8545-M854-O1 Rev B DCPOWER Installation
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DCPOWER
EXTERNAL DC POWER ADAPTER
INSTALLATION MANUAL
8545-M854-O1 Rev B
203 E. Daugherty, Webb City, MO 64870 USA
Printed in USA
11/14
Ph: 417-673-4631 Fax: 417-673-2153
www.cardinalscale.com
8545-M854-O1 Rev B DCPOWER Installation
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8545-M854-O1 Rev B DCPOWER Installation
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COPYRIGHT
All rights reserved. Reproduction or use, without expressed written permission, of editorial or
pictorial content, in any manner, is prohibited. No patent liability is assumed with respect to the
use of the information contained herein.
DISCLAIMER
While every precaution has been taken in the preparation of this manual, the Seller assumes no
responsibility for errors or omissions. Neither is any liability assumed for damages resulting from
use of the information contained herein. All instructions and diagrams have been checked for
accuracy and ease of application; however, success and safety in working with tools depend to a
great extent upon the individual accuracy, skill and caution. For this reason the Seller is not able
to guarantee the result of any procedure contained herein. Nor can they assume responsibility for
any damage to property or injury to persons occasioned from the procedures. Persons engaging
the procedures do so entirely at their own risk.
FCC COMPLIANCE STATEMENT
This equipment generates uses and can radiate radio frequency and if not installed and used in
accordance with the instruction manual, may cause interference to radio communications. It has
been tested and found to comply with the limits for a Class A computing device pursuant to
Subpart J of Part 15 of FCC rules, which are designed to provide reasonable protection against
such interference when operated in a commercial environment. Operation of this equipment in a
residential area may cause interference in which case the user will be responsible to take whatever
measures necessary to correct the interference.
You may find the booklet “How to Identify and Resolve Radio TV Interference Problems” prepared
by the Federal Communications Commission helpful. It is available from the U.S. Government
Printing Office, Washington, D.C. 20402. The stock number is 001-000-00315-4.
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8545-M854-O1 Rev B DCPOWER Installation
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PRECAUTIONS
Static Electricity
CAUTION! This device contains static sensitive circuit cards and components. Improper
handling of these devices or printed circuit cards can result in damage to or destruction of
the component or card. Such actual and/or consequential damage IS NOT covered
under warranty and is the responsibility of the device owner. Electronic components
must be handled only by qualified electronic technicians who follow the guidelines listed
below.
WARNING! ALWAYS use a properly grounded wrist strap when handling, removing or
installing electronic circuit cards or components. Make certain that the wrist strap ground
lead is securely attached to an adequate ground. If you are uncertain of the quality of the
ground, you should consult a licensed electrician.
ALWAYS handle printed circuit card assemblies by the outermost edges. NEVER touch
the components, component leads or connectors. ALWAYS observe warning labels on
static protective bags and packaging and never remove the card or component from the
packaging until ready for use. ALWAYS store and transport electronic printed circuit
cards and components in anti-static protective bags or packaging.
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8545-M854-O1 Rev B DCPOWER Installation
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INTRODUCTION
Thank you for purchasing the DCPOWER External DC Power Adapter for the 200 Series (205,
210, 215 and 225) and 825 Indicators. The DCPOWER adapter was built with quality and
reliability and has been designed for the environment where operating the indicator from a DC
power source is desired or required.
The DCPOWER adapter changes the input power requirement from 100 to 240VAC to 11 to
30VDC. The AC–DC converter is removed from the indicator and replaced with the DCPOWER
adapter.
This manual is divided into 3 sections. Each section will describe how to install DCPOWER into its
respective indicator. Each section provides step by step instructions for the removal of necessary
components, installation of the DCPOWER adapter and how to re-install the removed components.
Please read it thoroughly before attempting to install the adapter in your indicator and keep it
handy for future reference.
DCPOWER External DC Power Adapter Board
P1
P2
J1
J2
J3
D2
D6
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DC POWER ADAPTER BOARD
CONNECTORS
P1 = 3-pin Input connector
Pin #
Description
1
+11 to 30VDC
2
No Connection
3
GND
P2 = 6-pin Output connector
Pin #
Description
Pin #
Description
1
12VDC (11.75 ~ 12.25VDC )
4
GND
2
5VDC (5.03 ~ 5.13VDC )
5
GND
3
5VDC (5.03 ~ 5.13VDC)
6
No Connection
STATUS LED’S
POWER GOOD – D2
D2 illuminates when the 12VDC output has fallen out of regulation.
