Intermec PB50 Installation Manual
Forklift power supply
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- User manual (102 pages) ,
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Table of Contents
Troubleshooting
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Summary of Contents for Intermec PB50
- Page 1 Installation Guide PB50 and PW50 Forklift Power Supply...
- Page 2 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.
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Page 3: Table Of Contents
Connecting the Power Cable to the Forklift ... .16 PB50 and PW50 Forklift Power Supply Installation Guide ........1 Contents . - Page 4 Troubleshooting Charts ......30 PB50 and PW50 Forklift Power Supply Installation Guide ......27...
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Page 5: Before You Begin
Global Services and Support Warranty Information To understand the warranty for your Intermec product, visit the Intermec web site at www.intermec.com Returns and Repairs > Warranty. - Page 6 • Inquire about repair billing or other service invoicing questions. 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. PB50 and PW50 Forklift Power Supply Installation Guide and click Support >...
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Page 7: Who Should Read This Manual
Donggu, Daegu City, Korea E-mail: jmyou@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. PB50 and PW50 Forklift Power Supply Installation Guide korlim@gw.idif.co.kr... - Page 8 Before You Begin viii PB50 and PW50 Forklift Power Supply Installation Guide...
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Page 9: Introduction
Introduction This chapter describes installation practices and unique components of the forklift power supply kit. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 10: Understanding The Dc Power Supply Kit
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. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 11: Power Supply Considerations
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. -
Page 12: Using The Input Power Cable
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 PB50 and PW50 Forklift Power Supply Installation Guide , 14 A... -
Page 13: Using The Inline Fuse
These rugged connectors have heavy-duty metal housings and enhanced strain relief to provide added reliability in the mobile environment. PB50 and PW50 Forklift Power Supply Installation Guide Chapter 1 — Introduction Description Fast-blow (ships with power supply) -
Page 14: Contents Of The Forklift Power Supply Kit
(P/N 226-340-004) 6-60 V Fuse DC/DC converter (P/N 851-070-003) Installing the PB50 with the Forklift Power Supply Kit Contents of Forklift Power Kit P/N 203-880-001 Description Installation kit, vehicle power supply DC/DC converter, 6-60 Vin/12 Vout Cable, PB50 vehicle dock (AV8) forklift 236-193-001... - Page 15 H-S tubing, black, 3/8-inch diameter Bead, split w/sleeve Plug, 2-socket circular Plug, 4-socket circular Cable, 4 cond 18 AWG, foil-shielded Shield bead, .590/.275/1.10L, 300HM 309-091-008 PB50 and PW50 Forklift Power Supply Installation Guide Chapter 1 — Introduction Part Number Quantity 800-012-000 803-084-000 807-065-003...
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Page 16: 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 PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 17: Installing The Forklift Power Supply
This chapter outlines mechanical and electrical installation instructions. PB50 and PW50 Forklift Power Supply Installation Guide Installing the Forklift Power Supply... -
Page 18: Installation Recommendations
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. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 19: Tools Required
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 PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 20: Mounting The Power Supply
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. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 21: Creating A Custom Electrical Isolation Mount
(~100 ohms/1 watt minimum) to be electrically connected between the plate and the chassis of the vehicle to prevent static charge buildup. The isolation hardware and resistor are also not included in the installation kit. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 22: Using A Standard Power Supply Mount
3 Use a 1/4-20 tap to thread the mounting holes. 4 Place a lockwasher on each bolt. 5 Insert the bolt/lockwasher assemblies through the power supply holes and into the threaded mounting holes. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 23: Installing The Power Cable
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. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 24: Connecting The Power Cable To The Forklift
2 Slip heat shrink tubing (furnished in this kit) onto the cable or wires before terminating them. 3 Prepare the cable ends by installing the fuse holder in series with the positive wires and install a terminal ring on the negative wires. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 25: Cutting And Stripping The Power Cable
Sliding the Heat Shrink Tubing Onto Twisted Wires Note: Make sure to verify the wire connections with an ohmmeter. PB50 and PW50 Forklift Power Supply Installation Guide Green and white wires (negative) Red and black wires (positive) Shield wire with heat shrink applied... -
Page 26: Attaching Heat Shrink Tubing
3 Use the 1/8-inch shrink sleeve tubing over shield wire to prevent contact with other live (powered) circuits. Note: Be sure to shield wire to the metal surface on which the power supply is mounted. PB50 and PW50 Forklift Power Supply Installation Guide Red and black twisted pair 3/8” 3/8”... -
Page 27: Preparing The Cable Ends
Determine 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. PB50 and PW50 Forklift Power Supply Installation Guide... - Page 28 Repeat steps 2 through 8 for the negative wire (white-green pair) from the input power cable, connecting the wire to the negative (-) battery terminal. PB50 and PW50 Forklift Power Supply Installation Guide...
