Intermec CV60 Vehicle Power Supply Installation

Recommendations for Wal-Mart

Intermec has encountered several instances where there was

insufficient metal available in yard trucks used by Wal-Mart at
Distribution Centers to properly sink the heat generated by the
DC-DC power supplies used to operate the CV60 computers
in those yard trucks. In these circumstances, a metal plate
must be fabricated and provided by the site to accomplish the
heat sinking that these power supplies require.
In Wal-Mart Distribution Centers where pilot installations
were conducted, Intermec found that DC-DC power supplies
suffered from repeated shutdowns due to overheating without
the metal plate in yard trucks with fiberglass or composite
materials in the cab.
The Intermec CV60 Vehicle Power Supply Installation Guide
calls for a minimum of 130-160 square inches of metal for
mounting DC-DC power supplies to allow for proper heat sink
functionality. Intermec has found that a 6.5x25-inch aluminum metal plate ¼” thick has provided adequate heat sinking for
DC-DC power supplies in previous yard truck installations completed at Wal-Mart Distribution Centers. This metal plate can
be installed on the frame rail above the right side window
or other convenient location in the yard truck (out of
direct sunlight,) and then the DC-DC power supplies may
be mounted to the metal plate (see photos.)
Intermec recommends that Wal-Mart adopt this
method of installation for DC-DC power supplies for
all future implementations when the situation
indicates that there is insufficient material to achieve
proper heat sinking action.
Intermec has also found that the use of a 4x4-inch 1/8”
thick aluminum plate to be used for mounting the ball
mount on trucks with fiberglass dashboards will prevent
the tear-out of the mounting holes due to the rough
handling of the Yard Trucks. We recommend the use of
this mounting plate as well on trucks equipped with
fiberglass or composite dashboards.
In addition to the metal plates used for heat sinking the
power supplies, Intermec also recommends the installation of an isolation switch of a sufficient rating to handle the entire
current load of the two DC-DC power supplies. This should be installed on the positive leads of the power supplies so that
the entire CV60 and power supply combination can be isolated from the vehicle battery. The DC-DC power supplies may
draw up to 8 Amps when the CV60 is in operation with the screen heater functioning, and will continue to draw
approximately 350 milliamps when the CV60 is turned off. As a result, they may drain the battery if left connected for
extended periods of time. Intermec recommends a panel-mount SPST Toggle Switch rated for 15 Amps at 30VDC, designed
to be installed in a ½” mounting hole.
Intermec recommends that Wal*mart adopt the practice of installing of an isolation switch for all future DC Yard
truck implementations to eliminate the possibility of the vehicle battery being drained when the truck is parked for an
extended period of time (such as overnight.)
Recommended additional materials for each DC Yard truck:
Aluminum plate 6.5 x 25.0 inch by 1/4” thick for mounting the DC-DC power supplies (Qty -1).
Aluminum plate 4.0 x 4.0 inch by 1/8” thick for reinforcing the ball mount location (Qty – 1).
Toggle Switch 15 Amp, 30VDC SPST, panel mount, ½” mtg hole for system isolation (Qty – 1).