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Chapter 2 — Installation Process

26

Vehicle Power Supply Installation Guide

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.

• 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.

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Summary of Contents for CV60

Page 1: ...Vehicle Power Supply Installation Guide ...

Page 2: ...ect to change without prior notice and do not represent a commitment on the part of Intermec Technologies Corporation 2003 2007 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 Intellitag Gen2 JANUS LabelShop Mobil...

Page 3: ...t was originally released as version 001 Version Number Date Description of Change 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 ...

Page 4: ...iv Vehicle Power Supply Installation Guide ...

Page 5: ...Installation Guidelines 2 Power Supply Options 3 About the LEDs 4 Input Power Cable 5 Output Power Cable 6 Configuration Chart 6 Installation Diagrams 7 Wiring Diagram 9 2 Installation Process 11 Installation Recommendations 12 Installation Summary 12 Tools Required 13 Preparing the Power Input Cable 14 Mounting the Power Supply 14 Direct versus Isolation Mounting on Lift Chassis 15 Creating a Cus...

Page 6: ...nt 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 30 Inspecting the Cables and Connections 30 Inspecting the Fuse 31 Using Electrical Measurements 31 Measuring for voltage 31 Testing for continuity 31 Using Component Subs...

Page 7: ...obal Sales Service page appears From the Service Support menu move your pointer over Support then Service and Repairs and click Warranty Disclaimer of warranties The sample code included in this document is presented for reference only The code does not necessarily represent complete tested programs The code is provided as is with all faults All warranties are expressly disclaimed including the im...

Page 8: ...d Visit the Intermec technical knowledge base Knowledge Central at intermec custhelp com to review technical information or to request technical support for your Intermec product Telephone Support These services are available from Intermec Technologies Service Description In the U S A and Canada call 1 800 755 5505 and choose this option Order Intermec products Place an order Ask about an existing...

Page 9: ...he features of the vehicle 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 Service Get a return authorization number for authorized service center repair Request an on site repair technician 2 and then c...

Page 10: ...Vehicle Power Supply Installation Guide x ...

Page 11: ...Vehicle Power Supply Installation Guide 1 1 Introduction This chapter describes installation practices and unique components in the vehicle power supply kits ...

Page 12: ... 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 Power supply must be securely mounted Mounting surface must be sturdy Mounting surface must provide power supply heat si...

Page 13: ...ge and over temperature protection You can distinguish between the two power supplies in several ways Each supply displays the international symbols for input and output connectors including voltage information In addition the table below provides other means of identification The power supply should be mounted to the vehicle chassis or connected electrically via external wire to the vehicle chass...

Page 14: ...lows easy visibility to the LEDs for troubleshooting One LED indicates main power is functioning 3 pin connector The secondary power LED indicates the heater power 2 pin connector is functioning Power Supply P N 851 070 003 6 60V 14A Power Supply P N 851 041 003 15 96V 4 5A Note Use the hardware supplied in the kit or equivalent to mount the power supply Do not use sheet metal screws or other less...

Page 15: ...DC 1 4x1 1 4 inch fast blow fuse recommended for installation with 12 volt automotive batteries For other vehicle battery voltages please refer to the table that follows In general smaller fuse ratings offer faster acting protection The alternate fuses listed are not provided with the kit and must be obtained separately Note Keep the cable as short as possible Extra cable picks up noise adds power...

Page 16: ...tal housings and enhanced strain relief to provide added reliability in the mobile environment Configuration Chart Use the following configuration charts as a guide for your power supply installation Order the Smart UPS kit P N 203 788 xxx for the universal power supply UPS that provides backup power during battery change out Do not replace fuse with larger than recommended fuse values Use of larg...

Page 17: ...er supply 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 60 96V Fuse Fixed or Vehicle DC DC Converter P N 851 041 003 Input Cable P N 226 340 004 Mount Computer Output Cable P N VE012 8014 X Fuses DC DC Converters P N 851 041 003 Cable P N VE012 8017...

