Intermec 851-040-001, 851-041-001 Installation Manual

Installation Guide

Vehicle
Power Supply

Vehicle Power Supply

INSTALLATION GUIDE

" " " " " " " " " " " " " " " " " " " " " " " " " " " "

NPN: 962-054-004

Revision C

October 2002

" NOTICE This publicationcontains information proprietary to Intermec Corporation. It is being supplied

to you with the express understanding that the information contained herein is for the benefit
of the contracting party only, and may not be copied, distributed, or displayed to third parties
without the express written consent of Intermec Corporation, and shall be returned to the Cor­poration upon written request. If a purchase, license, or nondisclosure agreement has been
executed, the terms of that agreement shall govern this document.

This publication is furnished for information only,andtheinformation in it is subject to change
without notice. Although every effort has been made to provide complete and accurate
information, Intermec Corporation assumes no responsibility or liability for any errors or
inaccuracies that may appear in this document.

Wewelcomeyourcomments concerning this publication. Although every efforthas been made
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Send your comments to:

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Intermec Corporation
Norand Mobile Systems Division
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Ó 1998 Intermec TechnologiesCorporation. All rights reserved.

Acknowledgements

MICRO-CLEAN II is a registered trademark of ForesightInternational, Inc.
ChargeGuard is a registered trademark of ChargeGuard, Inc.

" NOTICE This equipment meets Class B digital device limits per Part 15 of FCC Rules. These limits

protect against interference in a residential area. Itemits,uses, and can radiate radio frequency
energy. If you do not install and use the equipment according to its instructions, it may inter­fere with radio signals. However, these is no guarantee that interference will not occur in a
particular installation.

CONTENTS "

CONTENTS

SECTION 1

General Information

About This Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Practices 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Considerations 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supplies 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Power Cable 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inline Fuse 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Power Cable 1-4. . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2

Installation Procedures

About this Installation 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Summary 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools Required 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before you Begin 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supplies 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect Power Input Cable 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Mount the Power Supply 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Cable Installation 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Cable Connections 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Termination 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cut and Strip the Power Cable 2-7. . . . . . . . . . . . . . . . . . . .

Heatshrink Tubing 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Cable Ends 2-9. . . . . . . . . . . . . . . . . . . . . . .

Power Source Connections 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direct to Battery Connections 2-10. . . . . . . . . . . . . . . . . . . . .

Side-mounted Battery Terminals 2-10. . . . . . . . . . . . . . .

Connection to Top-mounted Terminals 2-12. . . . . . . . . .

Cables Clamps 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Connections 2-14.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Power Supply Installation Guide i

CONTENTS "

SECTION 3

Troubleshooting Information

Procedures 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic Diagnostic Procedures 3-1. . . . . . . . . . . . . . .

Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supply 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cables, Connections 3-2. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Measurements 3-2. . . . . . . . . . . . . . . . . . . . . . . . .

Voltage 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Continuity 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Substitution 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advantages 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disdvantages 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

When to substitute 3-3.. . . . . . . . . . . . . . . . . . . . . . . . . .

Trouble Charts 3-3.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power supply reset 3-3.. . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURES

Figure 1-1 Power Supplies 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-1 Cut and Strip Cable Ends 2-7. . . . . . . . . . . . . . . . . .

Figure 2-2 Heatshrink Locations 2-8. . . . . . . . . . . . . . . . . . . . . .

Figure 2-3 Side-Mount Battery Terminals 2-11. . . . . . . . . . . . . .

Figure 2-4 Top-Mount Battery Terminals 2-13. . . . . . . . . . . . . .

Figure 2-5 Cable Clamp 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-1 Input Power Cable 3-7. . . . . . . . . . . . . . . . . . . . . . . . .

TABLES

Table 1-1 Power Supply Identification 1-2. . . . . . . . . . . . . . . .

Table 2-1 Parts List 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-1 Power Failure Trouble Chart I 3-4. . . . . . . . . . . . . .

Table 3-2 Power Failure Trouble Chart II 3-5. . . . . . . . . . . . . .

Table 3-3 Power Supply Pinouts 3-6. . . . . . . . . . . . . . . . . . . . .

ii Vehicle Power Supply Installation Guide

SECTION 1 " General Information

Section 1

General Information

" " " " " " " " " " " " " " " " " " " " " " " " " " " "

About This Manual

This manual is divided into three sections. Section One
describes installation practices and unique components in
this kit. Section Two contains mechanical and electrical
installation instructions. Section Three contains basic
troubleshooting information and pin-outs for connectors.