SHUTDOWN – D6
D6 illuminates when the regulator outputs are shutdown. This
occurs when the battery voltage is below the shutdown threshold.
Refer to Jumper J2 setting.
JUMPERS
Jumper J1
When installed changes the output voltage from 12V to 14V to be used on 200 series indicators
running 12V excitation. J1 should be removed when used on 825, 215, or 200 series indicators
with 8V excitation.
Jumper J2
Sets the voltage level of the shutdown comparator. When the jumper is removed the input
voltage can be 10.5 to 30 volts. When the jumper is installed the output will be shutdown when
the voltage falls below 17.8V to prevent excessive discharge of the battery when connected to a
24V system.
Jumper J3
When installed shuts down the 5V output and should only be installed when a 200 series
indicator is used.
The system does not have to run from an 18V battery source. The function of jumper J3 is to
shutdown the regulator based on the battery it is operating from. Install the jumper if it is a 24V
system so that it will shutdown at 17.8V and not discharge the battery down to 10.5V. Remove J3
for a 12V system and it will shutdown at 10.5V and not discharge the battery too much.
8545-M854-O1 Rev B DCPOWER Installation
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DC POWER ADAPTER BOARD, CONT.
JUMPERS, CONT.
The DC power board can operate in a buck or boost mode. It can power a 205 with 12V excitation
(output voltage will be approximately 14V) the only consideration is that the DC power board is
operating in boost mode all of the time with a 12V battery which is less efficient than running the
excitation at 8V.
J1 Boost Output
ON
Output voltage is 14VDC (for 12VDC excitation)
OFF
Output voltage is 12VDC
J2 (Shut down voltage)
ON
Shutoff at 17.8VDC (24VDC power supply)
OFF
Shutoff at 10.5VDC (12VDC power supply)
J3 (5VDC)
ON
5VDC output off
OFF
5VDC output active
825 Operation
J1
OFF (Does not require 14VDC power)
J2
(Selection depends on power source 12VDC or 24VDC)
J3
OFF (Must have 5VDC)
225 Operation
J1
OFF (If 8VDC Excitation is used (Optimum setting if possible)
ON (If 12VDC Excitation is required)
J2
(Selection depends on power source 12VDC or 24VDC)
J3
ON (NO 5VDC required)
8545-M854-O1 Rev B DCPOWER Installation
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825 INSTALLATION
ATTENTION! OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC
SENSITIVE DEVICES.
1. Unplug indicator from AC power source and then remove back panel of indicator.
2. Unplug power cord from power supply shield and remove terminal block from the cord.
Figure No. 1
3. Remove power supply shield from indicator.
4. Referring to Figure No. 2, cover the old power label with the new power label making sure GND
is on the right side.
Figure No. 2
TERMINAL BLOCK
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825 INSTALLATION, CONT.
5. Unplug both connectors (P1 and P2) from the power supply and then remove all four post and
screws from the four corners of the board. See Figure No. 3.
Figure No. 3
6. Remove the old power supply.
7. Referring to Figure No. 4, install screws into pre-tapped holes that fit DCPOWER board.
Figure No. 4
REMOVE POST AND
PHILLPS HEAD SCREW
REPLACE
SCREWS HERE
P1
P2
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825 INSTALLATION, CONT.
8. Install the DCPOWER board with the 3 pin connector (P1) facing the 3 pin plug. Making sure to
put nylon spacers back on screws under the board. Reconnect the short ground wire to the
screw next to the 3-pin connector. See Figure No. 5.
Figure No. 5
9. Reconnect the 3-pin plug to connector P1 and the 6-pin plug to connector P2. See Figure No. 6.
Figure No. 6
RECONNECT
GROUND WIRE HERE
P1
P2
P1
P2
8545-M854-O1 Rev B DCPOWER Installation
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825 INSTALLATION, CONT.
10. Referring to Figure No. 7, make sure jumpers J1, J2 and J3 are removed. NOTE: J2 may be
installed for 24VDC operation. Refer to JUMPERS section.
Figure No. 7
11. Reinstall power supply shield to indicator.
12. Run 11 to 30VDC and GND through a gland connector and connect to terminal block following
the DC power label.
