Intermec 851-040-001 User manual

Vehicle
Power Supply
Installation Guide

VehiclePowerSupply
INSTALLATION GUIDE
""""""""""""""""""""""""""""
NPN:962-054-004
Revision C
October 2002

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Acknowledgements
MICRO-CLEANII isaregisteredtrademarkofForesightInternational,Inc.
ChargeGuardisaregisteredtrademarkofChargeGuard,Inc.
"NOTICEThisequipmentmeetsClass Bdigitaldevice limitsperPart15 ofFCC Rules.Theselimits
protectagainst interference inaresidentialarea.Itemits,uses,and canradiateradiofrequency
energy.If you do not install and usethe equipmentaccording toitsinstructions,it mayinter-
ferewithradiosignals.However,theseisno guarantee that interference will notoccurina
particularinstallation.

CONTENTS"
VehiclePowerSupplyInstallation Guide i
CONTENTS
SECTION1
General Information
AboutThisManual1-1..................................
InstallationPractices1-1................................
Considerations1-1...................................
PowerSupplies1-1...............................
InputPowerCable1-4............................
InlineFuse1-4..................................
OutputPowerCable1-4..........................
SECTION2
Installation Procedures
About thisInstallation2-1...............................
InstallationSummary2-1................................
ToolsRequired2-2...................................
BeforeyouBegin2-3....................................
PowerSupplies2-3...............................
ConnectPowerInputCable2-3...........................
Mount thePowerSupply2-4.............................
PowerCableInstallation2-5.............................
PowerCableConnections2-6.............................
CableTermination2-6...............................
CutandStripthePowerCable2-7....................
HeatshrinkTubing2-8...........................
PreparetheCableEnds2-9.......................
PowerSourceConnections2-9............................
Direct toBatteryConnections2-10.....................
Side-mountedBatteryTerminals2-10...............
ConnectiontoTop-mountedTerminals2-12..........
CablesClamps2-14...................................
FinalConnections2-14...................................

CONTENTS"
ii VehiclePowerSupplyInstallation Guide
SECTION3
Troubleshooting Information
Procedures3-1..........................................
BasicDiagnosticProcedures3-1...............
Inspection3-1.......................................
PowerSupply3-1................................
Cables,Connections3-2..........................
Fuse3-2.........................................
ElectricalMeasurements3-2.........................
Voltage3-2......................................
Continuity3-2...................................
Substitution3-3.....................................
Advantages3-3..................................
Disdvantages3-3................................
Whentosubstitute3-3...........................
TroubleCharts3-3...................................
Powersupplyreset3-3...........................
FIGURES
Figure1-1PowerSupplies1-3............................
Figure2-1CutandStripCableEnds2-7..................
Figure2-2HeatshrinkLocations2-8......................
Figure2-3Side-MountBatteryTerminals2-11..............
Figure2-4Top-MountBatteryTerminals2-13..............
Figure2-5CableClamp2-14..............................
Figure3-1InputPowerCable3-7.........................
TABLES
Table1-1PowerSupplyIdentification1-2................
Table2-1PartsList2-2.................................
Table3-1PowerFailureTroubleChartI3-4..............
Table3-2PowerFailureTroubleChartII 3-5..............
Table3-3PowerSupplyPinouts3-6.....................

SECTION 1"GeneralInformation
VehiclePowerSupplyInstallation Guide 1-1
Section 1
GeneralInformation
""""""""""""""""""""""""""""
AboutThisManual
Thismanual isdividedintothree sections.SectionOne
describesinstallationpracticesanduniquecomponentsin
thiskit.SectionTwocontainsmechanicalandelectrical
installationinstructions.SectionThree containsbasic
troubleshootinginformationand pin-outsfor connectors.
Installation Practices
Installers shouldbefamiliarwiththeparticularbrandsand
modelsofequipmentwherethiskitisinstalled.Theyshould
betrainedandexperiencedonvehicle electricalsystems.
InstallersmustfollowtheseguidelinesandtheInstallation
Procedurespreciselytoensureasafeandreliableinstallation.
Failuretofollowall oftheinstructionshereincanresultin
damagedordestroyedequipment,degradedequipment
performance,prematurefailures,andvoidthewarranty.
Considerations
PowerSupplies
Twopower converters(“supplies”)areavailablethatshould
meet mostelectricalrequirements.Verifythatyou havethe
correctsupplyforaparticularinstallationbeforebeginning.
Onepowersupplyacceptsinputvoltagesrangingfrom6--36

