Intermec CV60 Installation Manual
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Intermec CV60 Installation Manual

Intermec CV60 Installation Manual

Vehicle power supply
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Installation Guide
Vehicle Power
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Summary of Contents for Intermec CV60

  • Page 1 Installation Guide Vehicle Power Supply...
  • Page 2 The information contained herein is provided solely for the purpose of allowing customers to operate and service Intermec-manufactured equipment and is not to be released, reproduced, or used for any other purpose without written permission of Intermec Technologies Corporation.
  • Page 3 Document Change Record This page records changes to this document. The document was originally released as version 001. Version Number Date Description of Change 10/2006 Added information about the metal surface on which the power supply may be attached. 08/2007 Corrections to voltage ratings, additional power supply isolation mounting instructions, and clarifications to troubleshooting tables.
  • Page 4 Vehicle Power Supply Installation Guide...

  • Page 5: Table Of Contents

    Contents Before You Begin....... . . vii Safety Information ......vii Global Services and Support .
  • Page 6 Installing the Power Cables ......17 Power Cable Connections ....18 Cable Termination –...

  • Page 7: Before You Begin

    Global Services and Support Warranty Information To understand the warranty for your Intermec product, visit the Intermec web site at www.intermec.com Support. The Intermec Global Sales & Service page appears.

  • Page 8: Web Support

    3 In the Select a Product field, choose the product whose documentation you want to download. Visit the Intermec technical knowledge base (Knowledge Central) at intermec.custhelp.com information or to request technical support for your Intermec product. Telephone Support These services are available from Intermec Technologies. Service...

  • Page 9: Who Should Read This Guide

    Renew a contract. Inquire about repair billing or other service invoicing questions. Outside the U.S.A. and Canada, contact your local Intermec representative. To search for your local representative, from the Intermec web site, click Contact. Who Should Read This Guide...
  • Page 10 Vehicle Power Supply Installation Guide...

  • Page 11: Introduction

    Introduction This chapter describes installation practices and unique components in the vehicle power supply kits. Vehicle Power Supply Installation Guide...

  • Page 12: About The Dc Power Supply Kit

    Installation Guidelines The installer should be familiar with the brands and models of equipment where this kit is installed, for example the CV60. They should also be trained and experienced in vehicle electrical systems. Installer must follow these guidelines and the installation procedures as well as those of the lift manufacturer to ensure a safe and reliable installation.

  • Page 13: Power Supply Options

    VDC for use with vehicles using electrical systems running 12-60V. • The other supply is rated for operation from 15-96V, and Intermec recommends it for use on electric vehicles running 60-96 VDC. • Both provide 12 VDC output which is filtered and regulated.

  • Page 14: About The Leds

    Chapter 1 — Introduction Since the power supply will produce heat, it is advisable to mount it on a minimum of 130-160 square inches (840 to 1030 square centimeters) of metallic surface to disperse heat. This location should not be in the vicinity of sources of vehicle-generated heat. Note: Use the hardware supplied in the kit, or equivalent, to mount the power supply.

  • Page 15: Input Power Cable

    Input Power Cable Note: Keep the cable as short as possible. Extra cable picks up noise, adds power loss, and can snag on equipment. The input power cable may be shortened as needed, but should not be extended on 12V or lower systems. For higher voltage systems, keep cable extensions to a minimum and use only equivalent or lower gauge (larger diameter) wire.

  • Page 16: Output Power Cable

    Chapter 1 — Introduction Should the fuse fail, diagnose and correct the underlying problem, and then replace with exactly the same size and type of fuse. Do not replace fuse with larger than recommended fuse values. Use of larger fuse values may result in damage to equipment.

  • Page 17: Installation Diagrams

    Installation Diagrams Note: Output cables used with P/N 851-041-xxx connect to the 3-pin output connector. There is only one connector per power supply. Power Supply Installation without Heater Fuse 60-96V Input Cable P/N 226-340-004 Power Supply Installation with Heater Fuses 60-96V Cable P/N 226-340-004...
  • Page 18 Chapter 1 — Introduction Materials List for Components Material Description 203-780-002 203-804-002 Installation Kit, Vehicle Power Supply 851-041-003 DC/DC Converter, 60-96V in/Dual 12V out VE012-8014-XX Cable, 3-pin VE012-8017-XX Cable, 3-pin/3-pin to 5-pin Y-cable 226-340-004 Cable 932-003-003 Vehicle Power Supply Installation Guide Power Supply Installation with Heater Optional Fuse 12-60V...

