Intermec CV60 Installation Manual
Dc-dc converter
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- User manual (110 pages) ,
- Installation manual (48 pages) ,
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Troubleshooting
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Summary of Contents for Intermec CV60
- Page 1 Installation Guide CV60 DC-DC Converter...
- Page 2 Intermec Technologies Corporation. © 2003-2006 by Intermec Technologies Corporation. All rights reserved. The word Intermec, the Intermec logo, Norand, ArciTech, Beverage Routebook, CrossBar, dcBrowser, Duratherm, EasyADC, EasyCoder, EasySet, Fingerprint, i-gistics, INCA (under license), Intellitag, Intell- itag Gen2, JANUS, LabelShop, MobileLAN, Picolink, Ready-to-Work,...
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Page 3: Table Of Contents
Contents Contents Before You Begin ......v Safety Information....v Global Services and Support . - Page 4 Contents Troubleshooting Information ... .21 Procedures ......22 Inspection .
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Page 5: 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 and click Service &... - Page 6 (in PDF). To order printed versions of the Intermec manuals, contact your local Intermec representative. To download a PDF manual 1 Visit the Intermec web site at www.intermec.com. 2 Click Service & Support > Manuals. 3 In the Select a Product field, choose the product whose docu- mentation you want to download.
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Page 7: Who Should Read This Guide
Outside the U.S.A. and Canada, contact your local Intermec rep- resentative. To search for your local representative, from the Intermec web site, click Contact. Who Should Read this Guide This guide is written for the person who is responsible for install- ing, configuring, and maintaining the dc-dc converter. - Page 8 viii CV60 DC-DC Converter Installation Guide...
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Page 9: Introduction
Introduction This chapter describes installation practices and unique components in the kits. CV60 DC-DC Converter Installation Guide... -
Page 10: Installation Guidelines
— Chapter Introduction Installation Guidelines The installer should be familiar with the brands and models of equipment where this kit is installed. 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 11: Input Power Cable
— Chapter Introduction A pair of green light-emitting diodes (LED), located near the output connectors on the power supply, will be lit whenever voltage is supplied to the output power cables. One LED indicates main power is OK (3 pin connector). The sec- ondary power LED will indicate Heater Power (2-pin connector) is Note: If the secondary LED is not lit when using both main and secondary power outputs, input pow-... -
Page 12: Output Power Cable
— Chapter Introduction power supply input. The fuse holder contains a 3AB, 20 ampere 250 Vdc fuse. Should it fail, diagnose the problem and correct it, then replace with exactly the same size and type fuse. The fuse is sized for a 12 volt system with heater. In systems that run at higher voltages, a smaller amperage fuse may be used. -
Page 13: Configuration Chart
— Chapter Introduction Configuration Chart Use the configuation chart on the following pages as a guide for your vehicle installation. Cable and Power Supply Chart Truck Voltage Power Supply Output Cable Heater 12V-60V 851-070-003 M2AF1800-XX Yes/No Use the chart below as a guide for your vehicle installation with the UPS (P/N: 851-059-002) and power supply. -
Page 14: New Installation
— Chapter Introduction New Installation Cable P/N 226-340-00X Input Cable P/N M2A-F1800-XX Output DC-DC Converter P/N 851-070-003 Material Description 203-669-001 Kit, CV60 PS 203-685-001 Installation Kit, Vehicle Power Supply 851-070-003 DC/DC Converter 6-60Vin/Dual 12Vout M2A-F1800-XX Cable, 3-pin/2-pin to 5-pin Y-cable 589162-001 CNTNR CDB, 8.25 x 6.125 x 4.00 962-054-107... -
Page 15: Installation Procedures
Installation Procedures This chapter outlines mechanical and electrical installation instructions. CV60 DC-DC Converter Installation Guide... -
Page 16: About This Installation
— Chapter Installation Procedures About this Installation Follow the instruction procedures as closely as possible while keeping the following in mind: S Power supply must be securely mounted. S Mounting surface must be sturdy. S Mounting surface must be able to sink power supply heat. S Fuse must be close to vehicle power source. -
Page 17: Installation Summary
— Chapter Installation Procedures Installation Summary Installation consists of five primary steps, which should be carried out in the following order: 1 Connect the input cable to the power supply. 2 Mechanically install and secure the power supply. 3 Route and secure the power cable. 4 Shorten cable as appropriate, then crimp the fuse holder to the joined RED and BLACK wires (positive). -
Page 18: Before You Start
— Chapter Installation Procedures Before You Start Equipment failure or damage will result if the vehicle power source voltage does not fall within the input voltage rating of the power supply furnished to you. Power Supplies Read the nomenclature on the power supply and verify that the input voltage rating is correct for the vehicle you will be instal- ling it in. -
Page 19: Mount The Power Supply
