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
CV60
Vehicle
Power Supply

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Summary of Contents for Intermec CV60

  • Page 1 Installation Guide CV60 Vehicle Power Supply...
  • Page 2 Intermec. Information and specifications contained in this document are subject to change without prior notice and do not represent a commitment on the part of Intermec Technologies Corporation. E 2004-2005 by Intermec Technologies Corporation. All rights reserved.

  • Page 3: Before You Begin

    Before You Begin Before You Begin Safety Summary Do not repair or adjust alone First aid Resuscitation Energized equipment CV60 Vehicle Power Supply Installation Guide...

  • Page 4: Safety Icons

    Attention: Une précaution vous avertit d'une procédure de fonctionnement, d'une méthode, d'un état ou d'un rapport qui doit être strictement respecté pour empêcher l'endommagement ou la destruction de l'équipement, ou l'altération ou la perte de données. CV60 Vehicle Power Supply Installation Guide...
  • Page 5 Before You Begin Global Services and Support Warranty Information Web Support CV60 Vehicle Power Supply Installation Guide...
  • Page 6 Before You Begin Telephone Support Call 1 800 755 5505 and Service Description choose this option CV60 Vehicle Power Supply Installation Guide...

  • Page 7: Who Should Read This Manual

    Before You Begin Who Should Read this Manual? Related Documents Document Title Part Number CV60 QuickStart Guide CV60 User Manual Mobile DC-DC Uninterruptible Power Supply CV60 Vehicle Power Supply Installation Guide...
  • Page 8 Before You Begin viii CV60 Vehicle Power Supply Installation Guide...
  • Page 9 Contents Contents Introduction CV60 Vehicle Power Supply Installation Guide...

  • Page 10: Installation Procedures

    Contents Installation Procedures Troubleshooting Information CV60 Vehicle Power Supply Installation Guide...
  • Page 11 Introduction CV60 Vehicle Power Supply Installation Guide...

  • Page 12: Installation Guidelines

    — Chapter Introduction Installation Guidelines About the CV60 DC Power Supply Kits CV60 Vehicle Power Supply Installation Guide...
  • Page 13 — Chapter Introduction Note Considerations Note: should not Use only the hardware supplied in the kit to mount the power supply, do not use sheet metal screws. CV60 Vehicle Power Supply Installation Guide...
  • Page 14 By cutting off the unneeded connector, a single cable can meet either low or high voltage input range power supply requirements. The cut end is then terminated for connection to the vehicle power source. Inline Fuse CV60 Vehicle Power Supply Installation Guide...

  • Page 15: Configuration Chart

    Chapter Introduction Output Power Cable Note Configuration Chart Cable and Power Supply Chart Truck Power Supply EMEA Filter Input Output Heater Volt Cable Cable Note: UPS Cable and Power Supply Chart DC-DC Use Cable: CV60 Vehicle Power Supply Installation Guide...

  • Page 16: New Installations

    — Chapter Introduction New Installations Cable P/N 226-340-001 Cable P/N Input M2A-F1100-XX DC-DC Converter P/N 851-041-002 Output High Voltage Option - No Heater Material Description CV60 Vehicle Power Supply Installation Guide...
  • Page 17 — Chapter Introduction Cable P/N Cable P/N M2A-F1400-XX 226-340-001 Output 2 Cables DC-DC Converters P/N 851-041-002 2 Fuses Input High Voltage Option - Heater Material Description CV60 Vehicle Power Supply Installation Guide...
  • Page 18 — Chapter Introduction Existing Installations - 5055 to CV60 Upgrade ( use 851-070-001 for inputs less than 60VDC 5055 Cable P/N 321-341-001 Cable P/N 321-340-001 Output Input DC-DC Converter P/N 851-041-002 CV60 Cable P/N 321-340-001 DC-DC Converter P/N 851-041-002 M2A-F1200-XX 12"...
  • Page 19 — Chapter Introduction Cable P/N 226-340-001 Cable P/N M2A-F1400-XX DC-DC Converter P/N 851-041-002 High Voltage Option - Heater Material Description CV60 Vehicle Power Supply Installation Guide...
  • Page 20 — Chapter Introduction AC Power Cord, Wall Charger 852-042-002 321-054-001 M2A-F1200-XX 12" Adapter Cable AC Desk Option Material Description CV60 Vehicle Power Supply Installation Guide...

  • Page 21: Installation Procedures

    Installation Procedures This chapter outlines mechanical and electrical installation instructions. CV60 Vehicle Power Supply Installation Guide...

  • Page 22: About This Installation

    S Mounting surface must be able to sink power supply heat. S Fuse must be close to vehicle power source. S Keep cables as short as possible, and secure them at least ev- ery 18 inches. CV60 Vehicle Power Supply Installation Guide...

  • Page 23: Installation Summary

    5 Make final connections to the vehicle power source. Tools Required S Common hand tools (screwdriver, pliers, etc.) S Heat gun for heat shrink tubing S Wire crimping and stripping tool S Electric drill, drill bits CV60 Vehicle Power Supply Installation Guide...
  • Page 24 3 Turn the cable connector collar clockwise to secure it. 4 Clamp the ferrite beard onto the input cable near the power supply. Make sure tabs are fully engaged. 5 Cut cable at the unused cable connector. 6 Discard the unused connector. CV60 Vehicle Power Supply Installation Guide...