  • Page 19: Wiring Diagram

    Materials List for Components (continued) Material Description VE012-8019-XX Cable, 3-pin/2-pin to 5-pin Y-cable 932-003-003 Vehicle Power Supply Installation Guide Wiring Diagram This wiring diagram outlines several possible connections to the power source in a vehicle lift truck. Use this as a reference during the planning phase of your power supply installation.
  • Page 20 Chapter 1 — Introduction Vehicle Power Supply Installation Guide...

  • Page 21: Installation Process

    Installation Process This chapter outlines mechanical and electrical installation instructions. Vehicle Power Supply Installation Guide...

  • Page 22: Installation Recommendations

    Chapter 2 — Installation Process Installation Recommendations Review the lift vehicles to be serviced before you start. Plan the installation following these safety and utility recommendations. • Install the power cable at the vehicle power source if possible or at the point where the connection is first made to the lift. •...

  • Page 23: Tools Required

    #8 flat washer Snap-in bushing Screw, m/s 1/4-20 x 1-1/4” Flat washer, 1/4” Locking nut, 1/4-20 Lockwasher, 1/4” Cable tie, locking Vehicle Power Supply Installation Guide Chapter 2 — Installation Process Intermec Part Number Quantity 226-340-004 315-075-003 315-074-003 800-099-001 803-099-001 802-099-001...

  • Page 24: Preparing The Power Input Cable

    (larger diameter) wire. Keep the cable as short as possible. Extra cable picks up noise, adds power loss, and is prone to snagging on equipment. Intermec Part Number Quantity 12.0” (30.5 cm) 6.0”...

  • Page 25: Direct Versus Isolation Mounting On Lift Chassis

    You should take these lengths and the intended location of your electronic equipment into consideration when choosing a mounting location for the power supply. The mounting surface location must provide 130-160 square inches (840 to 1030 square centimeters) of metallic surface to sink heat generated by the power supply.

  • Page 26: Creating A Custom Electrical Isolation Mount

    A fault condition like a wire shorting to the lift chassis may present a power path that could negatively impact the power supply and the Intermec computer, as well as any device connected to the shorted wire. While this is an uncommon secondary failure mode, you can avoid this by creating an electrical isolation mount.

  • Page 27: Installing The Power Cables

    Use Method B where the back side of the mounting location is inaccessible. Note that this method requires that the mounting plate be thick enough to accept and retain sufficient thread to provide a secure and reliable mechanical installation. To use mounting method A 1 Mark and center punch the two mounting hole locations.

  • Page 28: Power Cable Connections

    Chapter 2 — Installation Process • Secure the cables at least every 18 inches (46 cm) throughout the cable run. Use adjustable clamps (see the last page in this chapter) or wire-tie to existing vehicle cable runs Warning: If this installation will be on a gas- powered vehicle, you must install either an On/Off switch (minimum 15A DC rating such as ITW P/N 163-900-034) or an automatic shut-off device in...

  • Page 29: Cable Termination - Overview Of Process

    This kit contains additional bolts, nuts, and washers should you need to connect the input power cable directly to a vehicle battery. Use for these parts is detailed in the instructions that follow. Cable Termination – Overview of Process You must cut the cable to length, cut off a portion of the outer cable jacket, and strip the individual wire ends of the cable as instructed.

  • Page 30: Heat Shrink Tubing

    Chapter 2 — Installation Process Heat shrink tubing Input power cable Strip the cable jacket 12-14 inches (30-36 cm) Note: Make sure that the negative input connector wires connect to pins 1 and 2 of the input connector. Check that the other two wires connect to pins 3 and 4 of the input connector.

  • Page 31: Finishing The Cable Ends

    Green and white twisted pair 3/8” Completed Cable Ready for Connection to Vehicle Note: Be sure to attach shield wire to the metal surface on which the power supply is mounted. Finishing the Cable Ends Both large (3/8 inch) and small (#10) terminal rings are provided in the kit.

  • Page 32: Power Source Connections

    Chapter 2 — Installation Process Power Source Connections The next few pages show you the hardware (nuts, bolts, and washers) included in this kit if you are connecting the power cable directly to a vehicle battery. Note: No additional hardware is provided for connecting the power cable to other vehicle power sources.

