Honeywell CX85WCR User Manual

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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. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

If necessary, the user should consult the dealer or an experienced radio/television technician for additional suggestions. The user may find the following booklet helpful: “Something About Interference.” This is available at FCC local regional offices. Any radio or television interference caused by unauthorized modifications of this equipment or the substitution or attachment of connecting cables and equipment other than those specified in this document are the responsibility of the user. The correction is the responsibility of the user.

Use only shielded data cables with this system.

Any changes or modifications made to this equipment may void the FCC authorization to operate this equipment.

Canadian Compliance

This Class A digital apparatus complies with Canadian ICES-003. 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.

Conformitéàla règlementation canadienne

Cet appareil numérique de la Classe A est conforme àla norme NMB-003 du Canada. Son fonctionnement est assujetti aux conditions suivantes : (1) Cet appareil ne doit pas causer de brouillage préjudiciable. (2) Cet appareil doit pouvoir accepter tout brouillage reçu, y compris le brouillage pouvant causer un fonctionnement indésirable.

Europe

In accordance with Article 10.2 in Directive 2014/53/EU(RED), this device can be operated

in at least one Member State without infringing applicable requirements on the use of radio spectrum.

Table of Contents

1 - Introduction.......................................................................................................................	1-1
Deployment Plan ................................................................................................................	1-1
Technical Support...............................................................................................................	1-1
Definitions .........................................................................................................................	1-1
DIAD Delivery Information Acquisition Device............................................................	1-1
DIAD 6 Charge Rack....................................................................................................	1-1
DIAD 6 Charge Rack Wall Mounting Frame .................................................................	1-1
DCS .............................................................................................................................	1-1
DIAD Server ................................................................................................................	1-1
How to Use this Manual .....................................................................................................	1-2

2 - Specifications .....................................................................................................................	2-1
Model and Serial Numbers .................................................................................................	2-2
3 - Safety .................................................................................................................................	3-1
Grounding ..........................................................................................................................	3-1
Hazardous Waste................................................................................................................	3-1
Environment.......................................................................................................................	3-1
Power Cords.......................................................................................................................	3-1
Servicing ............................................................................................................................	3-1
Stability..............................................................................................................................	3-2
4 - Installing the Charge Rack ...............................................................................................	4-1
Inspection of the DIAD 6 Charge Rack...............................................................................	4-1
Package Contents..........................................................................................................	4-1
Reporting Shortages or Damages ..................................................................................	4-1
Receiving Replacement Parts........................................................................................	4-2
Charge Rack Installation. ...................................................................................................	4-2
Scheduling the Installation ............................................................................................	4-2
Installation Methods......................................................................................................	4-2
Unpacking and Preparing the Work Area............................................................................	4-2
Requirements................................................................................................................	4-3
Procedure .....................................................................................................................	4-3
Replacement Charge Rack Installation ...............................................................................	4-3
Required Parts and Hardware ........................................................................................	4-4
Tools ............................................................................................................................	4-4
Replacement Installation Procedure...............................................................................	4-4
New Charge Rack Installation ..........................................................................................	4-11
Required Parts and Hardware ......................................................................................	4-11
Tools ..........................................................................................................................	4-12
New Installation Procedure .........................................................................................	4-13
5 - Using the Charge Rack......................................................................................................	5-1
Overview............................................................................................................................	5-1
Charge Time .................................................................................................................	5-1

DIAD 6 Charge Rack Manual	i

Table of Contents

Convenient Storage.......................................................................................................	5-1
Capacity .......................................................................................................................	5-1
Parts and Functions.............................................................................................................	5-1
Front and Side Panel .....................................................................................................	5-1
Side Guard....................................................................................................................	5-2
Terminal Wells .............................................................................................................	5-2
AC Power Jack .............................................................................................................	5-2
Power.................................................................................................................................	5-2
Connecting Power to the Rack ......................................................................................	5-2
Charging the Main Battery..................................................................................................	5-3
To Power a Terminal and Charge its Main Battery ........................................................	5-3
Charging Status Through Notification LEDs .................................................................	5-3
6 - Part Replacement Procedures...........................................................................................	6-1
Big Harness - 200004056CNRKIT .....................................................................................	6-1
NyoGel® 760G Lubricant Procedure ................................................................................	6-15
I/O Board Cable - 50142485-001FRE...............................................................................	6-19
I/O Board - 50142380-001FRE.........................................................................................	6-21
Power Distribution - Board 50142378-001FRE.................................................................	6-23
Power Supply with PS-Harness Assembly - 100008187CNRKIT......................................	6-25
6-Slot Terminal Bay - 50143872-001FRE.........................................................................	6-33
Power Board (Wireless) - 50145763-001FRE ...................................................................	6-35
Core Module (Wireless) - 50145761-001FRE ...................................................................	6-37
7 - Maintenance ......................................................................................................................	7-1
Cleaning.............................................................................................................................	7-1
Approved Cleaner .........................................................................................................	7-1
Cleaning Procedure.......................................................................................................	7-1
Other Maintenance .............................................................................................................	7-2
8 - Troubleshooting ................................................................................................................	8-1
9 - Parts List ...........................................................................................................................	9-1

