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RD5000 DC to DC Power Converter
Quick Reference and Installation Guide
2 RD5000 DC to DC Power Converter
Zebra reserves the right to make changes to any product to improve reliability, function,
or design.
Zebra does not assume any product liability arising out of, or in connection with, the
application or use of any product, circuit, or application described herein.
No license is granted, either expressly or by implication, estoppel, or otherwise under
any patent right or patent, covering or relating to any combination, system, apparatus,
machine, material, method, or process in which Zebra products might be used. An
implied license exists only for equipment, circuits, and subsystems contained in Zebra
products.
Zebra Technologies Corporation, Inc.
3 Overlook Point
Lincolnshire, IL 60069, U.S.A.
http://www.zebra.com
Warranty
For the complete Zebra hardware product warranty statement, go to:
http://www.zebra.com/warranty
Quick Reference and Installation Guide 3
Introduction
This Installation Guide describes how to install the RD5000 DC to DC Power
Converter.
For details on installing the RD5000 (model number: RF1224) refer to the RD5000
Integrator Guide P/N 72E-109786-XX, or 72E-89956-XX available from:
http://www.zebra.com/support.
About This Guide
This guide contains the following:
• Power Converter and Cable Kits on page 4
• Safety Information on page 5
• Installation on page 7
• Overview on page 7
• Step 1. Plan the Installation and Obtain Hardware on page 8
• Step 2. Install/Mount the Power Converter on page 9
• Step 3. Connect Converter to the Power Source on page 11
• Step 4. Long Cable Installation on page 13
• Step 5. Route the Short Cable on page 15
• Step 6. Connector Assembly on page 17
• Step 7. Connector Disassembly on page 19
• Step 8. Final Cable Routing on page 20
• Step 9. Installation Check-Out on page 20
• Step 10. Strain Relief Loop Final installation on page 21
• Supported Devices on page 22
• Maintenance on page 22
• Troubleshooting on page 23
• Electrical Specifications on page 23
• Regulatory Information on page 24
• Waste Electrical and Electronic Equipment (WEEE) on page 26
4 RD5000 DC to DC Power Converter
Power Converter and Cable Kits
The power converter conditions the fork lift battery power for the RD5000 RFID
reader. In addition to the converter, one of the cable kits listed below is required.
• 50-14000-251R: Power/DC converter (supports 36, 48, 60 nominal VDC
systems)
• 50-14000-252R: Power/DC converter (supports 12, 24 nominal VDC systems)
• KT-111237-01R: RD5000 DC-to-DC converter cable kit with NO Relay Switch.
30 feet long.
• KT-111236-01R: RD5000 DC-to-DC converter cable kit with Relay Switch.
30 feet long.
Unpacking the Cable Kit
The following items are contained in the cable kit:
•This Quick Reference and Installation Guide
• 2 - Cables (1 short and 1 long (with serial Y extension))
• Connector Components
• Heat Shrink Tubing
• Optional, cut-off relay (36-60VDC) for electric fork lifts
Additional Items, Installer Supplied
Some additional items may be required and are defined by the particular
installation requirements. The following is not a complete list, but a sample of the
types of additional items that may be required.
• Cable holder(s)*
• Cable tensioning round belt pulley(s), for belt diameter of 1/2 inch with a
recommended minimum diameter of 4 inches*
• Cable tensioning spring(s)*
• Spring Hold Down(s)*
• Heat Gun (or other heat source) for use on heat shrink tubing
• Solder (low lead for corrosive environments) and Soldering Iron/Gun
• Crimp tool and crimp connectors
* Quantity as required for the specific installation (typically 2 required).
IMPORTANT The spring tension and cable grip are required and must be
installed.
Quick Reference and Installation Guide 5
Safety Information
Before using this product, read and understand all safety instructions in this guide.
WARNING
! A qualified installer must perform the installation. Improper
installation may injure the operator and/or damage the fork lift,
the RD5000 and/or RD5000, DC to DC Power Converter.
WARNING
! Do not use this equipment in hazardous locations as defined in
the NEC, CEC or other country specific electric codes.
