Intermec PB51 Forklift Power Supply Installation Guide
Intermec PB51 Manual
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Intermec PB51 manual content summary:
- Intermec PB51 | Forklift Power Supply Installation Guide - Page 1
Forklift Power Supply Installation Guide - Intermec PB51 | Forklift Power Supply Installation Guide - Page 2
.intermec.com The information contained herein is provided solely for the purpose of allowing customers to operate and service Intermec- Smart Mobile Computing, SmartSystems, TE 2000, Trakker Antares, and Vista Powered are either trademarks or registered trademarks of Intermec Technologies - Intermec PB51 | Forklift Power Supply Installation Guide - Page 3
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 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 4
iv Forklift Power Supply Installation Guide - Intermec PB51 | Forklift Power Supply Installation Guide - Page 5
Safety Information viii Global Services and Support viii Warranty Information viii Web Support ix Telephone Support ix Service Location Support ix Who Should Read This Manual x 1 Introduction 1 . . . . 13 Using a Standard Power Supply Mount 14 Forklift Power Supply Installation Guide v - Intermec PB51 | Forklift Power Supply Installation Guide - Page 6
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 Inspecting the Hardware 26 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 7
Contents Forklift Power Supply Installation Guide vii - Intermec PB51 | Forklift Power Supply Installation Guide - Page 8
topic or contain 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 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 9
for a particular purpose. Web Support Visit the Intermec web site at www.intermec.com to download 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 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 10
can be used 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 - Intermec PB51 | 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 PB51 | Forklift Power Supply Installation Guide - Page 12
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 sure the fuse is close to vehicle power source and is in line with Intermec equipment only. • Keep cables as short as possible, and secure them at Guide - Intermec PB51 | Forklift Power Supply Installation Guide - Page 13
(UPS) that provides backup power during battery change out. Power Supply Considerations Follow these printer or other equipment is then established through the power supply output cable. • Since the power supply produces heat, Intermec troubleshooting. Forklift Power Supply Installation Guide 3 - Intermec PB51 | 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 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 15
battery voltages, please refer to the table below. These alternate fuses are not provided with the kit and must be obtained separately. In general, smaller fuse ratings offer faster acting protection. Note: If your fuse fails, diagnose the problem . Forklift Power Supply Installation Guide 5 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 16
Output Power Cable Note: Ensure that you have the correct output power cables for the mobile printer you are installing. Output power cables (P/N 236-193-001) are approximately 2.2 m (7.2 Forklift Power Supply 932-011-xxx Installation Guide Quantity 1 1 1 1 6 Forklift Power Supply Installation - Intermec PB51 | Forklift Power Supply Installation Guide - Page 17
-295-005 Shield bead, .590/.275/1.10L, 309-091-008 300HM 309-091-008 2 Quantity 1 1 1 2 4 4 8 8 2 3 1 1 1 2 2 2 2 6 30.5 cm 15.2 cm 1 1 1 274.3 cm 2 Forklift Power Supply Installation Guide 7 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 18
as a reference during the planning phase of your power supply installation. Connector to battery - Best + To DC/DC converter Power-Acceptable Distribution panels work better than direct , very large voltage spikes Power Source Connection Possibilities 8 Forklift Power Supply Installation Guide - Intermec PB51 | Forklift Power Supply Installation Guide - Page 19
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 9 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 20
rating is correct for the forklift in which you will be installing the printer. • Remember that the supply with the lower input voltage rating (6-60 Vx simplify service because you can take the entire bracket down and replace it with another bracket while troubleshooting Installation Guide - Intermec PB51 | Forklift Power Supply Installation Guide - Page 21
(positive). Crimp a terminal ring to the joined white and green wires (negative). Insulate as instructed. 5 Make final connections to the forklift power source. Tools List You will need the following 2.2 m (7.2 feet) long and should not be lengthened. Forklift Power Supply Installation Guide 11 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 22
is not electrically connected to the battery negative or positive. Side-Mount Battery With View of Negative (-) and Positive the metal of the power supply, the printer, and the lift chassis. Directly mounting the for other forklift accessory devices making electrical contact with the - Intermec PB51 | Forklift Power Supply Installation Guide - Page 23