13. Plug terminal block into power supply shield.
14. Reinstall indicator back panel.
MAKE SURE ALL
JUMPERS ARE
REMOVED
J1
J2
J3
8545-M854-O1 Rev B DCPOWER Installation
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205, 210 and 225 INSTALLATION
ATTENTION! OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC
SENSITIVE DEVICES.
1. Unplug indicator from AC power source and then remove back panel of indicator.
2. Remove white high voltage shield and power cord from terminal block. See Figure No. 8.
Figure No. 8
3. Referring to Figures No. 9a and 9b, cover the old power label with the new power label making
sure GND is on the side nearest the power supply.
Figure No. 9a Figure No. 9b
TERMINAL BLOCK
OLD POWER LABEL
NEW POWER LABEL
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205, 210 AND 225 INSTALLATION, CONT.
4. Unplug both connectors from power supply and remove cable that connects to main board.
Next, unscrew all four posts in the four corners of the power supply and remove the board.
See Figure No. 10.
Figure No. 10
5. Referring to Figure No. 11, install the DCPOWER board and secure with the four posts
removed in step 4.
Figure No. 11
REMOVE
REMOVE
P2
P1
INSTALL POSTS HERE
8545-M854-O1 Rev B DCPOWER Installation
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205, 210 AND 225 INSTALLATION, CONT.
6. Install the 3-pin plug on connector P1 on the DCPOWER.
7. Using the longer cable provided, install the 6-pin plug onto connector P2 of the DCPOWER and
then the 3-pin connector end to P2 on the 205/210 main board (P5 on the 225 main board).
Figure No. 12
8. Connect the short ground wire to chassis ground screw on the back panel. See Figure No. 12.
9. Referring to Figure No. 13, make sure jumper J1 is installed. Refer to JUMPERS Section for
setting for J2 and J3.
Figure No. 13
10. Run 11 to 30VDC and GND through a gland connector and connect to terminal block according
to DC power label.
11. Reinstall the indicator back panel.
CONNECT GROUND
WIRE HERE
P2
NEW LONGER P2 TO
MAIN BOARD CABLE
PLUG 3-PIN END OF
NEW LONGER P2
TO MAIN BOARD
CABLE HERE
J1
J2
J3
MAKE SURE JUMPER J1 IS INSTALLED
8545-M854-O1 Rev B DCPOWER Installation
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215 INSTALLATION
ATTENTION! OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC
SENSITIVE DEVICES.
1. Unplug indicator from AC power source and then remove back panel of indicator.
2. Remove white high voltage shield and power cord from terminal block. See Figure No. 14.
Figure No. 14
3. Referring to Figures No. 15a and 15b, cover the old power label with the new power label sure
GND is on the side nearest the power supply.
Figure No. 15a Figure No. 15b
TERMINAL BLOCK
OLD POWER LABEL
NEW POWER LABEL
8545-M854-O1 Rev B DCPOWER Installation
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215 INSTALLATION, CONT.
4. Unplug both connectors from power supply and remove cable that connects to charger board
inside white high voltage shield. Next, unscrew all four posts in the four corners of the power
supply and remove the board. See Figure No. 16.
Figure No. 16
5. Referring to Figure No. 17, install the DCPOWER board and secure with the four posts
removed in step 4.
Figure No. 17
REMOVE
REMOVE
REMOVE
CABLE
CHARGER
BOARD
P2
P1
INSTALL POSTS HERE
8545-M854-O1 Rev B DCPOWER Installation
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215 INSTALLATION, CONT.
6. Install the 3-pin plug on connector P1 on the DCPOWER.
7. Using the shorter cable provided, install the 6-pin plug onto connector P2 of the DCPOWER
and then the small connector end to the charger board. See Figure No. 18.
Figure No. 18
8. Referring to Figure No. 19, make sure jumper J1 is installed. Refer to JUMPERS section for
setting for J2 and J3.
Figure No. 19
9. Reinstall the white high voltage shield.
10. Run 11 to 30VDC and GND through a gland connector and connect to terminal block according
to DC power label.
11. Reinstall indicator back panel.
NEW SHORTER P2 TO
CHARGER BOARD
CABLE
PLUG SMALL
END OF NEW
SHORTER P2
TO CHARGER
BOARD CABLE
HERE
P2
P1
J1
J2
MAKE SURE JUMPER J1 IS INSTALLED
J3
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