Difference between revisions of "Boost Converter Assembly"

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=Boost Converter Assembly=
 
=Boost Converter Assembly=
  
−
<span style="color: red">'''The Same process is used for the single channel video booster'''
+
<br><br>
  
 
==Purpose==
 
==Purpose==
Line 7: Line 7:
 
This accessory was created to address the issue of voltage drop over the 65 meter cables used on BNSF Cranes.  
 
This accessory was created to address the issue of voltage drop over the 65 meter cables used on BNSF Cranes.  
  
−
<span style="color: red"> '''The output voltage is set specifically for this cable length and is used for any other cable length the voltage would need to be adjusted'''
+
<span style="color: red"> '''The output voltage is set specifically for this cable length and camera type. If used for any other cable length or camera type the voltage would need to be adjusted'''
  
 
[[File:idrvboost_complete.jpg|350px|]]
 
[[File:idrvboost_complete.jpg|350px|]]
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[https://www.amazon.com/RioRand-Converter-Voltage-Adjustable-Circuit/dp/B071H39ZN5/ref=pd_lutyp_simh_2_1?_encoding=UTF8&pd_rd_i=B071H39ZN5&pd_rd_r=41994e03-2b24-40f4-9e1b-086d32b767b0&pd_rd_w=ftice&pd_rd_wg=on0aZ&refRID=BZRCJRCSYBN747MV628K&th=1  Rio Rand Boost Module]
 
[https://www.amazon.com/RioRand-Converter-Voltage-Adjustable-Circuit/dp/B071H39ZN5/ref=pd_lutyp_simh_2_1?_encoding=UTF8&pd_rd_i=B071H39ZN5&pd_rd_r=41994e03-2b24-40f4-9e1b-086d32b767b0&pd_rd_w=ftice&pd_rd_wg=on0aZ&refRID=BZRCJRCSYBN747MV628K&th=1  Rio Rand Boost Module]
  
−
[[File:idrvboost_module.jpg|350px|]]
 
  
−
<br><br><br><br><br><br><br>
+
[https://www.amazon.com/LemonBest-Waterproof-Electrical-Underground-Protection/dp/B01IQTX9YK/ref=pd_cp_60_1?_encoding=UTF8&pd_rd_i=B01IQTX9YK&pd_rd_r=bc8ab180-5de5-11e8-82d7-bd788d9ee510&pd_rd_w=kfoVD&pd_rd_wg=XODnH&pf_rd_i=desktop-dp-sims&pf_rd_m=ATVPDKIKX0DER&pf_rd_p=80460301815383741&pf_rd_r=58Z2HFNQ6ATK8VQMJXRH&pf_rd_s=desktop-dp-sims&pf_rd_t=40701&psc=1&refRID=58Z2HFNQ6ATK8VQMJXRH Enclosure]
 +
 
 +
 
 +
Adaptor Board (Custom)
 +
 
 +
 
 +
Camera Cable (using left over .5 meter cables we have in stock)
 +
 
 +
 
 +
"4 Berg Sticks"
 +
 
 +
 
 +
"2 Small Zip-Ties"
 +
 
 +
<br><br>
 +
 
 +
==Assembly Preparation==
 +
 
 +
<br><br>
 +
 
 +
===Prepare the Cables===
  
−
Adaptor Board
+
Cut the .5 meter cable to 6 inches from the end (face) of the connector to the cut
  
−
[[File:idrvboost_adaptorboard.jpg|350px|]]
+
With an Exacto Knife strip the outer insulation so that ~18mm of the 3 wires is showing
  
−
<br><br><br><br><br><br><br>
+
[[File:idrvboost_cableprep1.jpg|350px|]]
  
−
Enclosure
+
Unwrap the copper shielding from the Yellow video wire
  
−
[https://www.amazon.com/LemonBest-Waterproof-Electrical-Underground-Protection/dp/B01IQTX9YK/ref=pd_cp_60_1?_encoding=UTF8&pd_rd_i=B01IQTX9YK&pd_rd_r=bc8ab180-5de5-11e8-82d7-bd788d9ee510&pd_rd_w=kfoVD&pd_rd_wg=XODnH&pf_rd_i=desktop-dp-sims&pf_rd_m=ATVPDKIKX0DER&pf_rd_p=80460301815383741&pf_rd_r=58Z2HFNQ6ATK8VQMJXRH&pf_rd_s=desktop-dp-sims&pf_rd_t=40701&psc=1&refRID=58Z2HFNQ6ATK8VQMJXRH Enclosure]
+
[[File:idrvboost_cableprep2.jpg|350px|]]
 +
 
 +
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"
 +
 
 +
[[File:idrvboost_cableprep3.jpg|350px|]]
 +
 
 +
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)<span style="color: red"> '''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.
 +
 
 +
[[File:idrvboost_cableprep4.jpg|350px|]]
 +
 
 +
<br><br>
 +
 
 +
===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
 +
 
 +
<br><br>
 +
 
 +
==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
 +
 
 +
[[File:idrvboost_inputsolder.jpg|left|250px|]][[File:idrvboost_inputziptie.jpg|250px|]]
  
−
[[File:idrvboost_enclosure.jpg|350px|]]
+
<br><br>
  
−
<br><br><br><br><br><br><br>
+
[[File:idrvboost_inputdone.jpg|600px|]]
  
−
Camera Cable
+
<br><br>
  
−
[[File:idrvboost_camcable.jpg|350px|]]
+
===Output Cable===
  
−
<br><br><br><br><br><br><br>
+
Feed the male cable through the Wire Gland of the enclosure
  
−
"Berg Sticks"
+
Insert the wires into "J2" on the adapter board from the opposite side from the silkscreen and solder the wires
  
−
[[File:idrvboost_bergsticks.jpg|350px|]]
+
Fold the cable over and secure with a zip-tie
 +
 
 +
[[File:idrvboost_outputsolder.jpg|left|250px|]]
  
 
<br><br><br><br><br><br>
 
<br><br><br><br><br><br>
 +
 +
[[File:idrvboost_outputdone.jpg|600px|]]
 +
 +
<br><br>
 +
 +
===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
 +
 +
[[File:idrvboost_boostsolder.jpg|left|400px|]]
 +
 +
<br><br><br><br><br><br><br><br><br><br><br><br>
 +
 +
[[File:idrvboost_boostdone.jpg|400px|]]
 +
 +
<br><br>
 +
 +
==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 14.25v and 14.30v'''
 +
 +
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)
 +
 +
<br><br>
 +
 +
==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
 +
 +
<br><br>
 +
 +
==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
 +
 +
 +
<br><br>
 +
 +
===

Latest revision as of 22:53, 26 June 2018

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 camera type. If used for any other cable length or camera type the voltage would need to be adjusted

File:Idrvboost complete.jpg



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

File:Idrvboost cableprep1.jpg

Unwrap the copper shielding from the Yellow video wire

File:Idrvboost cableprep2.jpg

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"

File:Idrvboost cableprep3.jpg

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.

File:Idrvboost cableprep4.jpg



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

Idrvboost inputsolder.jpg

Idrvboost inputziptie.jpg



Idrvboost inputdone.jpg



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

Idrvboost outputsolder.jpg







Idrvboost outputdone.jpg



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

Idrvboost boostsolder.jpg













Idrvboost boostdone.jpg



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 14.25v and 14.30v

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




=

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