Page 18: ...0 004 Cable 932 003 003 Vehicle Power Supply Installation Guide 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 Materials List for Components Material Description 203 779 001 Kit 203 804 002 Installation Kit Vehicle Power Supply 851 070 003 DC DC Conv...

Page 19: ...ce Connection Possibilities VE012 8019 XX Cable 3 pin 2 pin to 5 pin Y cable 932 003 003 Vehicle Power Supply Installation Guide Materials List for Components continued Material Description Negative Worst Regenerative Braking System very large voltage spikes Connector to battery Best Power Acceptable Negative Marginal Negative Marginal Large output spikes possible on motors To DC DC converter Nega...

Page 20: ...Chapter 1 Introduction 10 Vehicle Power Supply Installation Guide ...

Page 21: ...Vehicle Power Supply Installation Guide 11 2 Installation Process This chapter outlines mechanical and electrical installation instructions ...

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 common to multiple lifts and use pre attached devices to simplify the device installation and service Installa...

Page 23: ...rill drill bits DC Ohmmeter Parts List Description Intermec Part Number Quantity Power cable 226 340 004 1 Fuse holder assembly 315 075 003 1 Fuse 20 A ceramic FB 315 074 003 1 Bolt 3 8 16 x 1 1 2 800 099 001 2 Washer 3 8 803 099 001 4 Nut 3 8 16 802 099 001 4 Adjustable wire clamps 808 011 001 8 Self tap screw 6 x 5 8 800 008 003 8 3 8 terminal ring 809 165 001 2 10 terminal ring 809 083 009 3 Se...

Page 24: ...later in the section Cable Termination Overview of Process on page 19 Mounting the Power Supply The input power cable is approximately 9 0 ft 2 74 m long and can be shortened as needed The output power cable is approximately 7 0 ft 2 13 m and should not be lengthened h s tubing black 1 8 diameter 321 650 003 12 0 30 5 cm h s tubing black 3 8 diameter 321 650 006 6 0 15 2 cm Ferrite bead 309 065 00...

Page 25: ...s Isolation Mounting on Lift Chassis Previously the power supply has been placed directly on the lift chassis Direct mounting provides both an adequate heat sink and prevents static charge buildup between the metal of the power supply computer and lift chassis Directly mounting the power supply is the most straight forward installation method This is also the preferred installation type when there...

Page 26: ...y attach this metal plate to the chassis of the vehicle while preventing direct metal to metal contact insulating hardware plastic shoulder washers or rubber isolators or an insulating surface plastic wood or rubber between the power supply and lift chassis Mounting the power supply on a metal plate also requires a small resistor 100 ohms 1W minimum to be electrically connected between the plate a...

Page 27: ...ations 2 Use a 7 drill bit to make the mounting holes 3 Use a 1 4 20 tap to thread the mounting holes 4 Place a lock washer on each bolt 5 Insert the bolt lock washer assemblies through the power supply holes and into the threaded mounting holes Installing the Power Cables Follow these guidelines and other instructions closely when installing power cables Completely install power cables before mak...

Page 28: ...ing with will do the installation Both large 3 8 inch and smaller terminal rings are provided to accommodate most installation needs 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 series with the in line fuse holder These devices prevent discharge of the vehi...

Page 29: ...ete the connections to the vehicle power source or battery and electrically connect the shield wire to the chassis using a self tapping screw and flat washer Preparing the Power Cable Be sure the power source is disconnected before starting to work with the cables All measurements are approximate lengths To prepare the power cable 1 Cut the power cable near the power source or battery 2 Strip the ...

Page 30: ...lows 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 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 Be sure to separate and pull out the shield wire Note Tubing must be in ...

Page 31: ...ed pair negative 3 Crimp one end of the fuse block on the red black twisted pair positive Crimp a similar gauge wire or twisted pair of wires onto the other 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 Note Be sure to attach shield wire to the metal surface on which the powe...