6 RD5000 DC to DC Power Converter
Power Converter and Cables
Power-In Cable (From Fork Lift Power Source)
Power-Out, Long Cable
In-Line Fuse
RD5000 Power, Short Cable
Serial Connector
Quick Reference and Installation Guide 7
Installation
Overview
The RD5000, DC to DC Power Converter and the (optional) cut-off relay should
be installed under the forklift engine cover (whenever possible). The power
converter long cable is approximately 30 feet (9.1 meters) long and is routed from
the engine compartment over the forks and it is trimmed to size to connect with
the RD5000 short cable. The long cable also has a serial connector that is routed
into the fork lift cab to provide data inputs to optional accessory devices.
Wiring Overview
The high-level installation steps are as follows:
Step 1. Plan the Installation and Obtain Hardware
Step 2. Install/Mount the Power Converter
Step 3. Connect Converter to the Power Source
Step 4. Long Cable Installation
Step 5. Route the Short Cable
Step 6. Connector Assembly
Step 7. Connector Disassembly
Step 8. Final Cable Routing
Step 9. Installation Check-Out
Step 10. Strain Relief Loop Final installation
WARNING
! A qualified installer must perform the installation. Improper
installation may injure the operator or damage the fork lift, the
RD5000 and/or the RD5000, DC to DC Power Converter.
Representative only. Drawing not to scale.
8 RD5000 DC to DC Power Converter
Step 1. Plan the Installation and Obtain Hardware
Installation Guidelines
Determine the power converter mounting location.
Route the power supply cable and position the power cut-off relay and the fuse.
Plan the power converter mounting location, how the power converter will be
connected to the fork lift power source, and the cable routings.
Review this entire guide before beginning installation. In particular, be sure to read
the installation guidelines:
• Power Converter Mounting Guidelines on page 9
• Power Source Connection and Cabling Guidelines on page 11
• Cabling Routing Guidelines on page 11
Required Hardware
The customer supplied hardware requirements are determined by the actual
installation. The following is a list of customer supplied hardware that is
recommended for a typical installation.
Power Converter:
• Four stainless steel cap screws, 1/4”-20-X (M6x1.0-X). Where X represents the
length of the cap screws required for the specific installation.
• Four 1/4”-20 (M6x1.0) nyloc nuts
• Four 1/4” (M6) flat washers
Cut-Off Relay:
• Two stainless steel cap screws, #8-32-X (M3.5x0.60-X. X). Where X
represents the length of the cap screws required for the specific installation.
• Two #8-32 (M3.5 x 0.60) nyloc nuts
• Two #8 (M3.5) flat washers
General Installation:
• Cable Ties
• Cable hold downs
IMPORTANT The spring tension and cable grip are required and must be
installed.
Quick Reference and Installation Guide 9
Step 2. Install/Mount the Power Converter
Power Converter Mounting Guidelines
Determine the optimum location for mounting the power converter, taking into
consideration the ease of accessing the power converter and mounting
requirements.
Access Requirements
• The power converter power-out connection must be accessible.
• All nuts and bolts must be accessible for periodic checks and re-torquing as
required.
Mounting Information
• Mounting surface must be flat and rigid and it must extend evenly for the full
length of the power converter.
• Use all four mounting holes.
• Use the correct mounting hardware. See Required Hardware on page 8.
• When installing the power converter, ensure that the mounting surface is fully
supported. Additional backup plate
(s) may be required.
• Check that all cables are routed so that they do not interfere with the operation
of forks or other moving parts.
• Torque the nuts to 320 inch
.
pounds ± 20 inch
.
pounds
(3.7 kilogram
.
meter ± 2.4 kilogram
.
meter).
10 RD5000 DC to DC Power Converter
Mounting Orientation Example
Power Converter and Cut-Off Relay Mounting
CAUTION Add a reinforcing plate, if mounting to a thin surface.
Power Converter
Nyloc Nuts
Flat Washers
Cut-Off Relay
(Optional)
Cap Screws
In-Line Fuse Screws
Quick Reference and Installation Guide 11
Step 3. Connect Converter to the Power Source
Power Source Connection and Cabling Guidelines
Determine the best method for routing the power converter cable to the power
source.