Installation Practices

Installers should be familiar with the particular brands and
models of equipment wherethis kitis installed. They should
be trained and experienced on vehicle electrical systems.

Installers must follow these guidelines and the Installation
Procedurespreciselytoensureasafeandreliableinstallation.
Failure to follow all of the instructions herein can result in
damaged or destroyed equipment, degraded equipment
performance, premature failures, and void the warranty.

Considerations

Power Supplies

Two power converters (“supplies”) are available that should
meet most electrical requirements. Verify that you have the
correct supply for a particular installation before beginning.
One power supply accepts input voltages ranging from 6--36

Vehicle Power Supply Installation Guide 1-1

SECTION 1 " General Information

V dc (typically gas-powered vehicles: 12 & 24 volts) and the
other accepts 15--96 V dc (typically electric-powered ve­hicles: 24, 36, 48, & 72 volts). Both supplies provide 12 V
dc output which is filtered and regulated. Both supplies
also provide short circuit, over voltage, and over tempera­ture protection.

You can distinguish between the two supplies in several
ways. Each supply displays the international symbologies
for input and output connectors, including voltage informa­tion. In addition, the table below provides other means of
identification.

Table 1-1

Power Supply Identification

Model
Number

Part
Number

Input
Connector

Input
Voltage

851-040-001 066776-01 4-pin, keyed 6--36 V dc
851-041-001 066777-01 2-pin, keyed 15--96 V dc

The power supply shall be mounted to the vehicle chassis
ground, or connected (electrically) via external wire to the
vehicle chassis. Chassis ground to the computer or other
equipment is then established via the power supply output
cable.

Since the power supply will produce heat, it is advisable to
mount it on a minimum of 130--160 square inches (approxi­mately one square foot or more) of metallic surface. This
location should not be in the vicinity of sources of vehicle­generated heat. Use only the hardware supplied in the

kit to mount the power supply; do not use sheet-metal
screws.

A green light-emitting diode (LED) indicator, located near
the output connector on the power supply, will be lighted
whenever voltage is supplied to the output power cable.

1-2 Vehicle Power Supply Installation Guide

SECTION 1 " General Information

""

""

Model: 851-041-001 P/N: 066777-01

15-96 V; 3,5 A

Input Connector

(power output indicator)

Green LED

Output Connector

""

Model: 851-040-001 P/N: 066776-01

Figure 1-1

Power Supplies

Vehicle Power Supply Installation Guide 1-3

""

6-36 V; 10 A

SECTION 1 " General Information

Input Power Cable

NOTE: The input power cable may be shortened as needed. It SHOULD

NOT be extended under any circumstances.

The input power cable isapproximately 9 feet long. One end
hasa 4-pin connector,theotherend has a 2-pin connector. By
cuttingoff the unneeded connector,asingle cable canmeetei­ther low or high voltage input-range power supply require­ments. The cut end is then terminated for connection to the
vehicle power source.

Inline Fuse

Asnap-twistinline fuse holder isfurnishedas part of thiskit.
It must be connected as close as possible (electrically and
physically) to the vehiclepower source. It provides short-cir­cuitprotectionfortheentire input power cable and the power
supplyinput. The fuse holder contains a3AB,20ampere/250
V dc (1/4” x 1-1/4”) fuse. Should it fail, diagnose the problem
andcorrectit,thenreplacewithexactlythesamesizeandtype
fuse.

Output Power Cable

NOTE: Ensure that you have the correct output power cable for the comput-

er(s) being installed in your location.

Output power cables are approximately 6 feet long and have
adurable 3-pin connector to matewiththe power supply. The
connector on the farend ofthe cableis specific to theteminal
(computer) or docking device in your particular installation.
Theseruggedconnectors haveheavydutymetalhousings and
enhanced strain relief to provide added reliability in themo­bile environment.

1-4 Vehicle Power Supply Installation Guide

SECTION 2 " Installation Procedures

Section 2

Installation Procedures

" " " " " " " " " " " " " " " " " " " " " " " " " " " "

About this Installation

Follow the procedures in this section as closely as possible
while keeping the following as primary considerations:

" Power Supply must be securely mounted.
" Mounting surface must be sturdy.
" Mounting surface must be able to sink power supply

heat.