Page 32: ... Disconnect the negative battery cable then disconnect the positive battery cable and remove the bolts from each cable 2 Screw a 3 8 inch nut as far as it will go onto a 3 8 x 1 1 2 inch bolt furnished in the kit then slip a 3 8 inch washer onto the bolt 3 Slide the positive red wire with fuse link terminal ring from the power input cable onto the bolt 4 Slip a second 3 8 inch washer onto that bol...

Page 33: ... shown in the Top Mount Battery Terminals illustration following the last step in this set of procedures To attach power supply cable 1 Disconnect the negative battery cable then disconnect the positive battery cable 2 Remove the bolts from the vehicle battery terminals 3 Replace those bolts with 3 8x1 1 2 inch bolts and nuts from the installation kit Tighten the nuts Note See the warning on page ...

Page 34: ...ive battery bolt 7 Slip a second 3 8 inch washer onto that bolt 8 Thread and tighten a second 3 8 inch nut onto that bolt 9 Use a self tapping screw and a flat washer to connect the shield wire to the metal surface on which the power supply is mounted Repeat steps 6 through 8 for the negative battery cable wire white green pair from the power input cable connecting the wire to the negative battery...

Page 35: ...he Output Power Cable Once the computer dock or other device is mechanically installed you can connect the output power cable between the power supply output and the device Connectors are keyed and operate the same as the input power connector To finish the connection 1 Mate the cable connector to the power supply and to the device connectors 2 Slide the cable connector as far as it will go into t...

Page 36: ...s 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 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 ...

Page 37: ...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 No direct sunlight in this environment helps maintain lower operating temperature ...

Page 38: ...ts 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 The installation is tedious time consuming and difficult to work on Troubleshooting problems made difficult An enclosed environment will significantly reduce the air flow raising the temperatures of all the components ...

Page 39: ...Vehicle Power Supply Installation Guide 29 3 Troubleshooting Information This chapter contains troubleshooting information and connector pin outs ...

Page 40: ...or The Main Output LED is lit when 12 VDC is present at the output connector If you suspect a power failure check for the following If the LED is not lit the power supply is not producing 12 VDC output power In this case a fault can exist anywhere in the system See the Troubleshooting Charts on page 32 to isolate identify and correct the fault If the LED is lit yet you suspect a power failure chec...

Page 41: ...ctrical Measurements Measuring for voltage Connector pinout information is provided to aid measuring voltage at the input power cable connector and at either end of the power output cable Testing for continuity Thorough continuity testing takes longer than either substitution or voltage measurements An ohmmeter is sufficient to diagnose simple opens or shorts If fuses blow sporadically or power su...

Page 42: ...ation Troubleshooting Charts The following troubleshooting chart 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 then reconnect it The power supply ha...

Page 43: ... to see whether they have any recommended in line filters or suppressors Flickers Power supply detected over current condition Disconnect the output cable If the flickering stops check the cables and add downstream elements Disconnect the UPS if one is present Bypass the UPS if one is present If the flickering stops replace the UPS Flickers Power supply detected over temperature condition Check ca...

Page 44: ...tage is still not present at connector Fuse blowing but no LED lit Power system is drawing too much current Have the forklift vendor recommend in line filter alternate connection point and check cables for nicks and shorts Power Supply Pinouts Connector Negative Positive Case Input Power Connector Pin 1 Pin 2 Pin 3 Pin 4 Shield Secondary Output Power Connector Heater Pin 1 Pin 2 Main Output Power ...

Page 45: ...l cut and discard one of these cable connectors 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 Alternate Color Green Blue White Gray Red Brown Black Red P N 226 340 003 and 226 340 004 108 0 3 0 2 1 4 3 2 1 Pin View 2 Pin View 1 2 1 2 3 4 ...

Page 46: ...Chapter 3 Troubleshooting Information 36 Vehicle Power Supply Installation Guide ...

Page 47: ...Chapter 3 Troubleshooting Information Vehicle Power Supply Installation Guide 37 ...

Page 48: ...llation Guide 932 003 003 P N 932 003 003 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 ...

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