Intermec PB50 Forklift Power Supply Installation Guide
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- Intermec PB50 | Forklift Power Supply Installation Guide - Page 1
Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 2
, and Vista Powered are either trademarks or registered trademarks of Intermec Technologies Corporation. There are U.S. and foreign patents as well as U.S. and foreign patents pending. Wi-Fi is a registered certification mark of the Wi-Fi Alliance. ii Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 3
This page records changes to this document. The document was originally released as Revision 001. Version Number 002 001 Date 6/2009 4/2008 Description of Change Updated to include new printer models and output cable number. First release of document Forklift Power Supply Installation Guide iii - Intermec PB50 | Forklift Power Supply Installation Guide - Page 4
iv Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 5
viii Web Support ix Telephone Support ix Service Location Support ix Who Should Read This Manual x 1 Introduction 1 Understanding the DC Power Supply Kit 2 Installation Guidelines 2 Power Supply Considerations 3 Understanding Power Supply LEDs 3 Using the Input Power Cable 4 Using the - Intermec PB50 | Forklift Power Supply Installation Guide - Page 6
to the Forklift Battery 19 Connecting to Side-Mount Battery Terminals . . . . 19 Connecting to Top-Mount Battery Terminals . . . . 20 Securing the Battery Cable 21 Connecting the Output Power Cable 21 Sample Installations 22 3 Troubleshooting 25 Identifying and Correcting Problems 26 - Intermec PB50 | Forklift Power Supply Installation Guide - Page 7
Contents Forklift Power Supply Installation Guide vii - Intermec PB50 | Forklift Power Supply Installation Guide - Page 8
special instructions for handling a particular condition or set of circumstances. Global Services and Support Warranty Information To understand the warranty for your Intermec product, visit the Intermec web site at www.intermec.com and click Support > Returns and Repairs > Warranty. viii Forklift - Intermec PB50 | Forklift Power Supply Installation Guide - Page 9
our current manuals (in PDF). To order printed versions of the Intermec manuals, contact your local Intermec representative or distributor. Visit the Intermec technical knowledge base (Knowledge Central) at www.intermec.com and click Support > Knowledge Central to review technical information - Intermec PB50 | Forklift Power Supply Installation Guide - Page 10
with the PB21, PB22, PB31, PB32, PB50, PB51, and PW50 mobile printers. This document provides you with information about the features of the forklift power supply, and how to install, configure, operate, maintain, and troubleshoot it. Before you work with the forklift power supply , you should be - Intermec PB50 | Forklift Power Supply Installation Guide - Page 11
1 Introduction This chapter introduces the forklift power supply that is used for your mobile printer. This chapter contains these topics: • Understanding the DC Power Supply Kit • Installation Guidelines • Power Supply Considerations • Contents of the Forklift Power Supply Kit • Wiring Diagram 1 - Intermec PB50 | Forklift Power Supply Installation Guide - Page 12
DC Power Supply Kit Use the DC power to help supply power to your mobile printer when it is on a forklift. The DC power supply kits include these items: • Power supply • Power supply input cable, 2.44 m (8 feet) • Fused power cable, 46 cm (18 inch) • #10 terminal ring • 3AB, 20A/250 Vx fuse for 12 - Intermec PB50 | Forklift Power Supply Installation Guide - Page 13
chassis or connect it (electrically) through external wire to the forklift chassis. Chassis ground to the printer or other equipment is then established through the power supply output cable. • Since the power supply produces heat, Intermec advises that you mount it on a metallic surface that is - Intermec PB50 | Forklift Power Supply Installation Guide - Page 14
the unneeded connector, a single cable can meet either 4 or 4.5 A current requirements. The cut end is then terminated for connection to the forklift power source. For instructions on attaching the power cable, see "Mounting the Power Supply" on page 11. 4 Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 15
) to the forklift power source. It provides catastrophic failure, short-circuit protection for the entire input power cable and the power supply input. The fuse holder contains a 3AB, 20 A/250 Vx (.25 inch x 1.25 inch) fast-blow fuse recommended for installations with 12 V automotive batteries. For - Intermec PB50 | Forklift Power Supply Installation Guide - Page 16