" Fuse must be close to vehicle power source.
" Keep cables as short as practical.
" Secure cables at least every 18 inches.

Installation Summary

Installationconsistsoffive(5)primarysteps,whichshould be
undertaken in the following order:

1. Connect the input cable to the power supply.

2. Mechanically install 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).
Crimp a terminal ring to the joined WHITE and
GREEN wires (negative). Insulate as instructed.

5. Make final connections to the vehicle power source.

Vehicle Power Supply Installation Guide 2-1

SECTION 2 " Installation Procedures

Tools Required

" Wire Crimping and stripping tool.
" Electric drill, drill bits.
" Common hand tools.
" Heat gun for shrink sleeve tubing.

Description NPN Qty

power cable 226-340-001 1
fuse holder assembly 315-075-001 1
fuse, 20 A ceramicFB 315-074-001 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” 800-008-001 8
3/8” terminal ring 809-165-001 2
#10 terminal ring 809-083-009 3
self-tap screw #8 X 5/8” 800-012-000 1
#8 flat washer 803--084-000 1
snap-in bushing 807-065-003 1
screw, m/s 1/4--20 x 1-1/4” 801-194-002 2
flat washer, 1/4” 801-100-000 2
locking nut, 1/4 --20 802-117-000 2
lockwasher, 1/4” 803-042-001 2
cable tie, locking 808-002-001 6
h/s tubing, blk, 1/8”dia. 321-042-000 12 in.
h/s tubing, blk, 3/8”dia. 321-143-001 6in.
ferrite bead 309-388-001 1

Table 2-1

Parts List

2-2 Vehicle Power Supply Installation Guide

SECTION 2 " Installation Procedures

Before you Begin

WARNING: 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
installing it in. See Section One for identifying information.

Remember that the supply with the lower input voltage rat­ing (6--36 V dc) has a 4-pin input connector while the power
supply with the higher input voltage rating (15-96 V dc) has
a 2-pin input connector.

Connect Power Input Cable

Only one of the input connectors will fit the power supply:

1. Mate the corresponding cable connector to the power
supply connector.

2. Slide the cable connector IN as far as it will go.

3. Turn the cable connector collar clockwise to secure it.

4. Clamp the ferrite bead onto the input cable near the
power supply. Make sure tabs are fully engaged.

5. Cut cable at the unused cable connector.

Discard this connector.

Vehicle Power Supply Installation Guide 2-3

SECTION 2 " 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 un-
der any circumstances. The output power cable is
approximately 6 feet in long and cannot be shortened. You
must take these lengths and the intended location of your
electronic equipment into consideration when choosing a
mounting location for the power supply.

The mounting location must provide 130--160 square inches
of metallic surface to sink heat generated by the power sup­ply. This metallic mounting surface must be connected to
the vehicle chassis electrically. In rare instances, you may
have to fabricate a flexible wire or braid to bond the
mounting surface to vehicle chassis ground.

Appropriate hardware is furnished in this installation kit
for mounting the power supply. Use mounting Method A in
situations where you can easily access the back side of the
mounting location to install a locknut and washer.

Use Method B where the back side of the mounting location
is inaccessible. Note that this method requires that the
mounting plate be thick enough to accept and retain suffi­cient threads to provide a secure and reliable mechanical
installation.

Method A:

1. Mark and center punch the two mounting hole loca­tions.

2. Use a 1/4-inch drill bit to make the two mounting
holes.

3. Use 1/4” hex bolts with flat washers and locking nuts
to install the power supply.

Method B:

1. Mark and center punch the two mounting hole loca­tions.

2. Use a #7 drill bit to make the mounting holes.

2-4 Vehicle Power Supply Installation Guide

3. Use a 1/4--20 tap to thread the mounting holes.

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.

" Completely install power cables before making connec-

tions to equipment.

" Route the power cables from the general area where

the power supply will be mounted.

" Use a snap-in bushing (requires 9/16” hole) if the

power cable passes through a firewall or other sheet­metal.

" Make sure that cable routing does not interfere with

other equipment or vehicle controls.

" Make sure that cable routing does not invite damage

to the cable.

