Intermec PW50 Installation guide

PB50 and PW50

Forklift Power

Supply

Installation Guide

ii PB50 and PW50 Forklift Power Supply Installation Guide

Intermec Technologies Corporation

Worldwide Headquarters

6001 36th Ave.W.

Everett, WA 98203

U.S.A.

www.intermec.com

The information contained herein is provided solely for the purpose of allowing

customers to operate and service Intermec-manufactured equipment and is not

to be released, reproduced, or used for any other purpose without written

permission of Intermec Technologies Corporation.

Information and specifications contained in this document are subject to

change without prior noticed and do not represent a commitment on the part of

Intermec Technologies Corporation.

The word Intermec, the Intermec logo, Norand, ArciTech, Beverage

Routebook, CrossBar, dcBrowser, Duratherm, EasyADC, EasyCoder, EasySet,

Fingerprint, INCA (under license), i-gistics, Intellitag, Intellitag Gen2, JANUS,

LabelShop, MobileLAN, Picolink, Ready-to-Work, RoutePower, Sabre,

ScanPlus, ShopScan, Smart Mobile Computing, SmartSystems, TE 2000,

Trakker Antares, 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.

Contents

PB50 and PW50 Forklift Power Supply Installation Guide iii

Contents

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . v

Global Services and Support . . . . . . . . . . . . . . . . . . v

Who Should Read This Manual . . . . . . . . . . . . . .vii

1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Understanding the DC Power Supply Kit . . . . . . . . . . . . . . .2

Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Power Supply Considerations . . . . . . . . . . . . . . . . . . . . . . . .3

Understanding the LEDs . . . . . . . . . . . . . . . . . . . .3

Using the Input Power Cable . . . . . . . . . . . . . . . . .4

Using the Inline Fuse . . . . . . . . . . . . . . . . . . . . . . .5

Using the Output Power Cable. . . . . . . . . . . . . . . .5

Contents of the Forklift Power Supply Kit . . . . . . . . . . . . . .6

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2

Installing the Forklift Power Supply. . . . . .9

Installation Recommendations . . . . . . . . . . . . . . . . . . . . . .10

Installation Summary . . . . . . . . . . . . . . . . . . . . . .10

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Preparing the Power Input Cable . . . . . . . . . . . . . . . . . . . .11

Mounting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . .12

Direct Versus Isolation Mounting on the Lift

Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Creating a Custom Electrical Isolation Mount . . .13

Using a Standard Power Supply Mount . . . . . . . .14

Installing the Power Cable. . . . . . . . . . . . . . . . . . . . . . . . . .15

Connecting the Power Cable to the Forklift . . . . . . . . . . . .16

Contents

iv PB50 and PW50 Forklift Power Supply Installation Guide

Terminating the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Cutting and Stripping the Power Cable . . . . . . . . 17

Attaching Heat Shrink Tubing . . . . . . . . . . . . . . . 18

Preparing the Cable Ends . . . . . . . . . . . . . . . . . . . 19

Connecting to the Forklift Battery . . . . . . . . . . . . . . . . . . . 19

Connecting to Side-Mount Battery Terminals . . . 20

Connecting to Top-Mount Battery Terminals . . . 21

Securing the Battery Cable . . . . . . . . . . . . . . . . . . 22

Connecting the Output Power Cable . . . . . . . . . . 23

Sample Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Identifying and Correcting Problems . . . . . . . . . . . . . . . . . 28

Troubleshooting the Power Supply . . . . . . . . . . . . 28

Inspecting the Hardware . . . . . . . . . . . . . . . . . . . 28

Checking the Electrical Measurements . . . . . . . . . 29

Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Before You Begin

PB50 and PW50 Forklift Power Supply Installation Guide v

Before You Begin

This section provides you with safety information, technical

support information, and sources for additional product

information.

Safety Information

Your safety is extremely important. Read and follow all warnings

and cautions in this document before handling and operating

Intermec equipment. You can be seriously injured, and

equipment and data can be damaged if you do not follow the

safety warnings and cautions.

This section explains how to identify and understand warnings,

cautions, and notes that are in this document.

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.

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.

A warning alerts you of an operating procedure,

practice, condition, or statement that must be

strictly observed to avoid death or serious injury to

the persons working on the equipment.

A caution alerts you to an operating procedure,

practice, condition, or statement that must be

strictly observed to prevent equipment damage or

destruction, or corruption or loss of data.

Note: Notes either provide extra information about a

topic or contain special instructions for handling a

particular condition or set of circumstances.

