
Part Replacement Procedures I/O Board Cable - 50142485-001FRE I/O Board Cable - 50142485-001FRE Part Name: I/O Board Cable Part #: 50142485-001FRE Tools Required: 1 medium #2 Phillips head screw driver Before working on the Charge Rack, always disconnect the AC cord from the power supply. After removing power, wait 15 minutes before servicing the unit to avoid shock. 1. Remove the 6-slot bay from the Charge Rack. 2. There are 6 cables on the 6-slot bay.
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Part Replacement Procedures I/O Board - 50142380-001FRE I/O Board - 50142380-001FRE Part Name: I/O Board Part #: 50142380-001FRE Tools Required: 1 medium #2 Phillips head screw driver Before working on the Charge Rack, always disconnect the AC cord from the power supply. After removing power, wait 15 minutes before servicing the unit to avoid shock. Isolate screws by size as you remove them to ensure proper placement when reinstalling. 1. Remove the 6-slot bay from the Charge Rack. 2.
Part Replacement Procedures I/O Board - 50142380-001FRE 4. Separate the board from the bay. 5. Replace the broken board with the new one. 6. Reload the 6-slot bay into the Charge Rack. Do not pinch wires during reinstallation as this may damage the equipment Be careful not to over-tighten the screws, which could damage the 6-Slot Bay and prevent the component from being adequately secured.
Part Replacement Procedures Power Distribution - Board 50142378-001FRE Power Distribution - Board 50142378-001FRE Part Name: Power Distribution Board Part #: 50142378-001FRE Tools Required: 1 medium #2 Phillips head screw driver Before working on the Charge Rack, always disconnect the AC cord from the power supply. After removing power, wait 15 minutes before servicing the unit to avoid shock. Isolate screws by size as you remove them to ensure proper placement when reinstalling. 1.
Part Replacement Procedures Power Distribution - Board 50142378-001FRE 6. Reload the 6-slot bay into the Charge Rack. Do not pinch wires during reinstallation as this may damage the equipment Be careful not to over-tighten the screws, which could damage the 6-Slot Bay and prevent the component from being adequately secured.
Part Replacement Procedures Power Supply with PS-Harness Assembly - 100008187CNRKIT Power Supply with PS-Harness Assembly - 100008187CNRKIT Part Name: Charge Rack Power Supply with PSHarness Assembly Part #: 100008187CNRKIT Tools Required: 1 medium #2 Phillips head screw driver Before working on the Charge Rack, always disconnect the AC cord from the power supply. After removing power, wait 15 minutes before servicing the unit to avoid shock. 1. Disconnect the AC cord from the power supply.
Part Replacement Procedures Power Supply with PS-Harness Assembly - 100008187CNRKIT 2. Remove the two screws from the power supply. Do not retain screws. (Use the screws provided in the kit for replacement.
Part Replacement Procedures Power Supply with PS-Harness Assembly - 100008187CNRKIT 3. Pull the power supply straight out by holding onto the heat sink. Heat Sink 4. Support the power supply with one hand and disconnect the main plug. Set the unit aside in a clean work area.
Part Replacement Procedures Power Supply with PS-Harness Assembly - 100008187CNRKIT 5. Take the new power supply to the Charge Rack and connect the main plug.
Part Replacement Procedures Power Supply with PS-Harness Assembly - 100008187CNRKIT 6. Remount the power supply into place. Do not pinch wires during reinstallation as this may damage the equipment.
Part Replacement Procedures Power Supply with PS-Harness Assembly - 100008187CNRKIT 7. Using the heat sink, place the power supply back into the main unit. Heat Sink 8. Install the two new screws supplied in the kit.
Part Replacement Procedures Power Supply with PS-Harness Assembly - 100008187CNRKIT 9. The installation of the power supply should be complete. Re-install the AC cord and test for functionality.
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Part Replacement Procedures 6-Slot Terminal Bay - 50143872-001FRE 6-Slot Terminal Bay - 50143872-001FRE Part Name: 6-Slot Terminal Part #: 50143872-001FRE Tools Required: 1 medium #2 Phillips head screw driver Before working on the Charge Rack, always disconnect the AC cord from the power supply. After removing power, wait 15 minutes before servicing the unit to avoid shock. Isolate screws by size as you remove them to ensure proper placement when reinstalling. 1.
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Part Replacement Procedures Power Board (Wireless) - 50145763-001FRE Power Board (Wireless) - 50145763-001FRE Part Name: Power Board (Wireless) Part #: 50145763-001FRE Tools Required: 1 medium #2 Phillips head screw driver Before working on the Charge Rack, always disconnect the AC cord from the power supply. After removing power, wait 15 minutes before servicing the unit to avoid shock. Isolate screws by size as you remove them to ensure proper placement when reinstalling. 1.
Part Replacement Procedures Power Board (Wireless) - 50145763-001FRE 3. Use a soldering tool to disconnect the soldering wires on the board. 4. Separate the board from the frame. 5. Replace the board with the new one and install the board into the 6-slot bays. 6. Reload the 6-slot bay into the Charge Rack.
Part Replacement Procedures Core Module (Wireless) - 50145761-001FRE Core Module (Wireless) - 50145761-001FRE Part Name: Core Module (Wireless) Part #: 50145761-001FRE Tools Required: 1 medium #2 Phillips head screw driver Before working on the Charge Rack, always disconnect the AC cord from the power supply. After removing power, wait 15 minutes before servicing the unit to avoid shock. Isolate screws by size as you remove them to ensure proper placement when reinstalling. 1.
Part Replacement Procedures Core Module (Wireless) - 50145761-001FRE 4. Remove the black screws between the frames and plastic bay cover. 5. Remove the four screws between the coil module and the frame. 6. Replace the coil module with new one and re-install it on the frame. 7. Re-install the frame and power board on the 6-slot bay. 8. Reload the 6-slot bay into the Charge Rack.
Maintenance Maintenance It is important to keep the outer case of the Charge Rack clean and free of debris. Regular cleaning will help prevent dirt from being transferred to the rack as well as protecting the terminal from excess scratches and damage. Cleaning DO NOT: • • • • DO: • Use only approved cleaning materials. • Clean the Charge Rack once a week. • Protect eyes when pouring or spraying the cleaning solution. DO NOT place coffee, soft drinks, or other materials in or on the Charge Rack.
Maintenance Other Maintenance Whenever a six-slot terminal bay is open, apply NyoGel 760G lubricant to the connector on the distribution board to the power supply cable (see page 6-15).
Troubleshooting Troubleshooting Symptoms Cause Suggested Action Terminal LED not illuminated on a single bay. Terminal not seated properly Verify that the terminal is pressed firmly into the bay. Defective terminal Verify that the terminal LEDs do not illuminate in a known good bay. If necessary, send the terminal for repair. Dirty I/O pins and/or terminal charge contacts Inspect the I/O pins and terminal charge contacts for dirt.
Troubleshooting Symptoms Cause Suggested Action Terminal LED not illuminated on all 30 bays (all five banks). Charge rack is not receiving power Verify that the power cord is not damaged and is properly plugged into the rack and outlet. Verify the outlet has power. Check the fuse or circuit breaker. If a power strip or surge protector is used, verify that it is turned on and functioning properly.
Parts List Parts List The following tables list the contents of each DIAD 6 Charge Rack service kit. Please disregard the color of Printed Circuit Boards (PCBs) as they may vary.
Parts List Part Number Kit Description Component Description Qty 50142485-001FRE Kit, Cable, I/O PCBA to Power Dist.
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