" Secure the cables at least every 18 inches throughout

the cable run: use adjustable clamps (see last page in
this section) or wire-tie to existing vehicle cable runs.

SECTION 2 " Installation Procedures

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 part number 163-900-034), or an automatic shut
off device, in series with the in-line fuse holder. Charge ­Guard, Inc., 400 Highland Avenue, Altoona, PA 16602
(814-941-4100) manufactures a “CHARGEGUARD ÒÒ“ device for
this purpose.

Vehicle Power Supply Installation Guide 2-5

SECTION 2 " Installation Procedures

Power Cable Connections

The fuse holder from the input power cable must be con­nected as close (physically and electrically) as possible to
the positive side of the vehicle power source. The remaining
colored wire(s) must be connected to the negative side of the
vehicle power source. In this installation, the shield wire

must be connected to the vehicle chassis. Instructions are
not included for connecting to various possible vehicle pow-

er sources. It is assumed that the trained professional in­staller will be knowledgeable on the brands and models of
vehicles he is working with. Both large (3/8-inch) and
smaller terminal 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 battery. The intended use for
these parts is detailed in the instructions that follow.

Cable Termination

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. Heatshrink tubing is furnished in this
kit and must be slipped onto the cable or wires before termi-
nating them. Then, you must install the fuse holder in se­ries with the positive wires and install a terminal ring on
the negative wires. 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 flatwasher.

2-6 Vehicle Power Supply Installation Guide

Cut and Strip the Power Cable

Heatshrink tubing

SECTION 2 " Installation Procedures

1. Cut the power cable near the power source or battery.

2. Strip the cable jacket back 12--14 inches.

3. Slide heatshrink tubing over cable jacket.

4. Strip 1/4” of insulation from individual wires.

5. Twist the white and green (negative) wires together.

6. Twist the red and black (positive) wires together.

7. Twist the shield wire and slide the 1/8” heatshrink
tubing onto it.

Green and White Wires

(negative)

Red and Black Wires

Input
Power
Cable

Shield wire w/heatshrink applied

Strip the Cable Jacket 12--14 inches

(positive)

Figure 2-1

Cut and Strip Cable Ends

NOTE: See “Note” on page 2-5 when installing on gas-powered vehicles.

Vehicle Power Supply Installation Guide 2-7

SECTION 2 " Installation Procedures

Heatshrink Tubing

This kit contains a 6 inch length of 3/8” heatshrink tubing
which you will cut into three pieces, and a 12 inch length of
1/8” heatshrink tubing for the shield wire. Tubing must be
in place before terminating wire ends. Crimp terminal rings
and fuse holder ends, then position all heatshrink tubing in
the locations shown. Use a heat gun to shrink tubing.

1

3/8”

b

1/8”

b

Arrows denote heatshrink
locations and diameter.

NOTE: See “Note” on page 2-5 when installing on gas-powered vehicles.

b

b

3/8”

b

3

1. Green and White twisted pair

2. Red and Black twisted pair

3. Shield wire, twisted

Figure 2-2

Heatshrink Locations

3/8”

b

2

2-8 Vehicle Power Supply Installation Guide

SECTION 2 " 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) terminal ring should be crimped to the shield
wire and then fastened to vehicle chassis ground.

1. Crimp a terminal ring onto the white-green twisted
pair (negative) of wires.

2. Cut the red-black twisted pair (positive) of wires at the
midpoint. Strip exposed ends.

3. Position short lengths of heatshrink tubing as in indi­cated in Figure 2-2.

4. Crimp the fuse holder to the positive wires from the
cable.

5. Shorten the remaining positive wires (pigtail) if de­sired and position a short length of heatshrink tubing
onto this pigtail.

6. Crimp this positive pigtail to the fuse holder.

7. Securely crimp a terminal ring to end of the positive
pigtail from the fuse holder.

8. Slide heatshrink over crimps, shrink with heatgun.

Power Source Connections

The next four pages show you the intended purpose of nuts,
bolts, and washers that are included in this kit if you will be
connecting the power cable directly to a vehicle battery.

Additionalhardwareisnotprovidedinthiskitforconnecting
the power cable to other vehicle power sources. Refer to the
manufacturer’s technical manualfor the vehicleif necessary.