ii	DIAD 6 Charge Rack Manual

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. The Charge Rack is to be installed no later than the weekend prior to the first operational date of use.

Technical Support

Call the local Technical Service Center (TSC) at 888-UPS-TECH (888-877-8324) for all problems or questions concerning the operation of the Charge Rack.

Definitions

DIAD Delivery Information Acquisition Device

The DIAD 6 is the sixth generation of the DIAD concept. This device is based on the Windows Mobile operating system and contains an internal battery that must be recharged on a daily basis.

DIAD 6 Charge Rack

The Charge Rack holds and charges the DIAD 6s. Each rack can contain up to thirty DIAD 6s. The DIAD 6 Charge Rack has the same exact footprint as the DIAD 5 Charge Rack, permitting quick installation and replacement of existing hardware.

DIAD 6 Charge Rack Wall Mounting Frame

A mounting frame is used to wall mount the Charge Rack on a variety of materials and surfaces. The mounting frame has a large number of slots open that allow maximum flexibility in meeting a variety of installation conditions.

DCS

DCS (DIAD Communication System) is a software program that runs on a computer within the operating center. This program controls the upload/download of the DIADs, queries and reports, and communication with other networked systems such as GTS, DIALs, etc.

DIAD Server

The software program allows the DCS program to communicate with the DIAD 6s utilizing an 802.11 wireless network.

DIAD 6 Charge Rack Manual

1-1

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.

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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; 1.75A@230VAC

* Only 120 VAC 60Hz is approved for use in the United States (UL Listed) and Canada (CSA Certified).

	Temperature Range

Operating Range		32 - 95°F (0 - 35°C)

Required Installation Location		In an office or climate-controlled envi-
		ronment that has a temperature range
		between 45°F and 85°F (7°and 29°C).

	RF Specification

Operating Frequency		144KHz

Max. TX H-field

The ambient temperature of the mounting location must remain between 32°F and 95°F (0°C and 35°C). Charging is not guaranteed if the ambient temperature exceeds these limits.

DIAD 6 Charge Rack Manual

2-1

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.

Serial

Number

Label

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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. Do not install near other equipment or machines that routinely produce conductive dust. Temperature extremes will affect the charging rates of the DIADs.

Power Cords

•The Charge Rack power must be supplied from a properly grounded outlet. The power outlet must be near the equipment and easily accessible after the equipment is installed.

•Power strips and extension cords should not be used.

Servicing

•Do not remove panels or attempt to service this equipment unless you are qualified to do so.

•After removing power from the rack, wait 15 minutes before servicing the unit to avoid shock.

•Pinched cables could cause serious damage to equipment. Always be aware of cable position while removing or replacing any parts.

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3-1

Safety

Stability

•The Charge Rack must be firmly fastened to a wall with enough room remaining to allow easy access.

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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.

Package Contents

Item (Quantity)	Part Number

DIAD 6 Charge Rack (1)	CN85-CR (wired)
	CN85-WCR (wireless)

Power Cord, US, IEC 320-C13 (1)	77900506E (with ferrite PN 10008320 attached)

Side Guard Kit (1)	99EX-CR-NRGUARDKIT
containing:
Right Guard Panel (1)
Left Guard Panel (1)
Screw 8-32x1/2” (4)

Regulatory Sheet (1)	n/a

Reporting Shortages or Damages

Immediately report any problems with the shipment to the District TSG Manager. District TSG should contact Julie Rutt via email (nat1jar@ups.com) with the following information:

•RRDDSLIC of the location that is missing equipment or received damaged parts.

