Intermec CV30 Vehicle Power Supply Installation Guide
Intermec CV30 Manual
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- Intermec CV30 | Vehicle Power Supply Installation Guide - Page 1
Installation Guide Vehicle Power Supply - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 2
ShopScan, Smart Mobile Computing, TE 2000, Trakker Antares, and Vista Powered are either trademarks or registered trademarks of Intermec Technologies Corporation. There are U.S. and foreign patents as well as U.S. and foreign patent applications pending. ii Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 3
002 10/2006 Added information about the metal surface on which the power supply may be attached. 003 08/2007 Corrections to voltage ratings, additional power supply isolation mounting instructions, and clarifications to troubleshooting tables. iii Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 4
iv Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 5
and Support vii Warranty Information vii Web Support viii Telephone Support viii Who Should Read This Guide ix 1 Introduction 1 About the DC Power Supply Kit 2 Installation Guidelines 2 Power Supply Options 3 About the LEDs 4 Input Power Cable 5 Output Power Cable 6 Configuration Chart - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 6
Battery Connections 22 Side-Mount Battery Terminals 22 Top-Mount Terminals 23 Cable Clamps 25 Connecting the Output Power Cable 25 Sample Installations 26 3 Troubleshooting Information 29 Identifying and Correcting Problems 30 Troubleshooting the Power Supply 30 Inspecting the Power Supply - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 7
instructions for handling a particular condition or set of circumstances. 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 & Support. The Intermec Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 8
an existing order. Order printer labels and ribbons. 1 and then choose 2 1 and then choose 1 Order spare parts Order spare parts 1 or 2 and then choose 4 Technical Support Talk to technical support 2 and then choose 2 about your Intermec product. Vehicle Power Supply Installation Guide viii - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 9
power supply, including how you install, configure, operate, maintain, and troubleshoot the power supply. Before you work with the vehicle power supply, you should be a trained service person or one familiar with forklift truck service and maintenance. Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 10
Vehicle Power Supply Installation Guide x - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 11
1 Introduction This chapter describes installation practices and unique components in the vehicle power supply kits. Vehicle Power Supply Installation Guide 1 - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 12
a safe and reliable installation. • Power supply must be securely mounted. • Mounting surface must be sturdy. • Mounting surface must provide power supply heat sink. • Fuse must be close to vehicle power source and be in line with Intermec equipment only. • Keep cables as short as possible, and - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 13
, the table below provides other means of identification. Intermec Part Number 851-070-003 851-041-003 Input Connector 4-pin, keyed 2-pin, keyed Input Voltage 6-60 VDC, 14A 15-96 VDC, 4.5 A The power supply should be mounted to the vehicle chassis, or connected (electrically) via external - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 14
located near the output connectors on the power supply, will be lit whenever voltage is supplied to the output power cable. Mount the power supply in a location that allows easy visibility to the LEDs for troubleshooting. One LED indicates main power is functioning (3-pin connector). The secondary - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 15
either low or high voltage input-range power supply requirements. See "Mounting the Power Supply" on page 14 for detailed instructions for attaching the power cable. Inline Fuse A snap-twist inline fuse holder is furnished as part of this kit. It must be connected as close as possible (electrically - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 16
in your location. Output power cables are approximately 6.0 feet (1.83 m) to 7.0 feet (2.13 m) long and have a durable 3-pin connector and/or a 2-pin connector to mate with the power supply. The connector on the far end of the cable is specific to the vehicle mount computer or docking device in - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 17
Converters P/N 851-041-003 Cable P/N VE012-8017-XX Note: Attach both connectors to the power supply even for non-heated vehicle mount computers. This prevents accidental damage, dirt accumulation, or unwanted electrical contact to the unused connector. Vehicle Power Supply Installation Guide 7 - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 18
12V out Cable, 3-pin Cable, 3-pin/3-pin to 5-pin Y-cable Cable Vehicle Power Supply Installation Guide Power Supply Installation with Heater Optional 12-60V Fuse Output Cable P/N VE012-8019-XX Input Cable P/N 226-340-004 DC-DC Converter P/N 851-070-003 Fixed or Vehicle Mount Computer Note - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 19
to 5-pin Y-cable 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. Connector to battery - Best + + To - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 20
Chapter 1 - Introduction 10 Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 21
2 Installation Process This chapter outlines mechanical and electrical installation instructions. Vehicle Power Supply Installation Guide 11 - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 22
VDC) voltage rating, P/N 851-041-003, has a 2-pin input connector. • Using a mounting bracket for the vehicle power supply simplifies service, since you can take down and replace the entire bracket with another bracket, and troubleshoot the system away from the lift. • Design a bracket that will be - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 23
as instructed. 5 Make final connections to the vehicle power source. Tools Required • Common hand tools (screwdriver set and pliers) • Heat gun for heat shrink tubing • Wire crimping and stripping tool • Electric drill, drill bits • DC Ohmmeter Parts List Description Power cable Fuse holder - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 24
Parts List Description Intermec Part Number h/s tubing, black, 1/8" diameter 321-650-003 h/s tubing, black, 3/8" diameter 321-650-006 Ferrite bead 309-065-006 Quantity 12.0" (30.5 cm) 6.0" (15.2 cm) 1 Preparing the Power Input Cable Only one of the input connectors will fit the power supply - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 25