heavy-duty metal housings and enhanced strain relief to provide added reliability in the mobile environment. For a diagram of the output cable, see the next section. Contents of the Forklift Power Supply Kit 6-60 V Cable input - Printer and vehicle cradle + Fuse DC/DC power supply ("converter - Intermec PB50 | Forklift Power Supply Installation Guide - Page 17
Forklift Power Kit (P/N 203-880-002) (continued) Description Part Number Cable assembly (input cable Washer, split-lock 803-042-001 Cable tie, locking 808-002-000 638-00 Plug, 4-socket circular 311-638- 311-638-006 006 1 Cable, 4 cond 18 AWG, foilshielded 321-295-005 Shield bead, .590/.275 - Intermec PB50 | Forklift Power Supply Installation Guide - Page 18
the power source in a forklift. Use this illustration as a reference during the planning phase of your power supply installation. Connector to battery - Best + To DC/ Braking System, very large voltage spikes Power Source Connection Possibilities 8 Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 19
forklift power supply. This chapter contains these topics: • Installation Recommendations • Preparing the Power Input Cable • Mounting the Power Supply • Installing the Input Power Cable • Connecting the Power Cable to the Forklift • Terminating the Input Cable • Connecting to the Forklift Battery - Intermec PB50 | Forklift Power Supply Installation Guide - Page 20
Chapter 2 - Installing the Forklift Power Supply Installation Recommendations Review the forklifts you want to use before you start. Plan the installation by following these safety and utility recommendations: • Install the power cable at the forklift power source if possible or at the point where - Intermec PB50 | Forklift Power Supply Installation Guide - Page 21
the Input Cable" on page 16. Mounting the Power Supply The input power cable is approximately 2.74 m (9.0 feet) long and may be shortened if necessary. The output power cable is approximately 2.2 m (7.2 feet) long and should not be lengthened. Forklift Power Supply Installation Guide 11 - Intermec PB50 | Forklift Power Supply Installation Guide - Page 22
part of, the forklift chassis as long as the chassis is not electrically connected to the battery negative or positive. Side-Mount Battery power supply, the printer, and the forklift accessory devices making electrical contact with the forklift chassis. 12 Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 23
battery negative and the forklift protection from other risks encountered on forklifts. A fault condition, like a wire shorting to the forklift chassis, may present a power path that could negatively impact the power supply, the printer to each forklift installation. portable printer is going to - Intermec PB50 | Forklift Power Supply Installation Guide - Page 24
the bolt/lockwasher assemblies through the power supply holes and into the threaded mounting holes. Installing the Input Power Cable Follow these guidelines and other instructions closely when installing power cables: . Never work on a powered system. 14 Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 25
. These devices prevent discharge of the forklift battery while the lift is off the holder. Charge Guard, Inc. 400 Highland Avenue, Altoona, PA 16602 (814.941.4100) manufactures a CHARGE GUARD™ device for this purpose. Connecting the Power Cable to the Forklift The fuse holder from the input power - Intermec PB50 | Forklift Power Supply Installation Guide - Page 26
connecting the input power cable directly to a forklift battery. These parts are described in more detail in the procedures below. Terminating the Input Cable Follow this procedure to terminate the input power cable (P/N 226-330-004). To terminate the power cable 1 Cut the cable to length, cut off - Intermec PB50 | Forklift Power Supply Installation Guide - Page 27
2 - Installing the Forklift Power Supply 7 Twist the shield wire and slide on the 1/8-inch heat shrink tubing (P/N 321-650-006). Heat shrink tubing Green and white wires (negative) Input power cable Red and black wires (positive) Shield wire with heat shrink applied Strip the cable jacket 30-36 - Intermec PB50 | Forklift Power Supply Installation Guide - Page 28
Installing the Forklift Power Supply 2 Use the heat gun to shrink tubing. 3 Wrap the 1/8-inch shrink sleeve tubing (P/N 321-650-003) over shield wire. Note: Be sure to shield wire to the metal surface on which the power supply is mounted. Preparing the Cable Ends Use these instructions to prepare - Intermec PB50 | Forklift Power Supply Installation Guide - Page 29