SECTION 1"GeneralInformation
1-2VehiclePowerSupplyInstallation Guide
Vdc(typically gas-poweredvehicles:12 &24 volts)andthe
otheraccepts15--96 Vdc(typicallyelectric-poweredve-
hicles:24,36,48,&72 volts).Bothsuppliesprovide12 V
dcoutputwhichisfilteredandregulated.Bothsupplies
alsoprovideshortcircuit,overvoltage,andovertempera-
tureprotection.
Youcandistinguishbetweenthetwosuppliesinseveral
ways.Eachsupplydisplaystheinternationalsymbologies
forinputandoutputconnectors,including voltageinforma-
tion.Inaddition,thetablebelowprovidesothermeansof
identification.
Table1-1
PowerSupplyIdentification
Model
NumberPart NumberInput ConnectorInput Voltage
851-040-001 066776-01 4-pin,keyed6--36 Vdc
851-041-001 066777-01 2-pin,keyed15--96 Vdc
Thepowersupplyshall bemountedtothevehiclechassis
ground,or connected(electrically)viaexternalwiretothe
vehiclechassis.Chassisgroundtothecomputerorother
equipmentisthenestablishedviathepowersupplyoutput
cable.
Sincethepowersupplywill produceheat,itisadvisableto
mountitonaminimumof130--160 squareinches(approxi-
matelyonesquarefootormore)ofmetallicsurface.This
locationshould notbeinthevicinityofsourcesofvehicle-
generatedheat.Useonlythehardwaresuppliedinthe
kittomount thepowersupply;donotuse sheet-metal
screws.
Agreenlight-emittingdiode(LED)indicator,locatednear
the outputconnectoronthepowersupply, will belighted
whenevervoltageis suppliedtothe outputpower cable.

SECTION 1"GeneralInformation
VehiclePowerSupplyInstallation Guide 1-3
Figure1-1
PowerSupplies
Model: 851-040-001 P/N: 066776-01
6-36 V; 10 A
Model: 851-041-001 P/N: 066777-01
15-96 V; 3,5 A
InputConnector
OutputConnector
Green LED
(poweroutputindicator)
""
""
""
""

SECTION 1"GeneralInformation
1-4VehiclePowerSupplyInstallation Guide
InputPowerCable
NOTE:The inputpowercablemaybe shortened asneeded. It SHOULD
NOTbe extended underany circumstances.
Theinputpower cableisapproximately9feetlong. One end
hasa4-pinconnector,theotherendhasa2-pinconnector.By
cuttingofftheunneededconnector,asinglecablecanmeetei-
therloworhighvoltageinput-rangepowersupplyrequire-
ments.Thecutendisthenterminatedfor connectiontothe
vehiclepowersource.
Inline Fuse
Asnap-twistinlinefuseholderisfurnishedaspartofthiskit.
It mustbeconnectedascloseaspossible(electricallyand
physically)tothevehiclepowersource.Itprovides short-cir-
cuitprotectionfortheentireinputpowercableandthepower
supplyinput.Thefuseholdercontainsa3AB,20ampere/250
Vdc(1/4”x1-1/4”) fuse.Shoulditfail,diagnosetheproblem
andcorrectit,thenreplacewithexactlythesamesizeandtype
fuse.
OutputPowerCable
NOTE:Ensurethatyou havethe correctoutputpowercableforthe comput-
er(s)being installed inyourlocation.
Outputpower cablesareapproximately6feetlongandhave
adurable3-pinconnectortomatewiththepowersupply.The
connectoronthefarendofthecableis specifictotheteminal
(computer)ordockingdeviceinyourparticularinstallation.
Theseruggedconnectorshaveheavydutymetalhousingsand
enhancedstrainrelieftoprovideaddedreliabilityinthemo-
bile environment.