•The serial number of the damaged/missing part(s).

•The tracking number for the missing/damaged equipment.

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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.pdf

Charge Rack Installation

Scheduling the Installation

TSG, Plant Engineering, and the operating center need to coordinate the optimum time for Charge Racks to be installed utilizing the locations that were determined during the wireless site survey conducted by TSG. It is imperative that the DIAD 6 Charge Racks are installed in accordance with the location determined in the wireless site survey.

Installation can occur well before scheduled DIAD 6 deployment provided the users can be provided a safe place to put spare DIAD 5 racks until the cutover to DIAD 6 takes place. A number of DIAD 5 Charge Racks will remain in place to support the peak DIAD population.

Installation Methods

There are several methods to install the DIAD 6 Charge Rack:

•Remove the DIAD 5 Net Racks and replace them with the DIAD 6 Charge Racks. or...

•Install DIAD 6 Charge Racks utilizing new mounting hardware in accordance with the locations agreed on during the wireless site survey conducted by TSG.

•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 must be installed in a location that will support the weight of the racks when fully loaded.

•Vertical mounting of the Charge Rack is not recommended.

•The DIAD 6 Charge Rack should 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.

Unpacking and Preparing the Work Area

This section explains how to unpack items and prepare the work area before assembling the Charge Rack. All Charge Rack parts, hardware, and tools must be close to the work area.

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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.Lay out and organize your tools in a clear area, preferably on an empty bench or table close to the work area.

2.Organize the containers of the various Charge Rack components for easy access. Place them at a comfortable distance so that unpacking them does not interfere with your work area.

3.Open all boxes and shipping containers. Take an inventory of the items received. Inspect hardware for damage. DIAD 6 equipment questions (damages, shortages, overages, and/or incorrect serial numbers received) should be emailed by district coordinator to Julie Rutt via email (nat1jar@ups.com). Please specify Region, District, SLIC and the serial numbers of any discrepancies.

4.Lay the units out in their intended locations to determine if any problems exist before installation, paying special attention to power cord lengths.

Replacement Charge Rack Installation

This section describes how to remove the existing DIAD 5 Charge Racks and replace with new DIAD 6 Charge Racks. The DIAD 6 Charge Rack is designed for horizontal wall mounting only. It has been manufactured to be a direct replacement to the existing DIAD 5 Charge Racks. The DIAD 5 and DIAD 6 Charge racks have the same footprint making utilization of existing mounting hardware possible.

•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 Charge Rack weighs 107.5 lbs (48.8 kg). The DIAD 6 and DIAD 5 Charge Racks must be installed in a location that will support the weight of the racks when fully loaded.

DIAD 6 Charge Rack Manual

4-3

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.

Required Parts and Hardware

The DIAD 6 Charge Rack Kit contains a Charge Rack and two side guards with sheet metal screws. The kit does not contain the four mounting bolts required. Use the existing bolts from your uninstall. The DIAD 6 Charge Rack is designed to mount on the previously installed DIAD 5 mounting frame.

Item (Quantity)	Part Number

DIAD 6 Charge Rack (1)	CN85-CR (wired)
	CN85-WCR (wireless)

Side Guard Kit (1)	99EX-CR-NRGUARDKIT

Tools

Before attempting to install the DIAD Charge Rack, you must have the following tools:

•9/16” Wrench or socket

•Tape Measure

•Level

•Large Straight Blade Screwdriver

•Small Straight Blade Screwdriver

•Phillips Screwdriver

Replacement Installation Procedure

1.Locate the existing DIAD 5 Charge Racks within the facility. Ensure the Charge Rack is empty of DIAD units. Have UPS operations remove all existing DIAD 5s. Locate the ON/ OFF toggle switch on the Charge Rack and turn to OFF. Unplug unit from electrical outlet. Disconnect all data cables from the unit using a small straight blade screwdriver and cover the cable ends with electrical tape.

2.Remove the top cover from the Base Station by unsnapping cover from slots located near rear wall of Base Station. For stacked multiple Base Station mountings, remove mid cover and upper Base Station and pry loose.