which battery is in your forklift and proceed with the applicable instructions. Connecting to Side-Mount Battery Terminals Perform the following procedure to attach the forklift battery cable to a side-mount battery terminal. To connect the forklift battery cable to a side-mount battery terminal - Intermec PB50 | Forklift Power Supply Installation Guide - Page 30
positive (fuse link with red wire) terminal ring from the input power cable onto the positive (+) battery bolt. 7 Slip a second 3/8-inch washer (P/N 803-099-001) onto the bolt. 8 Thread and tighten a second 3/8-inch nut (P/N 802-099-001) onto the bolt. 20 Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 31
Power Cable Once the printer, vehicle cradle, or other device is mechanically installed, you can connect the output power cable to the power supply output and the mobile computer. Connectors are keyed and operate the same as the input power connectors. Forklift Power Supply Installation Guide 21 - Intermec PB50 | Forklift Power Supply Installation Guide - Page 32
Chapter 2 - Installing the Forklift Power Supply To finish the connection 1 Connect the output cable (P/N 236-193-003) to the mobile printer. 2 Connect the other end of the output cable to the main output of the DC/DC power supply (P/N 851-070-003). 3 Slide the output cable as far as it will go into - Intermec PB50 | Forklift Power Supply Installation Guide - Page 33
is good access for cooling. • good access for component service. • full access to the UPS battery. Here is another example of an effective installation: In this example, the benefits include: • UPS is accessible without disconnecting it from the lift Forklift Power Supply Installation Guide 23 - Intermec PB50 | Forklift Power Supply Installation Guide - Page 34
difficult due to location • The installation is tedious, time-consuming, and difficult to work on • Troubleshooting problems will be as difficult • Enclosed environment will significantly reduce the air flow, raising the temperature of all the components 24 Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 35
3 Troubleshooting This chapter contains information for troubleshooting the forklift power supply. This chapter contains these topics: • Identifying and Correcting Problems • Troubleshooting Charts 25 - Intermec PB50 | Forklift Power Supply Installation Guide - Page 36
. The LED will flicker until the problem is resolved. In some cases, you may have to remove power to reset the power supply. Checking the Electrical Measurements You can measure the voltage or test for continuity to troubleshoot the battery cable. Measuring the Voltage Connector pinout information - Intermec PB50 | Forklift Power Supply Installation Guide - Page 37
assumes that your portable printer 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 efficiency. Some of the troubleshooting remedies tell you to reset the power - Intermec PB50 | Forklift Power Supply Installation Guide - Page 38
If too hot to touch, provide better heatsink and more air flow. 2 Replace damaged cables. 3 Protect from direct sunlight and mount in the shade. No output from the power supply. Test for input voltage. Power supply not working. Replace power supply. 28 Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 39
Troubleshooting Troubleshooting cable if input voltage is still not present at connector. The fuse is blowing, but no LED is lit Power system is drawing Have the forklift vendor too much current. recommended an inline filter and alternate connection point. Check cables for nicks - Intermec PB50 | Forklift Power Supply Installation Guide - Page 40
Positive Case Pin2 Main output Pin 3 power connector Pin 2 Pin 1 108.0 +/- 3.0" 2 1 Pin view 4 2 3 1 Pin view Power Cable Assembly for P/N 226-340-004 Note: During installation, you will cut and discard one of these cable connectors. 30 Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 41
Chapter 3 - Troubleshooting Note: The cables in the installation kit may contain alternate wire colors. Refer to the following chart for the wire color equivalent. Cable Wire Cable Equivalents Wire Color Green White Red Red Black Alternate Color Blue Gray Brown Brown Red Forklift Power Supply - Intermec PB50 | Forklift Power Supply Installation Guide - Page 42
Chapter 3 - Troubleshooting 32 Forklift Power Supply Installation Guide - Intermec PB50 | Forklift Power Supply Installation Guide - Page 43
- Intermec PB50 | Forklift Power Supply Installation Guide - Page 44
Worldwide Headquarters 6001 36th Avenue West Everett, Washington 98203 U.S.A. tel 425.348.2600 fax 425.355.9551 www.intermec.com © 2009 Intermec Technologies Corporation. All rights reserved. Forklift Power Supply Installation Guide *932-011-002* P/N 932-011-002
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Forklift Power Supply
Installation
Guide