SECTION 2"Installation Procedures
VehiclePowerSupplyInstallation Guide 2-1
Section 2
Installation Procedures
""""""""""""""""""""""""""""
About thisInstallation
Followtheproceduresinthis sectionascloselyaspossible
whilekeepingthefollowingasprimaryconsiderations:
"PowerSupplymustbesecurelymounted.
"Mountingsurfacemustbesturdy.
"Mountingsurfacemustbeabletosinkpowersupply
heat.
"Fusemustbeclosetovehiclepowersource.
"Keepcablesas shortaspractical.
"Securecablesatleastevery18 inches.
Installation Summary
Installationconsistsoffive(5)primarysteps,whichshouldbe
undertakeninthefollowingorder:
1.Connect theinputcabletothepowersupply.
2.Mechanicallyinstall thepowersupply.
3.Routeandsecurethepower cable.
4.Shortencableasappropriate,thencrimpthefuse
holdertothejoinedREDandBLACK wires(positive).
CrimpaterminalringtothejoinedWHITEand
GREENwires(negative).Insulateasinstructed.
5.Makefinalconnectionstothevehiclepowersource.

SECTION 2"Installation Procedures
2-2VehiclePowerSupplyInstallation Guide
ToolsRequired
"WireCrimpingandstrippingtool.
"Electricdrill,drill bits.
"Common handtools.
"Heatgun forshrinksleevetubing.
Table2-1
PartsList
DescriptionNPN Qty
powercable226-340-001 1
fuseholderassembly 315-075-001 1
fuse,20 AceramicFB315-074-001 1
bolt,3/8--16 X1-1/2”800-099-001 2
washer,3/8”803-099-001 4
nut,3/8--16 802-099-001 4
adjustablewire clamps808-011-001 8
self-tapscrew#6 X5/8”800-008-001 8
3/8”terminalring 809-165-001 2
#10 terminalring 809-083-009 3
self-tapscrew#8 X5/8”800-012-000 1
#8 flatwasher803--084-000 1
snap-in bushing 807-065-003 1
screw,m/s1/4--20 x 1-1/4”801-194-002 2
flatwasher,1/4”801-100-000 2
locking nut,1/4--20 802-117-000 2
lockwasher,1/4”803-042-001 2
cabletie,locking 808-002-001 6
h/stubing,blk,1/8”dia.321-042-000 12 in.
h/stubing,blk,3/8”dia.321-143-001 6 in.
ferritebead 309-388-001 1

SECTION 2"Installation Procedures
VehiclePowerSupplyInstallation Guide 2-3
Beforeyou Begin
WARNING:Equipment failureordamagewill resultif the vehiclepower
source voltagedoes not fall withintheinputvoltagerating of
thepowersupplyfurnishedtoyou.
PowerSupplies
Readthenomenclature onthepowersupplyandverifythat
theinputvoltageratingiscorrectforthevehicleyouwill be
installingitin.See SectionOneforidentifyinginformation.
Rememberthat thesupplywiththelowerinputvoltagerat-
ing(6--36 Vdc)hasa 4-pininputconnectorwhilethepower
supplywiththehigherinputvoltagerating(15-96 Vdc)has
a 2-pininputconnector.
ConnectPowerInputCable
Onlyone oftheinputconnectorswill fit thepowersupply:
1.Matethecorrespondingcableconnectortothepower
supplyconnector.
2.SlidethecableconnectorINasfarasitwill go.
3.Turnthecableconnector collarclockwise tosecureit.
4.Clamptheferritebeadontotheinputcablenearthe
powersupply.Makesuretabsarefullyengaged.
5.Cutcableat theunusedcableconnector.
Discardthis connector.

SECTION 2"Installation Procedures
2-4VehiclePowerSupplyInstallation Guide
Mount the PowerSupply
Theinputpower cableisapproximately9feetlongandcan
beshortenedasneeded.ItmustNOTbe extendedun-
deranycircumstances.The outputpower cableis
approximately6feetinlongandcannotbe shortened.You
must taketheselengthsandtheintendedlocationofyour
electronicequipmentintoconsiderationwhenchoosinga
mountinglocationforthepowersupply.
Themountinglocationmustprovide130--160 squareinches
ofmetallicsurfacetosinkheatgeneratedbythepowersup-
ply.Thismetallicmountingsurfacemustbeconnectedto
thevehiclechassiselectrically.Inrareinstances,youmay
havetofabricateaflexiblewire orbraidtobondthe
mountingsurfacetovehiclechassisground.
Appropriatehardwareisfurnishedinthisinstallationkit
formountingthepowersupply.UsemountingMethodAin
situationswhereyoucaneasilyaccess thebackside ofthe
mountinglocationtoinstall alocknutandwasher.
UseMethodBwherethebackside ofthemountinglocation
isinaccessible.Notethat thismethodrequiresthat the
mountingplatebethickenoughtoacceptandretainsuffi-
cient threadstoprovideasecureandreliablemechanical
installation.
Method A:
1.Markandcenterpunchthetwomountingholeloca-
tions.
2.Usea 1/4-inchdrill bit tomakethetwomounting
holes.
3.Use1/4”hexboltswithflatwashersandlockingnuts
toinstall thepowersupply.
Method B:
1.Markandcenterpunchthetwomountingholeloca-
tions.
2.Usea#7drill bit tomakethemountingholes.