  • Page 25: Mount The Power Supply

    4 Place a lockwasher on each bolt. 5 Insert the bolt/lockwasher assemblies through the power supply holes and into the threaded mounting holes. Power Cable Installation Follow these guidelines and other instructions closely when installing power cables. CV60 Vehicle Power Supply Installation Guide...
  • Page 26 This kit contains additional bolts, nuts, and washers in the event you will connect the input power cable directly to a vehicle bat- tery. The intended use for these parts is detailed in the instruc- tions that follow. CV60 Vehicle Power Supply Installation Guide...

  • Page 27: Cable Termination

    Finally, you must mechanically complete the connections to the vehicle power source or battery and electrically connect the shield wire to vehicle chassis ground using a self-tapping screw and flat washer. CV60 Vehicle Power Supply Installation Guide...
  • Page 28 Note: See Note on page 20 when installing on gas powered vehicles. Heatshrink Tubing Green and White WIres (negative) Red and Black WIres (positive) Input Power Shield wire w/heatshrink applied Cable Strip the Cable Jacket 12-14 inches CV60 Vehicle Power Supply Installation Guide...

  • Page 29: Heat Shrink Tubing

    Use a heat gun to shrink tubing. Green and White twisted pair Red and Black twisted pair 3/8” 3/8” 3/8” 1/8” Shield wire Heatshrink locations CV60 Vehicle Power Supply Installation Guide...

  • Page 30: Power Source Connections

    3 Slip a 3/8” washer onto the bolt. 4 Slide the positive (fuse holder red wire) terminal ring onto the positive battery bolt. 5 Slip a second 3/8” washer onto that bolt. CV60 Vehicle Power Supply Installation Guide...
  • Page 31 Repeat steps 2 through 8 for the negative wire (white-green pair) from the input power cable, connecting the wire to the negative (-) battery terminal. Note: See note on page 20 when installing on gas powered vehicles. CV60 Vehicle Power Supply Installation Guide...
  • Page 32 — Chapter Installation Procedures Vehicle battery Bolt Washers Vehicle Battery Cable Fuse holder Top Mount Battery Terminals CV60 Vehicle Power Supply Installation Guide...
  • Page 33 7 Use a self-tapping screw and a flat washer to connect shield wire to vehicle chassis ground. Repeat steps 3 through 6 for the negative wire (white-green pair) from the input power cable, connecting the wire to the negative (-) battery terminal. CV60 Vehicle Power Supply Installation Guide...
  • Page 34 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 20 when installing on gas powered vehicles. CV60 Vehicle Power Supply Installation Guide...

  • Page 35: Final Connections

    2 Slide the cable connector IN as far as it will go. 3 Turn the cable connector collar clockwise to secure it. Note: Refer to Chapter 3, “Troubleshooting Information,” for power fault diagnostic information. CV60 Vehicle Power Supply Installation Guide...
  • Page 36 — Chapter Installation Procedures CV60 Vehicle Power Supply Installation Guide...

  • Page 37: Troubleshooting Information

    Troubleshooting Information CV60 Vehicle Power Supply Installation Guide...
  • Page 38 — Chapter Troubleshooting Information Procedures Basic Diagnostic Procedures Inspection Power Supply lighted Cables, Connections Fuse CV60 Vehicle Power Supply Installation Guide...

  • Page 39: Troubleshooting Charts

    — Chapter Troubleshooting Information Electrical Measurements Voltage Continuity Caution: Cables MUST be disconnected at both ends before conducting continuity tests. Substitution Advantages Disadvantages When to Substitute Troubleshooting Troubleshooting Charts CV60 Vehicle Power Supply Installation Guide...
  • Page 40 Power Supply Reset Power Failure Troubleshooting Chart 1 Observe Result Meaning Remedy then reset the power supply. Power Failure Troubleshooting Chart 2(assumes steps in chart above have been followed). Observe Result Meaning Test or Remedy CV60 Vehicle Power Supply Installation Guide...
  • Page 41 — Chapter Troubleshooting Information Power Supply Pinouts Case Connector Positive Negative chassis is gnd Input Power Connector Pin 2 Pin 1 (HV) Output Power Connector Pin 2 Pin 1 Pin 3 CV60 Vehicle Power Supply Installation Guide...
  • Page 42 Note: During installation, you will cut and discard one of these cable connectors. Note: The cables in the installation kit may contain alternate wire colors. Refer to the chart below for the wire color equivalent. CV60 Vehicle Power Supply Installation Guide...
  • Page 44 Corporate Headquarters 6001 36th Avenue West Everett, Washington 98203 U.S.A tel 425.348.2600 fax 425.355.9551 www.intermec.com CV60 Vehicle Power Supply Installation Guide - March 2005 *962-054-076D* *962-054-076D* Rev D...

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