— Chapter Installation Procedures Mount the Power Supply The input power cable is approximately 9 feet long and can be shortened as needed. It must NOT be extended under any cir- cumstances. The output power cable is approximately 6 feet and cannot be lengthened. -
Page 20: Power Cable Installation
— Chapter Installation Procedures 4 Place a lockwasher on each bolt. 5 Insert the bolt/lockwasher assemblies through the power sup- ply holes and into the threaded mounting holes. Power Cable Installation Follow these guidelines and other instructions closely when installing power cables. Completely install power cables before making connections to equipment. -
Page 21: Cable Termination
— Chapter Installation Procedures or she is working with. Both large (3/8 inch) and smaller termi- nal rings are provided to accomodate most installation needs. This kit contains additional bolts, nuts, and washers in the event you will connect the input power cable directly to a vehicle bat- tery. -
Page 22: Cut And Strip Power Cable
— Chapter Installation Procedures Cut and Strip Power Cable 1 Cut the power cable near the power source or battery. 2 Strip the cable jacket back 12-14 inches. 3 Slide heat shrink tubing over cable jacket. 4 Strip 1/4” of insulation from individual wires. 5 Twist the white and green (negative) wires together. -
Page 23: Heat Shrink Tubing
— Chapter Installation Procedures Heat Shrink Tubing This kit contains a 6-inch length of 3/8 inch heat shrink tubing which you will cut into three pieces, and a 12 inch length of 1/8 inch heat shrink tubing for the shield wire. Tubing must be in place before terminating wire ends. -
Page 24: Prepare The Cable Ends
— Chapter Installation Procedures Prepare the Cable Ends Both large (3/8 inch) and smaller (#10) terminal rings are provided for your selection and use in the following steps. A small (#10) ter- minal should be crimped to the shield wire and then fastened to ve- hicle chassis ground. -
Page 25: Direct Battery Connections
— Chapter Installation Procedures Direct Battery Connections Side-Mount Battery Terminals 1 Remove both terminal screws from the vehicle battery. 2 Screw a 3/8” nut as far as it will go onto a 3/8” x 1-1/2” bolt furnished in the kit. 3 Slip a 3/8”... - Page 26 — Chapter Installation Procedures Vehicle battery 3/8 x 1-1/2” bolt 3/8” nut Vehicle battery cable 3/8” Washers Fuse holder Side Mount Battery Terminals Note: See note on page 12 when installing on gas powered vehicles. CV60 DC-DC Converter Installation Guide...
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Page 27: Top-Mount Battery Terminals
— Chapter Installation Procedures Top-Mount Battery Terminals 1 Remove the bolts from the vehicle battery terminals. 2 Replace those bolts with 3/8” x 1-1/2” bolts and nuts from the installation kit. Tighten the nuts. 3 Slip a 3/8” washer onto the end of each bolt. 4 Slide the positive (fuse holder red wire) terminal ring onto the positive battery bolt. -
Page 28: Cable Clamps
— Chapter Installation Procedures Cable Clamps Secure the cables every 18 inches using locking wire ties or adjust- able cable clamps. Remove the paper backing from a clamp and stick the clamp in place while drilling a pilot hole with a #26 drill bit. -
Page 29: Troubleshooting Information
Troubleshooting Information This chapter contains troubleshooting information and connector pin outs. CV60 DC-DC Converter Installation Guide... -
Page 30: Procedures
— Chapter Troubleshooting Information Procedures Three basic procedures within this chapter identify and correct most power supply problems you may encounter during installa- tion. Connector pin-out information is also furnished for your convenience. Recommended diagnostic procedures are listed below and in gen- eral, should be followed in the order given. -
Page 31: Electrical Measurements
— Chapter Troubleshooting Information Electrical Measurements Voltage Connector pinout information is provided to allow you to measure voltage at the input power cable and at either end of the power output cable. Continuity Caution: Cables MUST be disconnected at both ends before conducting continuity tests. -
Page 32: Troubleshooting Charts
— Chapter Troubleshooting Information Troubleshooting Charts The following troubleshooting chart assumes that your computer or other equipment does not work and that the problem is caused by the power supply or its associated cables. Follow the procedures in the tables in the order shown for maximum efficiency. Power Supply Reset Where the troubleshooting chart tells you to “reset the power supply”... -
Page 33: Power Supply Pinouts
— Chapter Troubleshooting Information Power Supply Pinouts Case Connector Negative Positive chassis is gnd Input Power Connector Pin 1 Pin 3 Pin 2 Pin 4 Secondary Output Power Connector (Heater) Pin 2 Pin 1 Main Output Power Connector Pin 2 Pin 1 Pin 3 CV60 DC-DC Converter Installation Guide... - Page 34 — Chapter Troubleshooting Information P/N 321-040-001 108.0 +/- 3.0” Pin View Pin View Note: During installation, you will cut and discard the two pin cable connector. Note: The cables in the installation kit may contain alternate wire colors. Refer to the chart below for the wire color equivalent. CV60 DC-DC Converter Installation Guide...
- Page 36 Worldwide Headquarters 6001 36th Avenue West Everett, Washington 98203 U.S.A. tel 425.348.2600 fax 425.355.9551 www.intermec.com CV60 DC-DC Converter Installation Guide *962-054-107B* P/N 962-054-107B...
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