Boost Converter Assembly

Boost Converter Assembly

Purpose

This accessory was created to address the issue of voltage drop over the 65 meter cables used on BNSF Cranes.

The output voltage is set specifically for this cable length and if used for any other cable length the voltage would need to be adjusted

Parts required

Rio Rand Boost Module

Enclosure

Adaptor Board (Custom)

Camera Cable (using left over .5 meter cables we have in stock)

"4 Berg Sticks"

"2 Small Zip-Ties"

Assembly Preparation

Prepare the Cables

Cut the .5 meter cable to 6 inches from the end (face) of the connector to the cut

With an Exacto Knife strip the outer insulation so that ~18mm of the 3 wires is showing

Unwrap the copper shielding from the Yellow video wire

Hold the wires in the following order; RED, White, Yellow and pull the copper shield wire so it is next to the yellow wire

separate and cut off ~6 strands of the shield and twist the rest into one "wire"

Tin the copper wire with solder to form the 4th wire

Using an Exacto know carefully strip the Red, White & Yellow wires so that 8mm of insulation is still exposed (this is important so that the zip tie used for strain relief and contact the outer insulation of the cable) The Yellow wire is smaller than the others so ensure you do not cut any of the wire strands!!

Tin the 3 remaining wires with solder.

Prepare the Adapter Board

With the board silkscreen side up insert the 4 berg sticks into the holes in the corner of the adapter board

Place the Boost module on the berg sticks to help with alignment (Vertical so the boost module and adapter board are aligned)

Solder the berg sticks to the Adapter board only

Remove the boost module

Assembly

Input Cable

Feed the female cable through the Wire Gland of the enclosure

Insert the wires into "J1" on the adapter board from the opposite side from the silkscreen and solder the wires

Fold the cable over and secure with a zip-tie

Output Cable

Feed the male cable through the Wire Gland of the enclosure

Insert the wires into "J2" on the adapter board from the opposite side from the silkscreen and solder the wires

Fold the cable over and secure with a zip-tie

Boost Module

Place the boost module on the berg sticks with the "IN+" aligned with "12V-IN" on the adapter board

Solder the 4 connections and pull the cable slack through the glands

Test and adjustment

1)Connect leads of the voltmeter to the output of the boost module

2)Plug the boost module into the DVR ONLY

3)Adjust the voltage to between 14.35v and 14.40v

4)Remove leads from the boost module and plug the output into the 65m meter cable.

5)Measure the voulage at the camera end of the cable to ensure the boost module handles a load.

6)Voltage without the IR Leds should be ~12.75v to 13.5v

7)Cover the camera to engage the IR LEDs and the voltage should be ~ 11.25v - 11.5v

8) Secure the potentiometer in place with Locktite 424 (blue)

Final Assembly

1)pull the slack out of the cables

2)Place the module sideways into the case with the potentiometer side up

3)Tighten the two glands to secure and seal the cables

4)Place the cover on the case and secure with 4 screws.

5) Retest the module

Label the assembly

Label format:

Part number IDRD8BOOST14.5 is composed of:

IDRD8BOOST (we had to call it something)

14.5 (the voltage that the booster was set to)(this could be different is used for another cable length)

Serial Number 1806389

Year 18

Month 06

Number 389

Made in USA