3.The following steps are easier to perform with two people. One person should hold the existing Base Station while the second person loosens the four 3/8-16 x 1” Hex Head Screws and 3/8” x 1 flat washers from the Base Station. Screws and washers are located on the vertical

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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. Coil the existing communication cable and secure it away from the new Charge Racks. Coordinate with local Plant Engineering and TSG on the complete removal of cabling, if possible. Centers will no longer use DIAD 5 Charge Racks. DIAD 6 will become the peak device in all centers where DIAD 6 is deployed. DIAD 5 racks should be disposed of in accordance with established procedures.

5.Lift the new DIAD 6 Charge Rack into place on the existing mounting frame so that the tabs on the back of the Charge Rack support the weight during installation.

The Charge Rack must be fastened to the wall with the hardware removed in Step 3. DO NOT use tabs to permanently mount the Charge Rack.

DIAD 6 Charge Rack Manual

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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.

CN85-CR (Wired)

CN85-WCR (Wireless)

4-6

DIAD 6 Charge Rack Manual

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.

DIAD 6 Charge Rack Manual

4-7

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.

DIAD 6 Rack left side rail

Left facing side rail/rack mounting position

4-8	DIAD 6 Charge Rack Manual

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.

Charge Rack Mounting Holes

DIAD 6 Charge Rack Manual

4-9

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

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.

4-10	DIAD 6 Charge Rack Manual

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.

•The Mounting Frame MUST be used to secure the DIAD 6 Charge Rack to the wall to prevent possible damage to the Charge Rack. Failing to use the Mounting Frame could result in issues charging/powering terminals within the rack.

•The DIAD 6 Charge Rack should be installed in an interior location that is not subject to excessive dust or moisture and is out of direct sunlight.

This section describes how to mount the DIAD 6 Charge Rack where no rack was previously installed. The DIAD 6 Charge Rack is designed for horizontal wall mounting only. The mounting frame attaches to a wall that can structurally support the DIAD 6 Charge Rack. The mounting frame must be attached to structural supports within the wall. The DIAD 6 Charge Rack fastens to the mounting frame.

Required Parts and Hardware

All parts required to assemble DIAD 6 Charge Rack systems are pre-package as assembled groups or as bagged parts.

Item (Quantity)	Part Number

DIAD 6 Charge Rack Kit (1)	CN85-CR (Wired)
(kit does not contain 4 mounting bolts)	CN85-WCR (Wireless)

Side Guard Kit (1)	99EX-CR-NRGUARDKIT

Wall Mount Frame (1)	By Local P.E.

Channel Frame 3/8” Nut w/retainer (4)	By Local P.E.

1/8” - 16 1” Hex Head Screw (4)	By Local P.E.

3/8” - 2.5” Hex Lag Screw (6)	By Local P.E.

5/16” Toggle Bolt (4)	By Local P.E.

0.375”x1.6”x 0.125” Fender Washer (4)	By Local P.E.

0.265”x8.875”x 0.035” Fender Washer (4)	By Local P.E.


DIAD 6 Charge Rack Manual	4-11

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.

Use Existing Bolts from DIAD 5 Uninstall	From Uninstall

Tools

Before attempting to install the DIAD Charge Rack, you must have the following tools:

•1/8” Blade, 2” Shaft Screwdriver

•3/8” Drill and Appropriate Bit (see page 4-15)

•9/16” Wrench or Socket

•Tape Measure

•Level

•Stud Sensor

•Large Straight Blade Screwdriver

•Phillips Screwdriver

4-12	DIAD 6 Charge Rack Manual

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.

Minimum distance between mounted DIAD 6 Charge Racks is 3” (7.62 CM)

Charge Rack Installation Specifications

2.Identify the locations of the structural supports within the wall designated for mounting the Charge Rack. Plant Engineering should verify and mark the correct structural mounting location.

3.The following steps are easier to perform with two people: one person should hold the mounting frame in place while the second person checks to make sure it is level and marks the hole locations with the tip of a mounting screw, pencil, or pen. Two or more screws support each channel of the mounting frame. If a second person is not available, use the mounting template to mark the mounting hole locations. Failing to install a mounting frame could damage the Charge Rack and result in issues charging/powering terminals located within the Charge Rack.

Check with the responsible plant management group before drilling any holes through walls. Extreme caution should be used to avoid contacting power lines.

DIAD 6 Charge Rack Manual

4-13

Installing the Charge Rack

Single Charge Rack Install

Single Charge Rack Mounting Specifications

Multiple Charge Rack Install

Multiple Charge Rack Mounting Specifications

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