  • Page 33: Top-Mount Terminals

    Repeat steps 2 through 8 for the negative wire (white-green pair) from the power input cable, connecting the wire to the negative (-) battery terminal. Note: See the warning on page 18 if you are installing on gas-powered vehicles. Vehicle battery 3/8 x 1-1/2”...
  • Page 34 Chapter 2 — Installation Process 4 Reinstall the positive battery cable, then tighten the nut securely. 5 Slip a 3/8-inch washer onto the extended end of each bolt. 6 Slide the positive (fuse link with red wire) terminal ring from the input power cable onto the positive (+) battery bolt.

  • Page 35: Cable Clamps

    Cable Clamps Secure the cables every 18 inches (46 cm) using locking wire ties or adjustable cable clamps. To install cable clamps 1 Remove the paper backing from a clamp and adhere the clamp in place. 2 Drill a pilot hole with a #26 drill bit and use #6 sheet metal screws to permanently hold each clamp in place.

  • Page 36: Sample Installations

    Chapter 2 — Installation Process Sample Installations In this installation example, the power supply is securely attached with good air flow, easy access, and neatly tied-off cabling. Additionally, this installation allows: • Easy access to power supply components, LED visibility is good.
  • Page 37 Here is another example of an effective installation. In this example, the benefits include: • UPS is accessible without disconnecting it from the lift. • Battery swap is accommodated without removing the UPS entirely. • Metal area contact is reduced, but ventilation is good, reducing the need for additional heat sink.
  • Page 38 Chapter 2 — Installation Process A poorly planned installation presents several challenges, including: • Difficult access to power supply components, LED visibility in operation is impossible. • Damage could occur to lift or power supply components if something fails. • UPS battery removal is difficult due to location. •...

  • Page 39: Troubleshooting Information

    This chapter contains troubleshooting information and connector pin outs. Vehicle Power Supply Installation Guide Troubleshooting Information...

  • Page 40: Identifying And Correcting Problems

    Chapter 3 — Troubleshooting Information Identifying and Correcting Problems Three basic procedures within this chapter identify and correct most power supply problems you may encounter during installation. Connector pin-out information is also furnished for your convenience. The recommended diagnostic procedures listed below should be followed in the order given.

  • Page 41: Inspecting The Fuse

    • Make sure cables are adequately dressed (protected) to go around sharp edges, through holes without burrs, and do not run unprotected around the lift. • The sheath of the power cable adds protection from accidental nicks and cuts. Additional sheathing may be beneficial to protect the cables in highly vulnerable locations.

  • Page 42: Using Component Substitution

    Chapter 3 — Troubleshooting Information Using Component Substitution Component substitution is the most expedient and certain troubleshooting technique.This is especially valuable when trying to resolve intermittent problems. • Use the guidelines in the following troubleshooting charts, substituting only when directed to do so. •...

  • Page 43: Advanced Troubleshooting

    Troubleshooting - Main Output LED (continued) Meaning Still not lit Still no output from power supply Flickers Intermittent main power connection Flickers Power supply detected over-voltage condition Flickers Power supply detected over-current condition Flickers Power supply detected over-temperature condition Advanced Troubleshooting Assuming steps in the previous troubleshooting chart were taken, proceed to these next steps to resolve power failure problems.

  • Page 44: Power Supply Pinouts

    Chapter 3 — Troubleshooting Information Advanced Troubleshooting Steps (continued) LED/Voltage Meaning Voltage not No input power present to the power supply Voltage still Still no input not present power to the power supply Fuse blowing, Power system is but no LED lit drawing too much current Power Supply Pinouts...
  • Page 45 2-Pin View Note: During installation, you will cut and discard one of these cable connectors. Wire coloring to pins follows this pattern. Note: The cables in the installation kit may contain alternate wire colors. Refer to the following chart for the wire color equivalent.
  • Page 46 Chapter 3 — Troubleshooting Information Vehicle Power Supply Installation Guide...
  • Page 47 Chapter 3 — Troubleshooting Information Vehicle Power Supply Installation Guide...
  • Page 48 Worldwide Headquarters 6001 36th Avenue West Everett, Washington 98203 U.S.A. tel 425.348.2600 fax 425.355.9551 www.intermec.com © 2007 Intermec Technologies Corporation. All rights reserved. Vehicle Power Supply Installation Guide *932-003-003* P/N 932-003-003...

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