surface to sink heat generated by the power supply. This metallic mounting surface may be connected to or actually be part of the vehicle chassis as long as the chassis is not electrically connected to the battery negative or positive. Side-Mount Battery with View of Negative (-) and Positive - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 26
chassis may provide additional protection from other risks encountered on forklifts or vehicles. 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 - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 27
the Power Cables Follow these guidelines and other instructions closely when installing power cables. Never work on a powered (hot) system. • Completely install power cables before making connections to equipment. • Route the power cables from the general area where the power supply will be mounted - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 28
is mounted. Prior to connecting power recheck to make sure the fuse is connected to the positive connection on the DC/DC input, and that the negative lead connects to the return to the battery at a location not shared with motors, flyback diodes, or other sources of electrical noise. Instructions - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 29
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 -powered or - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 30
holder ends, then position all heat shrink tubing in the locations shown in the illustration that follows. 2 Use a heat gun to shrink tubing. 3 Use the 1/8-inch shrink sleeve tubing over shield wire to prevent contact with other live (powered) circuits. 20 Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 31
on which the power supply is mounted. Finishing the Cable Ends Both large (3/8 inch end of the fuse block and then a terminal ring on the other end of this wire (see previous Completed Cable illustration). 4 Crimp the small terminal ring on the shield wire. Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 32
applicable instructions. Side-Mount Battery Terminals Attach the vehicle battery cable to a side-mount battery terminal as shown in the "Side-Mount Battery Terminals" illustration following the last step in this set of procedures. To attach power supply cable 1 Disconnect the negative battery cable - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 33
Vehicle battery cable Fuse holder Side-Mount Battery Terminals Top-Mount Terminals Attach the vehicle battery cable to a top-mount battery terminal as shown in the "Top-Mount Battery Terminals" illustration following the last step in this set of procedures. To attach power supply cable 1 Disconnect - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 34
6 through 8 for the negative battery cable wire (white-green pair) from the power input cable, connecting the wire to the negative (-) battery terminal. Nut Vehicle battery Bolt Washers Vehicle battery cable Fuse holder Top-Mount Battery Terminals 24 Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 35
as far as it will go into the power supply. 3 Turn the cable connector collar clockwise to secure it. 4 After all connections are secure, connect power to the system. Note: See "Troubleshooting Charts" on page 32 for power fault diagnostic information. Vehicle Power Supply Installation Guide 25 - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 36
allows: • Easy access to power supply components, LED visibility is good. • Power cables are out of the way and tied off, with adequate heat sink, and good air access for cooling. • Good access for component service. • Full access to the UPS battery. 26 Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 37
. • 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. • No direct sunlight in this environment helps maintain lower operating temperature. Vehicle Power Supply Installation Guide 27 - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 38
impossible. • Damage could occur to lift or power supply components if something fails. • UPS battery removal is difficult due to location. • The installation is tedious, time-consuming, and difficult to work on. • Troubleshooting problems made difficult. • An enclosed environment will significantly - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 39
3 Troubleshooting Information This chapter contains troubleshooting information and connector pin outs. Vehicle Power Supply Installation Guide 29 - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 40
or current. The LED will flicker until the problem is resolved. In some cases, you may have to remove power to reset the power supply. Inspecting the Cables and Connections Visually inspect all cable connectors and connections to the vehicle power source. Correct any obvious faults. • Use your hands - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 41
sporadically, or power supply shut down occurs at random, you may want to use a megohmmeter to check cables for high-resistance shorts between wires or between a wire and the cable shield. See the "Troubleshooting Charts" on page 32 for more information. Vehicle Power Supply Installation Guide 31 - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 42
assumes that your vehicle mount computer or other equipment does not work and that the problem is caused by the power supply or its associated cables Power Supply Reset Where the troubleshooting chart instructs you to "reset the power supply," you must disconnect the input power cable for 10 seconds - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 43
supply. If too hot to touch, provide better heat sink and more air flow. Replace damaged cables. Protect from direct sunlight, mount in the shade. Advanced Troubleshooting Assuming steps in the previous troubleshooting chart were taken, proceed to these next steps to resolve power failure problems - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 44
present at connector Replace input power cable if input voltage is still not present at connector Have the forklift vendor recommend in-line filter, alternate connection point, and check cables for nicks, and shorts. Power Supply Pinouts Connector Input Power Connector Negative Positive Case Pin - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 45
. 1 1 2 2 3 4 Note: The cables in the installation kit may contain alternate wire colors. Refer to the following chart for the wire color equivalent. Wire Color Equivalents Wire Color Green White Red Black Alternate Color Blue Gray Brown Red Vehicle Power Supply Installation Guide 35 - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 46
Chapter 3 - Troubleshooting Information 36 Vehicle Power Supply Installation Guide - Intermec CV30 | Vehicle Power Supply Installation Guide - Page 47
Chapter 3 - Troubleshooting Information Vehicle Power Supply Installation Guide 37 - Intermec CV30 | 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
Vehicle Power
Supply
Installation Guide