Cradlepoint COR IBR600 Manuale utente

White Paper /COR IBR600 Vehicle Installation Guide

Cradlepoint Vehicle

Best Practices

Installation Guide

Using Cradlepoint COR IBR600

Router in 12 V and 24 V

Vehicles

WHAT YOU’LL GET:

+Overview of basic in-vehicle

electrical systems.

+The basics of power

management.

+Voltage regulation &

DC-DC converters.

+Filters, installation, fusing,

wiring, mechanical, and

thermal considerations.

White Paper /COR IBR600 Vehicle Installation Guide

OVERVIEW

The automotive environment can be particularly harsh for

electrical equipment such as routers and mobile devices. Power

in automotive systems is not stable and is often subject to

uctuations and noise.

Vehicle electrical systems are typically 12 V or 24 V, but the

actual voltage can vary widely depending on the condition of the

batteries and whether the engine is o, cranking, or running.

Just as important, many potentially damaging transient voltages

exist on vehicle power wiring. These transients, sometimes called

“spikes,” are caused by motors for electric windows, solenoids

for door locks, alternators, relays, light switches, loose electrical

connections, and corroded battery terminals. The inductance in

the vehicle’s wiring harnesses may exacerbate these transients.

Transients of hundreds of volts, both positive and negative, can

be generated with the potential to cause damage to any

electrical equipment.

Our COR IBR600 router can operate safely on 9–18 volts DC.

However, for reliable operation in a vehicle, it requires additional

ltering and conditioning in 12 V vehicles and

additional voltage regulation in 24 V systems. Most other

Cradlepoint routers are specied to operate safely from 11.4

to 12.6 volts and require regulation and ltering for all vehicle

installations.

This paper will provide background on the problems

and solutions as well as guidance for the installation

of Cradlepoint devices. We’ll recommend some

commercially available products to help minimize the

eects of the harsh automotive power environment.

FOR PROPER

AND SAFE

INSTALLATION,

THE ROUTER

MUST BE

CONNECTED TO A

FUSED CIRCUIT IN

THE VEHICLE.

BASIC SYSTEM (NO PROTECTION)

It is possible to quickly wire a basic 12 volt system such as the simple installation shown in

this diagram where power is provided to the router by connecting the 12 V input lead from

the router to a connection in the vehicle fuse block and the ground wire to chassis ground.

However, this method provides no protection against voltage variations or voltage transients.

Erratic operation or even damage to your Cradlepoint product is much more likely than if

the methods shown in the following pages are used to condition the power provided to your

Cradlepoint product or other mobile device.

White Paper /COR IBR600 Vehicle Installation Guide

Battery

Ignition Switch

Power Manager

Fig 1. Battery Voltage During Engine Start

POWER MANAGEMENT

These devices monitor the state of the battery

and other lines such as the ignition switch to

determine if power should be applied to the

mobile device. Possible features provided by

these may include the following:

+ Provides power only when ignition

switch is turned on.

+ Monitors the battery voltage. If the

battery voltage is too low or too high,

power to the mobile device is not allowed.

+ Monitors whether the starter motor is

engaged. Does not apply power to the

mobile device while engaged.

+ May allow the device to remain powered

on for a specied time after the ignition is

switched o to prevent battery drain. This

time is typically user programmable.

The graph in Figure 1 shows how the voltage

available from the battery is reduced signicantly

when the starter motor is engaged. The voltage

may fall well below the recommended minimum

voltage required by the router causing “brown

out” conditions and possible malfunction.

VOLTAGE REGULATION

Most vehicles are designated as either 12 or

24 volt systems, yet even though the battery

is designated as 12 volts the actual voltage at

its terminals during normal vehicle operation is

typically about 13.6 V. However, depending on

its age, state of charge, and electrical load can

typically range between 10 and 16 volts. 24 volt

systems have similar characteristics and can range

between 17 and 32 volts during normal operation.

Depending on model, Cradlepoint routers can

accept an input voltage of 9–18 volts which

means some sort of voltage regulation and

conditioning is generally required.

DC TO DC CONVERTERS

Commercially available DC-DC converters take a

wide voltage range from the battery and provide

a regulated DC voltage output, typically about

13.6 volts. These converters should supply low

ripple voltage, typically less than 250 mV. Higher

quality converters may also provide features such

as reverse polarity protection, isolation, current

limiting, short circuit protection, and overvoltage

protection.

For a 24 volt system a standard regulator that

simply lowers the voltage to 12–14 volts is

acceptable. In a 12 volt system a regulator may

need to either boost the voltage or reduce it.

This dual mode regulator may be somewhat more

expensive but will protect against “brown

out” conditions caused by low input voltage.

It is important that the DC-DC converter can

provide enough power for all devices with some

extra safety margin (reserve power). Do not use

an underpowered converter.

White Paper /COR IBR600 Vehicle Installation Guide

Vehicle

Type

12 Volt

System

24 Volt

System

Input

Range to

DC-DC

Converter

10–16 VDC

20–50 VDC

Typical

Output

Voltage

13.6 VDC

Battery

12 V / 24 V

10–16 V (12 V system)

17–32 V (24 V system) 13.6 V

DC-DC

Converter

(12 V or 24 V

Model)

White Paper /COR IBR600 Vehicle Installation Guide

FILTERS

Voltage transients on the router’s 12 V input power lines

may cause erratic behavior or damage. This “noise” can

range in frequency from a single spike to a few kilohertz

or hundreds of megahertz and is typically caused by

electromechanical components in the vehicle, or even by

additional electrical accessories installed in the vehicle.