Vehicle Power Supply Installation Guide 2-9

SECTION 2 " Installation Procedures

Direct to Battery Connections

Side-mounted 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 kit.

3. Slip a 3/8” washer onto the bolt.

4. Slide the positive (fuse holder) terminal ring onto the
positive battery terminal bolt.

5. Slip a second 3/8” washer onto the bolt.

6. Slide the vehicle positive battery cable onto the bolt.

7. Thread the bolt assembly (steps 1--6, above) into the
positive battery terminal. Tighten the bolt until it bot­toms out but do not overtighten the bolt.

8. Tighten the nut securely against the washers and
cables.

9. Use self-tapping screw and a flat washer to connect
shield wire to vehicle chassis ground.

Repeat steps 2 through 8 for the negative (white--green pair) wire from the input
power cable, hooking up the negative cables to the negative (--) battery terminal.

NOTE: See “Note” on page 2-5 when installing on gas-powered vehicles.

2-10 Vehicle Power Supply Installation Guide

SECTION 2 " Installation Procedures

2

1

3

4

6

5

1. Bolt

2. Nut

3. Vehicle battery

4. Vehicle battery cable

5. Fuse holder

6. Washers

Figure 2-3

Side-Mount Battery Terminals

NOTE: See “Note” on page 2-5 when installing on gas-powered vehicles.

Vehicle Power Supply Installation Guide 2-11

SECTION 2 " Installation Procedures

Connection to Top-mounted 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.

5. Slip a second 3/8” washer onto that bolt.

6. Thread a second 3/8” nut onto that bolt. Tighten the
nut.

7. Use 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.

2-12 Vehicle Power Supply Installation Guide

SECTION 2 " Installation Procedures

2

3

1

6

4

5

1. 3/8” nut

2. 3/8” X 1-1/2” bolt

3. Vehicle battery

4. Vehicle battery cable

5. Fuse holder

6. 3/8” washers

Figure 2-4

Top-Mount Battery Terminals

NOTE: See “Note” on page 2-5 when installing on gas-powered vehicles.

Vehicle Power Supply Installation Guide 2-13

SECTION 2 " Installation Procedures

Cables Clamps

Secure the cables every 18 inches using locking wire ties or
adjustable 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. Use #6 sheet-metal screws to per­manently hold clamps in place.

#6 Sheet-metal

Screw Goes Here

Figure 2-5

Cable Clamp

Final Connections

Once the computer, dock, or other device is mechanically
installed,youcanconnecttheoutputpowercablebetweenthe
power supply output and the device. Connectors are keyed
and operate the same as the input power connector:

1. Mate the cable connector to the power supply and to
the device connectors.

2. Slide the cable connector IN as far as it will go.

3. Turn the cable connector collar clockwise to secure it.

NOTE: See Section Three for power fault diagnostic information.

2-14 Vehicle Power Supply Installation Guide

SECTION 3 " Troubleshooting Information

Section 3

Troubleshooting Information

" " " " " " " " " " " " " " " " " " " " " " " " " " " "

Procedures

Three basic procedurescontained in this section allow you to
identify and correct most power supply problems you may
encounter in the foregoing installation. Connector pin-out
information is also furnished for your convenience.
Recommended diagnostic procedures are listed below and —
in general — should be followed in the order given. The
Trouble Charts will instruct you when to use a particular
method.

Basic Diagnostic Procedures

1. Inspection

2. Voltage and Continuity Measurements

3. Component Substitution

Inspection

Power Supply

The power supply has a green light-emitting diode (LED)
indicator near the output connector. This LED is lighted
whenever 12 V dc is present at the output connector. Any­time you suspect a power failure, check to see if the LED is
lighted. If this LED is lighted and you believe there is a
power failure, the failure is either in the output power cable
or downstream from it.

Vehicle Power Supply Installation Guide 3-1

SECTION 3 " Troubleshooting Information

If the LED is not lighted, the power supply is not producing
12 V dc output power. In this case a fault can exist any­where in the system. Table 3-1 will help isolate and identi­fy and correct the failure.

Cables, Connections

Visually inspect all cable connectors and the connections to
the vehicle power source. Any obvious faults should be cor­rected. Use your hands to jiggle cable connectors to ensure
these are not loose or disconnected. Again, correct any
faults before proceeding.

