Zebra RD5000 Quick Reference

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.

IMPORTANT The spring tension and cable grip are required and must be

installed.

• 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).

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-In Cable (From Fork Lift Power Source)

Power-Out, Long Cable

In-Line Fuse

RD5000 Power, Short Cable

Serial Connector

Power Converter and Cables

Quick Reference and Installation Guide 7

Representative only. Drawing not to scale.

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.

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

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

• 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
(3.7 kilogram

.

meter ± 2.4 kilogram.meter).

(s) may be required.

.

pounds ± 20 inch.pounds

10 RD5000 DC to DC Power Converter

Power Converter

Nyloc Nuts

Flat Washers

Cut-Off Relay
(Optional)

Cap Screws

In-Line Fuse Screws

Mounting Orientation Example

CAUTION Add a reinforcing plate, if mounting to a thin surface.

Power Converter and Cut-Off Relay Mounting