Before You Begin

vi PB50 and PW50 Forklift Power Supply Installation Guide

Visit the Intermec technical knowledge base (Knowledge

Central) at www.intermec.com and click Support > Knowledge

Central to review technical information or to request technical

support for your Intermec product.

Telephone Support

These services are available from Intermec.

Outside the U.S.A. and Canada, contact your local Intermec

representative. To search for your local representative, from the

Intermec web site, click About Us > Contact Us.

Services Description

In the USA and

Canada call 1-800-

755-5505 and

choose this option

Order Intermec

products

• Place an order.

• Ask about an existing

order.

1 and then choose 2

Order Intermec

media

Order printer labels and

ribbons.

1 and then choose 1

Order spare

parts

Order spare parts 1 or 2 and then

choose 4

Te chn ic a l

Support

Talk to technical support

about your Intermec product.

2 and then choose 2.

Service • Get a return authorization

number for authorized

service center repair.

• Request an on-site repair

technician.

2 and then choose 1

Service

contracts

• Ask about an existing

contract.

• Renew a contract.

• Inquire about repair billing

or other service invoicing

questions.

Before You Begin

PB50 and PW50 Forklift Power Supply Installation Guide vii

Service Location Support

For the most current listing of service locations, click Support >

Returns and Repairs > Repair Locations.

For technical support in South Korea, use the after service

locations listed below:

AWOO Systems

102-1304 SK Ventium

522 Dangjung-dong

Gunpo-si, Gyeonggi-do Korea, South 435-776

Contact: Mr. Sinbum Kang

Telephone: +82-31-436-1191

E-mail: [email protected]

IN Information System PTD LTD

6th Floor

Daegu Venture Center Bldg 95

Shinchun 3 Dong

Donggu, Daegu City, Korea

E-mail: jmy[email protected] or korlim@gw.idif.co.kr

Who Should Read This Manual

This guide is written for trained Intermec service personnel

familiar with forklift service and maintenance. You should be

familiar with forklift service and maintenance.

Before You Begin

viii PB50 and PW50 Forklift Power Supply Installation Guide

PB50 and PW50 Forklift Power Supply Installation Guide 1

1

Introduction

This chapter describes installation practices and unique

components of the forklift power supply kit.

Chapter 1 — Introduction

2 PB50 and PW50 Forklift Power Supply Installation Guide

Understanding the DC Power Supply Kit

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 V installations

• Insulated quick-connect tabs (2)

The power supply provides 12 Vx output that is filtered and

regulated. It also provides over-current, over-voltage, over-

temperature, and shorted-output protection.

Installation Guidelines

The installer should be familiar with the brands and models of

equipment where this kit is installed. They should also be trained

and experienced in forklift electrical systems.

The installer must follow these guidelines and the installation

procedures as well as those of the lift manufacturer to ensure a

safe and reliable installation.

• Power supply must be securely mounted.

• Mounting surface must be sturdy.

• Mounting surface must provide power supply heat sink.

• Fuse must be close to vehicle power source and be in line with

Intermec equipment only.

• Keep cables as short as possible, and secure them at least every

46 cm (18 inch).

Installation must not violate the forklift manufacturer’s

requirements and should be done by trained professionals.

Chapter 2 details the step-by-step procedure that you will follow

to properly mount the forklift power supply.

Order the Smart UPS kit (P/N 203-788-xxx) for a universal

power supply (UPS) that provides backup power during battery

change out.

Chapter 1 — Introduction

PB50 and PW50 Forklift Power Supply Installation Guide 3

Power Supply Considerations

Use the following considerations when you are installing the

power supply.

• The power supply (P/N 851-070-003) accepts input voltage

ranging from 6 to 60 Vx for use with forklifts using electrical

systems running 12 to 60 Vx. It provides 12 Vx output

which is filtered and regulated. It also provides short-circuit,

over-voltage, and over-temperature protection.

• You should mount the power supply to the forklift 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 a minimum of 838

to 1032 square cm (130 to 160 square inches which is

approximately one square foot or more) to disperse heat. This

location should not be in the vicinity of sources of forklift-

generated heat.

Understanding the LEDs

A single or a pair of green light-emitting diodes (LEDs), located

near the output connectors on the power supply, lights up

whenever you apply voltage to the output power cable. Mount

the power supply in a location that allows easy visibility to LEDs

for troubleshooting.

Note: This document assumes that you have already

installed the vehicle mount printer on your forklift

and that you have the correct power supply and power

supply input cable for your forklift before you proceed

with the installation.