Fuse

Openthe twist-lock fuse holderand remove the fusefor a con­tinuitytest. Ifyou substituteanew fuseandit alsoblows,the
mostlikely cause(s) would be a shorted ormiswiredpowerin­put cable, or a faulty (or incorrect) power supply.

Electrical Measurements

Voltage

Connector pin-out information is provided to allow you to
measure voltage at the input power cable connector and at
either end of the power output cable.

Continuity

CAUTION: Cables MUST be disconnected at both ends before conducting

continuity tests. Failure to disconnect cables completely is
likely to result in damage or destruction of your test equipment.

Thorough continuity testing will take longer, in most cases,
than either substitution or taking voltage measurements.
An ohmmeter is sufficient to diagnose simple opens or
shorts.

If fuses blow sporadically, or power supply shut down occurs
at random, you may want to use a megger to check cables
for high-resistance shorts between wires or between a wire
and the cable shield.

3-2 Vehicle Power Supply Installation Guide

SECTION 3 " Troubleshooting Information

Substitution

Advantages

Component substitution is the most expedient and certain
troubleshooting technique. It is especially valuable when
trying to resolve intermittent problems.

Disdvantages

You must either have spare parts (power supply and both
cables in this instance) on hand, or be prepared to “borrow”
components from another, working installation.

When to Substitute

Follow the guidelines in the Trouble Charts that follow, sub­stituting only when directed to do so.

If an installation suffers intermittent input power cable
fuse failures, or if the power supply shutdowns without
good cause, do not hesitate to substitute a known-good pow­er supply.

Trouble Charts

The following trouble 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 they are shown for
maximum troubleshooting efficiency.

Power Supply Reset

Where the trouble chart tells you to “reset the power sup­ply” you must disconnect the input power cable for 10 sec­onds, then reconnect it. The power supply has automatic
over-voltage, over-current, over-temperature, and shorted­output protection and must be reset by disabling input pow­er whenever any of these faults activates that protection.

Vehicle Power Supply Installation Guide 3-3

SECTION 3 " Troubleshooting Information

Power Failure Trouble Chart I

Observe Result Meaning Remedy

Table 3-1

LED Lighted Power Supply

is working.

LED NOT lighted No output

power from
supply.

LED NOT lighted No output

from power
supply.

LED Lighted (now)

Power supply
is working.

Test or sub­stitute out­put power
cable.

Reset the
power sup­ply.

Disconnect
power OUT­PUT cable,

then reset
the power
supply.

Substitute
power out­put cable.

3-4 Vehicle Power Supply Installation Guide

SECTION 3 " Troubleshooting Information

Table 3-2

Power Failure Trouble Chart II

(assumes steps in Chart I have been followed)

Observe Result Meaning Test or

Remedy

LED

Voltage

Voltage

NOT lighted

Normal

NOT pres­ent

No output
from power
supply.

Power Supply
not working.

No input pow­er to the power
supply

Test for input
voltage.

Replace pow­er supply.

Replace in­line fuse if
voltage is
NOT present
at connector.

Replace input
power cable if
input voltage
is still not
present at
connector.

Vehicle Power Supply Installation Guide 3-5

SECTION 3 " Troubleshooting Information

Power Supply Pinouts

Connector Negative Positive Case

Input Power

conn. (LV)

Table 3-3

(chassis gnd.)

124

3

Input Power

conn. (HV)

2

1

Output

Power

Connector

1

3

2

Pin 1

Pin 3

NC

Pin 2

Pin 4

Pin 1 Pin 2 NC

Pin 3 Pin 2 Pin 1

3-6 Vehicle Power Supply Installation Guide

SECTION 3 " Troubleshooting Information

.

108.0 +/-- 3.0”< >

4

1

12

23

Pin View Pin View

Note: During installation, you will cut and discard one of these cable connectors

--DC

+DC

1

2

SS SS

Green

White

Red

Black

Shield

--DC

1
2

--DC
+DC

3

+DC

4

Figure 3-1

Input Power Cable

Vehicle Power Supply Installation Guide 3-7

SECTION 3 " Troubleshooting Information

3-8 Vehicle Power Supply Installation Guide

Corporate Headquarters

6001 36th Avenue West
Everett, Washington 98203

tel [phone]

fax [phone]

www.intermec.com

Vehicle Power Supply Installation Instructions - October 2002

*962054004*

*962054004* Revision C