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Page 29: Connecting To Top-Mount Battery Terminals
(+) battery bolt. 7 Slip a second 3/8-inch washer onto the bolt. 8 Thread and tighten a second 3/8-inch nut onto the bolt. PB50 and PW50 Forklift Power Supply Installation Guide Forklift battery cable Fuse holder... -
Page 30: Securing The Battery Cable
2 Drill a pilot hole with a #26 drill bit (equal to a hole diameter of 3.73 mm) and use #6 sheet metal screws to permanently hold clamps in place. #6 sheet metal screw goes here PB50 and PW50 Forklift Power Supply Installation Guide Forklift battery Forklift battery cable Fuse holder... -
Page 31: Connecting The Output Power Cable
Note: See “Troubleshooting Charts” on page 30 power fault diagnostic information. Sample Installations In this installation example, the power supply is securely attached with good air flow, easy access, and neatly tied-off cabling. PB50 and PW50 Forklift Power Supply Installation Guide... - Page 32 • 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. PB50 and PW50 Forklift Power Supply Installation Guide...
- Page 33 • 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 temperatures of all the components. PB50 and PW50 Forklift Power Supply Installation Guide...
- Page 34 Chapter 2 — Installing the Forklift Power Supply PB50 and PW50 Forklift Power Supply Installation Guide...
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Page 35: Troubleshooting
Troubleshooting This chapter contains troubleshooting information and connector pin-outs. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 36: Identifying And Correcting Problems
• If the LED is flickering, the power supply has detected a fault condition related to temperature, voltage, or current. The LED will flicker until the problem is resolved. In some cases, you may have to remove power to reset the power supply. PB50 and PW50 Forklift Power Supply Installation Guide... -
Page 37: Checking The Electrical Measurements
Thorough continuity testing takes longer than either substitution or taking voltage measurements. An ohmmeter is sufficient to diagnose simple opens or shorts. PB50 and PW50 Forklift Power Supply Installation Guide Chapter 3 — Troubleshooting... -
Page 38: Troubleshooting Charts
The power supply has automatic over-voltage, over-current, over- temperature, and short-circuit protection. If the problem persists, the LEDs will continue to flicker. Disable input power when these faults activate that protection. PB50 and PW50 Forklift Power Supply Installation Guide... - Page 39 Flickers The power supply detected an over- temperature condition. PB50 and PW50 Forklift Power Supply Installation Guide Chapter 3 — Troubleshooting Possible Solution Test or substitute output power cable. Try the possible solutions in this order: •...
- Page 40 Connector Input power connector Secondary output power connector (heater) Main output power connector Pin 3 PB50 and PW50 Forklift Power Supply Installation Guide Test or Possible Solution Test for input voltage. Replace power supply. Try the possible solutions in this order: •...
- Page 41 Refer to the following chart for the wire color equivalent. Cable Wire Cable Equivalents Wire Color Alternate Color Green Blue White Gray Brown Black PB50 and PW50 Forklift Power Supply Installation Guide Chapter 3 — Troubleshooting Pin view...
- Page 42 Chapter 3 — Troubleshooting PB50 and PW50 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 PB50 and PW50 Forklift Power Supply Installation Guide *932-011-001* P/N 932-011-001...