Power Cut-Off Relay (optional) Connection Guidelines
• The optional, cut-off relay (36-60 volts DC) is supplied. Connect the Power
cut-off Relay as close to the main terminal block as possible. Do not connect
directly from the battery terminals, and not bypass the main fuse.
Power Source Connection Guidelines
• Mount the fuse as close as possible to the power source (do not bypass the
main fuse).
• Securely mount the fuse in an accessible location.
Cabling Routing Guidelines
• The cable route must be clear of moving parts, hot surfaces, and sharp edges.
• Do not install where the cable may create a hazardous condition, such as a trip
hazard or where it may interfere with safety of day-to-day activities.
• Attach the cable to existing cable runs inside the fork lift using cable ties.
• Use a protective grommet when routing the cable through a panel,.
• The minimum recommended bend radius is 2.5" (6.5 cm), do not install the
cable around tight bends.
• Ensure cables do not swing or chafe on any surface. Use cable ties at
approximately every foot (0.3 m) intervals to minimize the cable flex, especially
at the connection points.
• Do not wind a cable in and out of the mesh on a cage.
• Do not route the cables on the outside forklift surfaces, or any forklift surfaces
that may have contact with other objects.
12 RD5000 DC to DC Power Converter
Connecting to the Fork Lift Power Source
1. Disconnect the fork lift battery.
2. Refer to the Wiring Overview on page 7 for wiring and connection information.
3. Confirm the fuse is in the fuse mount:
• Use an 8A fast blow ceramic fuse.
4. Route the cable from the power converter to the power source using the Power
Source Connection and Cabling Guidelines on page 11.
If the optional cut-off relay is not used:
a. Position the cable and trim to length as required.
b. Connect the red wire to the fork lift positive power source. Connect the
black wire to the fork lift negative power source.
If the optional cut-off relay is used:
a. Position the cable and trim to length (as required) leaving enough extra wire
to have at least 3 inches on both sides of the fuse holder.
b. Strip back enough wire to cut off the fuse holder (leave at least 3 inches on
both sides of the fuse holder). Cut the fuse holder off the cable.
c. Route the Red wire (with the fuse holder) from the positive power source to
the common leg of the cut-off relay.
d. Route the red wire from the power converter to the relay NO connection.
e. Connect one leg of the relay coil to ground and connect the other end to an
ignition power source.
f. Secure the connections by soldering or using crimp connectors.
5. Ensure the wiring connections are sufficiently insulated from each other.
6. Open the fuse holder and remove the fuse. Put the fuse in a safe location until
the installation is completed.
7. Reconnect the fork lift battery.
NOTE See the fork lift User Manual for specific wiring information.
WARNING
! Failure to disconnect the battery may result in an electric
shock that may cause injury or death.
CAUTIONUse only the recommended fuse as identified on the fuse
mount label and in this guide.
Quick Reference and Installation Guide 13
Step 4. Long Cable Installation
Long Cable Routing
Determine the optimum cable routing. Refer to the Cabling Routing Guidelines on
page 11 for routing requirements.
1. Connect the forward power converter cable to the power converter.
2. Route the cable to the cable connection point (refer to the Cabling Routing
Guidelines on page 11).
3. Identify and mark the location where the cable pulley will be installed.
4. Identify and mark the location where the serial connector will be installed (or
secured).
5. Identify and mark the location where the tensioning spring will be installed.
6. Identify and mark the location where the connector will be installed.
7. Remove cable for pulley and tensioning spring installation.
Cable Pulley Installation
1. Securely mount an additional Cable Pulley on the fork by either welding or
bolting the pulley in place.
2. Confirm that the cable routing conforms to the Cabling Routing Guidelines on
page 11.
Cable Pulley Installation
Added Cable Pulley
Long Cable
14 RD5000 DC to DC Power Converter
Cable Tensioning Spring Installation
1. Securely mount the tensioning spring on the fork by either welding or bolting
the tensioning spring hold-down to the forklift.
2. Confirm that the cable routing conforms to the Cabling Routing Guidelines on
page 11.