SECTION 2"Installation Procedures
VehiclePowerSupplyInstallation Guide 2-5
3.Usea 1/4--20 taptothreadthemountingholes.
4.Placealockwasheroneachbolt.
5.Insert thebolt/lockwasherassembliesthroughthe
powersupplyholesandintothethreadedmounting
holes.
PowerCableInstallation
Followtheseguidelinesandotherinstructionscloselywhen
installingpower cables.
"Completelyinstall power cablesbefore makingconnec-
tionsto equipment.
"Routethepower cablesfromthegeneralareawhere
thepowersupplywill bemounted.
"Useasnap-inbushing(requires9/16”hole)ifthe
power cablepassesthroughafirewall orothersheet-
metal.
"Makesurethatcableroutingdoesnotinterferewith
otherequipmentorvehiclecontrols.
"Makesurethatcableroutingdoesnotinvitedamage
tothecable.
"Securethecablesatleastevery18 inchesthroughout
thecablerun:useadjustableclamps(see lastpagein
this section)orwire-tieto existing vehiclecableruns.
WARNING: If thisinstallation will beon agas -poweredvehicle, you
MUST install eitheranOn/Offswitch(minimum15Adcrating,
suchas ITWpartnumber163-900-034),oranautomatic shut
offdevice,inseries withthein-linefuse holder.Charge-
Guard,Inc., 400 Highland Avenue,Altoona,PA16602
(814-941-4100)manufactures a“CHARGEGUARD
ÒÒ“device for
thispurpose.

SECTION 2"Installation Procedures
2-6VehiclePowerSupplyInstallation Guide
PowerCableConnections
Thefuseholderfrom theinputpower cablemustbecon-
nectedasclose(physicallyandelectrically)aspossibleto
thepositive sideofthevehiclepowersource.Theremaining
coloredwire(s)mustbeconnectedtothenegativeside ofthe
vehiclepowersource.Inthisinstallation,the shieldwire
mustbe connectedtothevehicle chassis.Instructionsare
notincludedfor connectingtovariouspossiblevehiclepow-
ersources.Itisassumedthat thetrained professional in-
stallerwill beknowledgeable onthebrandsandmodelsof
vehiclesheisworkingwith.Bothlarge(3/8-inch)and
smallerterminalringsareprovidedtoaccomodatemost
installation needs.Thiskitcontainsadditionalbolts,nuts,
andwashersinthe eventyouwill connect theinputpower
cabledirectlytoavehiclebattery.Theintendedusefor
thesepartsisdetailedintheinstructionsthatfollow.
CableTermination
Youmustcut thecabletolength,cutoff aportionofthe out-
er cablejacketandstriptheindividualwire endsofthe
cableasinstructed.Heatshrinktubingisfurnishedinthis
kitandmustbe slippedontothe cableorwires before termi-
natingthem.Then,youmustinstall thefuseholderinse-
rieswiththepositivewiresandinstall aterminalringon
thenegativewires.Finally,youmust mechanicallycom-
pletetheconnectionstothevehiclepowersource orbattery
andelectricallyconnect theshieldwiretovehiclechassis
groundusingaself-tappingscrewandflatwasher.

SECTION 2"Installation Procedures
VehiclePowerSupplyInstallation Guide 2-7
Cutand Stripthe PowerCable
1.Cut thepower cablenearthepowersource orbattery.
2.Stripthecablejacketback12--14 inches.
3.Slideheatshrinktubingover cablejacket.
4.Strip1/4”ofinsulationfromindividualwires.
5.Twist thewhiteandgreen(negative)wirestogether.
6.Twist theredandblack(positive)wirestogether.
7.Twist theshieldwireandslidethe1/8”heatshrink
tubingontoit.
Input
Power
Cable
Figure 2-1
Cutand StripCableEnds
Heatshrinktubing
Redand Black Wires
(positive)
Greenand WhiteWires
(negative)
Shieldwirew/heatshrink applied
StriptheCableJacket12--14 inches
NOTE:See “Note”on page 2-5wheninstalling on gas-poweredvehicles.