Filters may help control these transients; however, good

installation techniques must be followed to ensure best

router performance and protection.

+IMPORTANT—Filters should be placed as close as

practical to the router input power. Keep power

lines to the device short. Failure to do so may

reduce the eectiveness of the lter.

+ Noise lters can be as simple as a capacitor (or

two) placed across the 12 V power line into the

device. Adding an inductor and second capacitor

to form a “pi” lter is more eective. Fig 2. Location of the filter is important. Keep lines to

mobile devices short.

Fig 3. Filter component types. Pi is preferred.

Battery

Noise received Noise generated

Noise generated

Battery

Input

Ground

Output

Keep short

+ Capacitors (caps) should be rated at least

150% of the expected voltage and a low

ESR is preferred. Over time, a higher

temperature rated cap will be less likely to

fail.

+ Caps have eective frequency ranges

depending on the material used in their

construction.

+ Aluminum electrolytic, or “metal can,” caps

are used for lower frequency noise and

voltage dips. These caps have positive and

negative terminals and must be connected

correctly or damage will occur. Capacitance

values ranging from tens to hundreds of

thousands of microfarads (uF) are available.

For example a 5000 uF 35 V 85 ºC aluminum

capacitor would be a good starting value.

+ Ceramic capacitors are used to control high

frequency noise. It is critical to keep these

as close a possible to the device input and

keep lead lengths short. Typical values are

0.001–0.47 uF, 50 VDC.

+ Inline inductors must be capable of

handling the full load current of the

device(s) attached to it.

+ Pi lters are typically sold as “noise lters”

by automotive audio stores. These must

also be able to handle full load current.

INSTALLATION, FUSING AND WIRING

Proper installation of the power conditioning

devices in relation to the mobile device you are

trying to protect is important.

+ It is best to locate all conditioning

devices such as DC-DC converters, power

management devices, distribution blocks,

and lters as close to the router equipment

as possible. That being said, some are more

critical than others.

+ Filters and distribution blocks should be

located as close to the mobile device(s) as

possible. Long power leads from the lter

to the mobile device can degrade or nullify

lter performance.

+ Use the proper wire size for the amount

of current being drawn. Long cable lengths

with undersized wire will result in voltage

losses over the length of the cable and

can possibly overheat (see table for

recommended wire size).

+ Use of a dedicated ground wire, rather

than attaching to chassis ground, may be

preferred.

+ Chassis ground can be susceptible to

corrosion eects and intermittent

connections.

White Paper /COR IBR600 Vehicle Installation Guide

Fig 4. Standardized Examples of Automotive Transients (ISO-7637-2)

White Paper /COR IBR600 Vehicle Installation Guide

Fig 5. Possible Installation Configuration

Battery

12 V / 24 V

+-DC-DC

Converter

GND

IN OUT

13.6 VDC

No connection

if converter is

ISOLATED

Ignition

Switch

Fused Distribution

Block

Keep

cables

short

12 V IN 12 V OUT

IGNITION SW GROUND

Power Management

Long Cables Use

correct wire size

10–16 V (12 V system)

17–32 V (24 V system)

Filter

+ Isolation between devices is recommended.

Noise generated by one device can aect

another. If multiple devices are connected

at the same distribution point it may be

necessary to lter each device separately.

+ For proper and safe installation, the router

must be connected to a fused circuit in

the vehicle. For the COR IBR600 this fused

circuit requires a 1.5 A maximum time delay

(slow blow) high interrupting rating fuse. If

the supply connection is made directly to

the battery, the fuse should be installed in

the positive lead. For North America, a UL

Listed fuse is to be used.

AMPS Cable Length (AWG)

10’ 20’

3–10 #14 #12

11–20 #14 #10

21–35 #8 #6

MECHANICAL AND THERMAL

Electronics mounted in vehicles may subject to

high levels of mechanical and thermal stress. It is

important to understand that these parameters be

addressed to ensure a reliable installation.

+ Be sure the router is securely mounted

within the vehicle. For example with the

COR IBR600 family of routers includes a

mounting bracket. This bracket can hold the

router solidly in most installations. In high

shock environments it may be advisable to

add a supplemental cable tie to secure the

router in the bracket.

+ Vibration can cause early failure if not

reduced to an acceptable level. Using the

same COR IBR600 mounting bracket as

an example, special anti-vibration rubber

grommets such as the Keystone 773

(available from DigiKey) may be used. Insert

the grommets and then tighten the screw to

the point where the grommet just begins to

compress to provide vibration isolation.

+ Thermal ratings must be taken into

consideration for reliable operation. All

devices and components used in the

installation are subject to the same thermal

stresses. The COR IBR600 is rated for

ambient temperatures from -20 °C to 60 °C

(-4 °F to 140 °F). Various power conditioners

may have lower or higher ratings. Take care

that your installation is within the thermal

ratings of each device.

+ The ambient thermal environment may

be aected by many factors. Lack of

ventilation, being mounted in an auxiliary

box, or being mounted where the sun heats

it can all increase the relative ambient

temperature. Care must be taken to

understand these thermal aspects.

White Paper /COR IBR600 Vehicle Installation Guide

Fig 6. COR IBR600 Mounting Bracket

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