have a connection between the battery negative and the forklift chassis power path that could negatively impact the power supply, the printer, and any device connected to the shorted wire. Although when good air flow is available or if the portable printer is going to be used in a refrigerated area. - Intermec PB51 | 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 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 25
in series with the in-line fuse holder. These devices prevent discharge of the forklift battery while the lift is off the holder. Charge Guard, Inc. 400 Highland Avenue, lead connects to the return to the battery at a location not shared with motors, flyback diodes, or other - Intermec PB51 | Forklift Power Supply Installation Guide - Page 26
outer cable jacket, and strip the individual wire ends of the cable as instructed. 2 Slip heat shrink tubing (furnished in this kit) onto the cable and strip the power cable 1 Cut the power cable near the power source or battery. 2 Strip the cable jacket back 30 to 36 cm (12 to 14 inch Guide - Intermec PB51 | Forklift Power Supply Installation Guide - Page 27
install heat shrink tubing 1 Crimp terminal rings and fuse holder ends, then position all heat shrink tubing in the locations shown. Forklift Power Supply Installation Guide 17 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 28
shield wire to the metal surface on which the power supply is mounted. Preparing the Cable Ends Use these instructions to prepare the cable ends. Note: All crimps should be checked to ensure the wire is completely captured (P/N 809-083-009) on to it. 18 Forklift Power Supply Installation Guide - Intermec PB51 | Forklift Power Supply Installation Guide - Page 29
manual for the forklift if necessary. Your forklift has either a side-mount battery with the terminals on the side; or a top-mount battery with the terminals on the top. Determine which battery is in your forklift and proceed with the applicable instructions Power Supply Installation Guide 19 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 30
battery cable to a top-mount battery terminal. To connect the forklift battery cable to a top-mount battery terminal 1 Disconnect the negative battery cable, and then disconnect the positive battery Reinstall the positive battery cable, and then cable onto the positive (+) battery bolt. 7 Slip a - Intermec PB51 | Forklift Power Supply Installation Guide - Page 31
battery Bolt Washers Forklift battery cable Fuse holder Securing the Battery Cable Secure the cables every 46 cm (18 inch) using locking wire ties or adjustable cable clamps. To install cable clamps 1 Remove the paper the Output Power Cable Once the printer, vehicle cradle, or other device is - Intermec PB51 | Forklift Power Supply Installation Guide - Page 32
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 are secure, connect power to the system. Note: See "Troubleshooting Charts" on page 27 for power fault diagnostic information. Sample - Intermec PB51 | Forklift Power Supply Installation Guide - Page 33
the way and tied off, there is adequate heat sink, and there 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 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 34
could occur to lift or power supply components if something fails • UPS battery removal is 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 - Intermec PB51 | 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 PB51 | Forklift Power Supply Installation Guide - Page 36
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 to diagnose simple opens or shorts. 26 Forklift Power Supply Installation Guide - Intermec PB51 | 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 PB51 | Forklift Power Supply Installation Guide - Page 38
Troubleshooting Troubleshooting solutions in this order: 1 Disconnect the power output cable. 2 Reset the power supply. 3 Check the fuse. There is an intermittent condition. Try the possible solutions in this order: 1 Check the case temperature of the power supply. If too hot to touch, Guide - Intermec PB51 | Forklift Power Supply Installation Guide - Page 39
Chapter 3 - Troubleshooting Troubleshooting Power Failure With the Main Output LED (continued) LED Meaning Possible Solution and so on. Power Supply Pinouts Connector Input power connector Negative Pin 1 Pin2 Positive Case Pin3 NC Pin4 Forklift Power Supply Installation Guide 29 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 40
Chapter 3 - Troubleshooting Power Supply Pinouts (continued) Connector Negative Secondary Pin1 output power connector heater 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: - Intermec PB51 | 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 Cable Equivalents Wire Color Green White Red Red Black Alternate Color Blue Gray Brown Brown Red Forklift Power Supply Installation Guide 31 - Intermec PB51 | Forklift Power Supply Installation Guide - Page 42
Chapter 3 - Troubleshooting 32 Forklift Power Supply Installation Guide - Intermec PB51 | Forklift Power Supply Installation Guide - Page 43
- Intermec PB51 | 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