Note: Use the hardware supplied in the kit, or

equivalent, to mount the power supply. Do not use

sheet metal screws or other less permanent or rugged

mounting solutions.

Chapter 1 — Introduction

4 PB50 and PW50 Forklift Power Supply Installation Guide

One LED indicates main power is functioning (3-pin connector).

The secondary power LED indicates the heater power (2-pin

connector) is functioning.

Power Supply (P/N 851-070-003) 6 to 60 Vx, 14 A

Using the Input Power Cable

The input cable from the power supply is approximately 2.74 m

(9.0 feet) long. One end has a 4-pin connector, the other has a

2-pin connector. By cutting off 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 detailed instructions on attaching the power cable, see

“Mounting the Power Supply” on page 12.

Note: If the secondary LED is not lit, the input power

to the DC-DC converter is less than 9 to 10 Vx. It

will continue to provide 12 V output power to the

main power connector.

Note: Keep the cable as short as possible. Extra cable

picks up noise, adds power loss, and can snag on

equipment.

The input power cable may be shortened as needed. It

should not be extended on 12 V or lower systems. On

higher voltage systems, extensions should be kept to a

minimum and should be of equivalent or lower gauge

(larger diameter) wire. Keep the cable as short as

possible. Extra cable picks up noise, adds power loss,

and can snag on equipment.

Output connector (secondary power)

Green LEDs (power output indicators)

Output connector (main power)

Chapter 1 — Introduction

PB50 and PW50 Forklift Power Supply Installation Guide 5

Using the Inline Fuse

A snap-twist inline fuse holder is furnished as part of this kit. It

must be connected as close as possible (electrically and physically)

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 other vehicle

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.

Using the Output Power Cable

Output power cables are approximately 2.2 m (7.2 feet) long and

have a durable 2-pin connector to mate with the power supply.

The connector on the far end of the cable is specific to the vehicle

cradle for the printer. These rugged connectors have heavy-duty

metal housings and enhanced strain relief to provide added

reliability in the mobile environment.

Note: If your fuse fails, diagnose the problem and

then correct it before replacing the fuse with the exact

same size and type you are replacing.

Recommended Fuse Values

Lift Voltage Fuse Ratings Description

12 V 20 A Fast-blow (ships with power supply)

24 V 10 A Slow-blow, maximum fuse value

36 V 6 A Slow-blow, maximum fuse value

48 V 5 A Slow-blow, maximum fuse value

Do not replace the fuse with larger fuse values than

recommended. Use of a larger fuse may result in

damage to equipment.

Note: Ensure that you have the correct output power

cables for the portable printer being installed in your

location.

Chapter 1 — Introduction

6 PB50 and PW50 Forklift Power Supply Installation Guide

Contents of the Forklift Power Supply Kit

Installing the PB50 with the Forklift Power Supply Kit

Contents of Forklift Power Kit P/N 203-880-001

Description Part Number Quantity

Installation kit, vehicle power supply 203-804-002 1

DC/DC converter, 6-60 Vin/12 Vout 851-070-003 1

Cable, PB50 vehicle dock (AV8) forklift 236-193-001 1

PB50 and PW50 Forklift Power Supply

Installation Guide

932-011-001

Power cable 226-340-004 1

Fuse holder assembly 315-075-003 1

Fuse, 20 A ceramic FB 315-074-003 1

Bolt, 3/8-16 x 1-1/2-inch 800-099-001 2

Washer, 3/8-inch 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-inch 800-008-003 8

3/8-inch terminal ring 809-165-001 2

#10 terminal ring 809-083-009 3

6-60 V

Fuse

PB50 printer

and vehicle cradle

Cable input

(P/N 226-340-004)

DC/DC converter

(P/N 851-070-003)

Cable output

(P/N 236-193-001)

-

+

Chapter 1 — Introduction

PB50 and PW50 Forklift Power Supply Installation Guide 7

Self-tapping screw, #6 x 5/8-inch 800-012-000 1

#8 flat washer 803-084-000 1

Snap-in bushing 807-065-003 1

Screw, 1/4-20 x 1-1/4 inch, hex head 801-194-002 2

Flat washer, 1/4-inch 803-100-001 2

Locking nut, 1/4-20 802-117-000 2

Washer, split-lock, 1/4-inch 803-042-001 2

Cable tie, locking 808-002-000 6

H-S tubing, black, 1/8-inch diameter 321-650-003 30.5 cm

(12 in)

