Intermec 203-880-002 Installation Manual
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Intermec 203-880-002 Installation Manual

Intermec 203-880-002 Installation Manual

Forklift power supply kit
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Forklift Power Supply
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Summary of Contents for Intermec 203-880-002

  • Page 1 Forklift Power Supply Installation Guide...
  • Page 2 Intermec Technologies Corporation. Information and specifications contained in this document are subject to change without prior notice and do not represent a commitment on the part of Intermec Technologies Corporation. © 2008-2009 by Intermec Technologies Corporation. All rights reserved.
  • Page 3 Document Change Record This page records changes to this document. The document was originally released as Revision 001. Version Number Date Description of Change 6/2009 Updated to include new printer models and output cable number. 4/2008 First release of document Forklift Power Supply Installation Guide...
  • Page 4 Forklift Power Supply Installation Guide...

  • Page 5: Table Of Contents

    Contents Contents Before You Begin ........viii Safety Information .
  • Page 6 Contents Installing the Input Power Cable..... . 14 Connecting the Power Cable to the Forklift... . 15 Terminating the Input Cable .
  • Page 7 Contents Forklift Power Supply Installation Guide...

  • Page 8: 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 and click Support > Returns and Repairs > Warranty.

  • Page 9: Web Support

    Intermec product. Telephone Support In the U.S.A. and Canada, call 1-800-755-5505. 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.

  • Page 10: Who Should Read This Manual

    Before You Begin IN Information System PTD LTD 6th Floor Daegu Venture Center Bldg 95 Shinchun 3 Dong Donggu, Daegu City, Korea E-mail: jmyou@idif.co.kr korlim@gw.idif.co.kr Who Should Read This Manual This document is for the person who is responsible for installing, configuring, and maintaining the Forklift Power Supply.

  • Page 11: Introduction

    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 • Installation Guidelines • Power Supply Considerations • Contents of the Forklift Power Supply •...

  • Page 12: Understanding The Dc Power Supply Kit

    Make sure the mounting surface provides power supply heat sink. • Make 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 least • every 46 cm (18 inch).

  • Page 13: Power Supply Considerations

    • 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 14: Using The Input Power Cable

    Chapter 1 — Introduction The main output LED indicate that the main power is functioning (3-pin connector). The secondary power LED indicates the heater power (2-pin connector) is functioning. Note: If the secondary LED is not lit, the input power to the DC-DC converter is less than 9 to 10 Vx.

  • Page 15: Using The Inline Fuse

    Chapter 1 — Introduction 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.

  • Page 16: Using The Output Power Cable

    Cable input 6-60 V Fuse Cable output DC/DC power supply (“converter”) Installing the Printer With the Forklift Power Supply Kit Contents of Forklift Power Kit (P/N 203-880-002) Description Part Number Quantity Installation kit, vehicle power 203-804-002 supply DC/DC converter 6-60 Vin/12...
  • Page 17 Chapter 1 — Introduction Contents of Forklift Power Kit (P/N 203-880-002) (continued) Description Part Number Quantity Cable assembly (input cable) 226-340-004 Fuse holder assembly 315-075-003 Fuse, 20 A ceramic FB 315-074-003 Bolt, 3/8-16 x 1-1/2-inch 800-099-001 Washer, 3/8-inch 803-099-001 Nut, 3/8-16...

  • Page 18: Wiring Diagram

    Chapter 1 — Introduction 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. Connector to battery - Best + To DC/DC converter Distribution panels work better than direct...

  • Page 19: Installing The Forklift Power Supply

    Installing the Forklift Power Supply This chapter describes how to install the forklift power supply. This chapter contains these topics: • Installation Recommendations • Preparing the Power Input Cable • Mounting the Power Supply • Installing the Input Power Cable •...

  • Page 20: Installation Recommendations

    Chapter 2 — Installing the Forklift Power Supply 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 •...

  • Page 21: Tools List

    Chapter 2 — Installing the Forklift Power Supply 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.

  • Page 22: Direct Versus Isolation Mounting On The Lift Chassis

    Chapter 2 — Installing the Forklift Power Supply 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, keep extensions to a minimum and use a wire of equivalent or lower gauge (larger diameter).

  • Page 23: Creating A Custom Electrical Isolation Mount

    Chapter 2 — Installing the Forklift Power Supply Note: Lift vehicles in countries requiring CE Mark certification and that have a connection between the battery negative and the forklift chassis require additional installation steps. To confirm this requirement, consult the respective lift manufacturer Electrically isolating the power supply from the chassis maintains conformance to CE requirements.

  • Page 24: Using A Standard Power Supply Mount

    Chapter 2 — Installing the Forklift Power Supply Using a Standard Power Supply Mount The installation kit includes the standard hardware for mounting the power supply. Use mounting Method A when you can easily access the back side of the mounting location to install a lock nut and washer.

  • Page 25: Connecting The Power Cable To The Forklift

    Chapter 2 — Installing the Forklift Power Supply • Completely install power cables before making connections to equipment. • Route the power cables from the general area where the power supply will be mounted. If the power cable passes through a firewall or other sheet •...