Cable Tensioning Spring Installation
Long Cable
Cable Holder
Spring
Quick Reference and Installation Guide 15
Install the Long Cable
1. Connect the forward power converter cable to the power converter.
2. Route the cable over the pulley and install the cable holder and the tensioning
spring. Move the fork slowly to full extension and then to full retraction to
confirm that the installation meets the Cabling Routing Guidelines on page 11.
3. Install appropriate cable tie-downs and hold-downs as required.
Step 5. Route the Short Cable
RD5000 Cable Installation Guidelines
1. Connect the short cable to the RD5000 and route the cable to the connection
point.
RD5000 Connector Installation
Short Cable Connector
RD5000
16 RD5000 DC to DC Power Converter
2. Position the cables in a strain relief loop and mark the lengths for the connector
installation.
Strain Relief Loop Positioning
3. The cable position must leave enough extra wire to strip the interior wire
strands.
4. Trim the cables to length.
Cable Tie-Downs
Short Cable
Long Cable
Quick Reference and Installation Guide 17
Step 6. Connector Assembly
The pin to pin connector wiring instructions are provided in the Connector Wiring
table.
Connector Wiring
Deutsch Pin Connections
Signal
Name
Wire
Color
Long Cable Connectors Short Cable Connectors
Y Junction
9 Pin
Subminiature
D Connector
Deutsch
DT
(Female)
Deutsch
DT
(Male)
RD5000,
Molded
Rt Angle
Pin # Pin # Pin # Pin #
V+ Red 2 2 2
V+ Yel 5 5
Gnd Blk 5 1 1 1
Gnd Grn 6 6
Serial
Tx
White 2 3 3 3
Serial
Rx
Blue 3 4 4 4
18 RD5000 DC to DC Power Converter
1. Cut two 4-inch lengths of the heat shrink tubing. Slide one piece of tubing over
the end of the Long Cable and slide one piece of tubing over the end of the
Short Cable.
2. Slide the tubing down the cables far enough that it is not in the way of the
Connector Assembly procedure.
3. Strip the wires and insert the wires into the connector pins. Crimp or solder the
pins to the wire ends.
Deutsch Connector, Pin Assembly
4. Refer to Connector Wiring, and the Deutsch Pin Connections on page 17, to
identify the correct pin location and push the pin through the appropriate
numbered hole in the rubber grommet. There will be a soft click as the pins
lock into place.
5. Repeat the procedure for both halves of the connector, until the pins have been
installed on all the wires and the wires have been correctly positioned in the
rubber grommet.
Deutsch Connector,
Wire Insertion
6. Press the rubber grommet into the connector housing to form a tight fit.
2
3
1
5
4
6
2
3
1
5
4
6
2
3
1
5
4
6
2
3
1
5
4
6
Quick Reference and Installation Guide 19
7. Insert the lock wedges into the connectors to complete the final connector
assembly.
Deutsch Connector Wedge Installation,
Final assembly
Step 7. Connector Disassembly
Skip this step if there is no need to rewire the connectors. Perform this step only if
repair or re-wiring is necessary.
1. Remove the lock wedges to disassemble the connectors.
2. Use a small screwdriver to release the Pin Locking Tab.
Release Pin Locking Tab
20 RD5000 DC to DC Power Converter
3. While the Pin Locking Tab is released, slide the pin out of the connector
housing.
4. Repeat the procedure for all the pins that need to be removed.
Step 8. Final Cable Routing
1. Install the cables in the final positions and secure with appropriate cable
tie-downs. Ensure that the routing conforms to all of the Cabling Routing
Guidelines on page 11.
Step 9. Installation Check-Out
1. Visually inspect the cable routing with the fork lift, fork fully extended and fully
retracted to ensure that the routing conforms to all of the Cabling Routing
Guidelines on page 11.
2. Disconnect the connector from the RD5000.
3. Check that the data connection continuity, is less than 0.75 ohms:
• Continuity from the RD5000 connector pin 1 to the serial connector pin 5.
• Continuity from the RD5000 connector pin 3 to the serial connector pin 2.
• Continuity from the RD5000 connector pin 4 to the serial connector pin 3.
RD5000 Connector
Serial Connector
5
43
2
1
98
7
6
/