H-S tubing, black, 3/8-inch diameter 321-650-006 15.2 cm

(6 in)

Bead, split w/sleeve 309-065-006 1

Plug, 2-socket circular 311-638-004 1

Plug, 4-socket circular 311-638-006 1

Cable, 4 cond 18 AWG, foil-shielded 321-295-005 274.3 cm

(108 in)

Shield bead, .590/.275/1.10L, 300HM 309-091-008 2

Contents of Forklift Power Kit P/N 203-880-001 (continued)

Description Part Number Quantity

Chapter 1 — Introduction

8 PB50 and PW50 Forklift Power Supply Installation Guide

Wiring Diagram

This wiring diagram outlines several possible connections to the

power source in a forklift. Use this illustration as a reference

during the planning phase of your power supply installation.

Power Source Connection Possibilities

Negative - Worst

Regenerative Braking System, very

large voltage spikes

Connector to battery - Best

Power -

Acceptable

Negative- Marginal

Negative - Marginal

Large output spikes

possible on motors

+ To DC/DC converter

Negative- Acceptable

Distribution

panels work

better than

direct connect

to motors

PB50 and PW50 Forklift Power Supply Installation Guide 9

2

Installing the Forklift

Power Supply

This chapter outlines mechanical and electrical installation

instructions.

Chapter 2 — Installing the Forklift Power Supply

10 PB50 and PW50 Forklift Power Supply Installation Guide

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 the connection is first made to the lift.

• Keep the power cable length as short as possible.

• Connect the negative lead to a point on the lift that other

electronic systems use.

• Read the label on the power supply and verify that the input

voltage rating is correct for the forklift in which you will be

installing the PB50 or PW50.

• Remember that the supply with the lower input voltage rating

(6-60 Vx) has a 4-pin input connector.

• Design a bracket that would be common to multiple lifts with

pre-attached devices to simplify the device installation and

service. Designing a common bracket would reduce your

installation time because the mounting bracket would be

more straightforward and consistent. It would also simplify

service because you can take the entire bracket down and

replace it with another bracket while troubleshooting the

system away from the lift.

Installation Summary

Carry out the primary installation steps in the order outlined

below. The sections that follow include detailed steps for each

segment of the vehicle power supply installation process.

To install the vehicle power supply

1 Connect the input cable to the power supply.

2 Mechanically install and secure the power supply.

3 Route and secure the power cable.

Warning: Equipment failure or damage will result

if the vehicle power source voltage does not fall

within the power supply input voltage rating.

Chapter 2 — Installing the Forklift Power Supply

PB50 and PW50 Forklift Power Supply Installation Guide 11

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 forklift power source.

Tools Required

You will need the following tools to properly install the forklift

power supply:

• Common hand tools (screwdriver, pliers, and so on)

• Heat gun for heat shrink tubing

• Wire crimping and stripping tool

• Electric drill, drill bits

• DC Ohmmeter

Preparing the Power Input Cable

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

To connect the power input cable

1 Attach the corresponding cable connector to the power supply

connector.

2 Slide the connector in as far as possible.

3 Turn the cable connector collar clockwise to secure it.

4 Cut the cable at the unused connector end.

5 Discard the unused connector.

6 Remove the cable connector from the power supply with a

counterclockwise turn of the cable connector collar.

Additional details for installation are covered later in the

section, “Terminating the Cable” on page 16.

Chapter 2 — Installing the Forklift Power Supply

12 PB50 and PW50 Forklift Power Supply Installation Guide

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.

You should take these lengths and the intended location of your

electronic equipment into consideration when choosing a

mounting location for the power supply.

The mounting surface location must provide 838 to 1032 square

cm (130 to 160 square inches) of metallic surface to sink heat

generated by the power supply. This metallic mounting surface

may be connected to, or actually part of, the forklift chassis as

long as the chassis is not electrically connected to the battery

negative or positive.

Side-Mount Battery With View of Negative (-) and Positive (+)

Direct Versus Isolation Mounting on the Lift Chassis

Previously, the power supply has been placed directly on the lift

chassis. Direct mounting provides both an adequate heat sink

and prevents static charge buildup between the metal of the

power supply, the printer, and the lift chassis.

Note: Although you can shorten the input power

cable if necessary, you should not extend the cable on

12V or lower systems. On higher voltage systems,

extensions should be kept to a minimum and should

be of equivalent or lower gauge (larger diameter) wire.

Keep the cable as short as possible.

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