SECTION 2"Installation Procedures
2-8VehiclePowerSupplyInstallation Guide
Heatshrink Tubing
Thiskitcontainsa6inchlengthof3/8”heatshrinktubing
whichyouwill cutintothree pieces,anda12inchlengthof
1/8”heatshrinktubingfortheshieldwire.Tubingmustbe
inplacebefore terminatingwire ends.Crimpterminalrings
andfuseholderends,thenpositionall heatshrinktubingin
thelocations shown.Useaheatgun toshrinktubing.
1.Greenand Whitetwisted pair
2.Redand Black twisted pair
3.Shieldwire,twisted
Figure 2-2
Heatshrink Locations
b
1
2
3
b
3/8”
b
b
3/8”3/8”
Arrowsdenote heatshrink
locationsand diameter.
1/8”
b
b
NOTE:See “Note”on page 2-5wheninstalling on gas-poweredvehicles.

SECTION 2"Installation Procedures
VehiclePowerSupplyInstallation Guide 2-9
Preparethe CableEnds
Bothlarge(3/8inch)andsmaller(#10)terminalringsare
providedforyourselectionanduseinthefollowingsteps.A
small (#10)terminalringshouldbecrimpedtotheshield
wireandthenfastenedtovehiclechassisground.
1.Crimpaterminalringontothewhite-greentwisted
pair(negative)ofwires.
2.Cut thered-blacktwisted pair(positive)ofwiresat the
midpoint.Stripexposedends.
3.Positionshortlengthsofheatshrinktubingasinindi-
catedinFigure2-2.
4.Crimpthefuseholdertothepositivewiresfrom the
cable.
5.Shortentheremainingpositivewires(pigtail)ifde-
siredand positionashortlengthofheatshrinktubing
ontothispigtail.
6.Crimpthispositivepigtail tothefuseholder.
7.Securelycrimpaterminalringto endofthepositive
pigtail from thefuseholder.
8.Slideheatshrinkover crimps,shrinkwith heatgun.
PowerSource Connections
Thenextfourpages showyoutheintended purpose ofnuts,
bolts,andwashersthatareincludedinthiskitifyouwill be
connectingthepower cabledirectlytoavehiclebattery.
Additionalhardwareisnotprovidedinthiskitforconnecting
thepower cableto othervehiclepowersources.Refertothe
manufacturer’stechnicalmanualforthevehicleifnecessary.

SECTION 2"Installation Procedures
2-10 VehiclePowerSupplyInstallation Guide
Direct toBatteryConnections
Side-mounted BatteryTerminals
1.Removebothterminalscrewsfrom thevehiclebattery.
2.Screwa 3/8”nutasfarasitwill go ontoa 3/8”X1-1/2”
boltfurnishedinkit.
3.Slipa 3/8”washerontothebolt.
4.Slidethepositive(fuseholder)terminalringontothe
positivebatteryterminalbolt.
5.Slipasecond3/8”washerontothebolt.
6.Slidethevehiclepositivebatterycable ontothebolt.
7.Threadtheboltassembly(steps1--6,above)intothe
positivebatteryterminal.Tightentheboltuntil itbot-
tomsoutbutdonotovertightenthebolt.
8.Tightenthenutsecurelyagainst thewashersand
cables.
9.Useself-tappingscrewandaflatwashertoconnect
shieldwiretovehiclechassisground.
Repeatsteps2through 8 forthenegative (white--green pair)wirefromtheinput
powercable,hooking up thenegative cablestothenegative (--)batteryterminal.
NOTE:See “Note”on page 2-5wheninstalling on gas-poweredvehicles.

SECTION 2"Installation Procedures
VehiclePowerSupplyInstallation Guide 2-11
1.Bolt
2.Nut
3.Vehiclebattery
4.Vehiclebattery cable
5.Fuse holder
6.Washers
1
Figure 2-3
Side-MountBatteryTerminals
2
6
3
4
5
NOTE:See “Note”on page 2-5wheninstalling on gas-poweredvehicles.