  • Page 26: Terminating The Input Cable

    Chapter 2 — Installing the Forklift Power Supply Instructions are not included for connecting to various possible forklift power sources. A trained professional installer, knowledgeable on the brands and models of forklifts should perform this installation. Both large and smaller terminal rings are included to accommodate most installation needs.

  • Page 27: Attaching Heat Shrink Tubing

    Chapter 2 — Installing the Forklift Power Supply 7 Twist the shield wire and slide on the 1/8-inch heat shrink tubing (P/N 321-650-006). Heat shrink tubing Green and white wires (negative) Red and black wires (positive) Input power cable Shield wire with heat shrink applied Strip the cable jacket 30-36 cm (12-14”) Sliding the Heat Shrink Tubing Onto Twisted Wires Note: Make sure to verify the wire connections with an...

  • Page 28: Preparing The Cable Ends

    Chapter 2 — Installing the Forklift Power Supply 2 Use the heat gun to shrink tubing. 3 Wrap the 1/8-inch shrink sleeve tubing (P/N 321-650-003) over shield wire. Note: Be sure to shield wire to the metal surface on which the power supply is mounted.

  • Page 29: Connecting To The Forklift Battery

    Chapter 2 — Installing the Forklift Power Supply 5 Crimp the small terminal ring (P/N 809-083-009) on the shield wire. Connecting to the Forklift Battery The next few pages show you the intended purpose of nuts, bolts, and washers that are included in this kit if you will be connecting the power cable directly to a forklift battery.

  • Page 30: Connecting To Top-Mount Battery Terminals

    Chapter 2 — Installing the Forklift Power Supply 9 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. Forklift battery 3/8 x 1-1/2” bolt 3/8”...

  • Page 31: Securing The Battery Cable

    Chapter 2 — Installing the Forklift Power Supply 9 Use a self-tapping screw (P/N 800-008-003) and a flat washer (P/N 803-084-000) to connect the shield wire to the metal surface on which the power supply is mounted. 10 Repeat steps 6 through 8 for the negative battery cable wire (white-green pair) from the input power cable, connecting the wire to the negative (-) battery terminal.

  • Page 32: Sample Installations

    Chapter 2 — Installing the Forklift Power Supply To 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 the DC/DC power supply (P/N 851-070-003). 3 Slide the output cable as far as it will go into the power supply.
  • Page 33 Chapter 2 — Installing the Forklift Power Supply Additionally, this installation allows: • easy access to power supply components, LED visibility is good. power cables are out of the way and tied off, there is adequate • heat sink, and there is good access for cooling. •...
  • Page 34 Chapter 2 — Installing the Forklift Power Supply • Battery swap is accommodated without removing the UPS entirely • Metal area contact is reduced, but ventilation is good, reducing the need for additional heat sink No direct sunlight in this environment helps maintain lower •...

  • Page 35: Troubleshooting

    Troubleshooting This chapter contains information for troubleshooting the forklift power supply. This chapter contains these topics: • Identifying and Correcting Problems • Troubleshooting Charts...

  • Page 36: Identifying And Correcting Problems

    Chapter 3 — Troubleshooting Identifying and Correcting Problems The following is an overview for troubleshooting the forklift power supply installation: 1 Inspect the hardware. 2 Check the electrical measurements. 3 Substitute components. Use the procedures within this chapter to identify and the power supply problems you may encounter during installation.

  • Page 37: Substituting Components

    Chapter 3 — Troubleshooting If fuses blow sporadically, or power supply shut down occurs randomly, you may want to use a megohmmeter to check cables for high-resistance shorts between wires or between a wire and the cable shield. For more information, see “Troubleshooting Charts”...
  • Page 38 Chapter 3 — Troubleshooting Troubleshooting Power Failure With the Main Output Meaning Possible Solution The power supply is Test or substitute output power working. cable. Not lit No output from the Try the possible solutions in this power supply. order: 1 Disconnect the power output cable.
  • Page 39 Chapter 3 — Troubleshooting Troubleshooting Power Failure With the Main Output LED (continued) Meaning Possible Solution Voltage not No input power to the Try the possible solutions in this present power supply. order: 1 Replace inline fuse if voltage is not present at connector. 2 Replace input power cable if input voltage is still not present at connector.
  • Page 40 Chapter 3 — Troubleshooting Power Supply Pinouts (continued) Connector Negative Positive Case Secondary Pin1 Pin2 output power connector heater Main output Pin 3 Pin 2 Pin 1 power connector 108.0 +/- 3.0” Pin view Pin view Power Cable Assembly for P/N 226-340-004 Note: During installation, you will cut and discard one of these cable connectors.
  • 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 equivalent. Cable Wire Cable Equivalents Wire Color Alternate Color Green Blue White Gray Brown Brown Black Forklift Power Supply Installation Guide...
  • Page 42 Chapter 3 — Troubleshooting 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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