Zebra RD5000 Reference guide

Brand: Zebra

Model: RD5000

Type: Reference guide

Zebra RD5000, a DC to DC Power Converter, conditions the fork lift battery power for the RD5000 RFID reader, and with the right cable kit, it supports 12, 24, 36, 48, and 60 nominal VDC systems. The converter requires additional items like a cable holder and tensioning spring, which are sold separately.

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

(Female)

Deutsch

(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

White 2 3 3 3

Serial

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.

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

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Zebra RD5000 Reference guide

Zebra RD5000 Reference guide

Zebra RD5000 Reference guide

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