(12V) 6842547 (24V-48V)
Contents
1. deteriorate Angular Alignment allow ance non parallel face angle Radial Orientation Limits for mounting around center line None Sleep Mode time out at SR Aligned Power up ST Not Aligned Vibration is required ST power on to communicate Wake Up Accelerometer Field Adjustable contact Sensitivity Cascade Corp Wake Up response time 2 sec max Wire Color and Function Code Fork Lift Battery Cascade Battery Positive Positive 2 Black Fork Lift Battery Cascade Battery Negative Negative 3 e wne No Connecton Loa GND fe Voe fenno omnoz e ue feronn feroni Certifications YES DoC maintained by CE Mark OEM PbP EN12895 FCC Part 18 ROHS UL Classified File AU3546 UL 558 583 Sleep Mode wake up Do you have questions you need answered right now Call your nearest Cascade Service Department Visit us online at www cascorp com AMERICAS Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade ltalia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR Italy Tel 39 045 89891 11 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 9771 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 82. from Battery Up to 72W nom 2200mAhrs at full charge Up to 72W nom 2200mAhrs at full charge on Load Line and GPO from Battery only Inductive Power at optimal Alignment range Not Aligned for Inductive Power SR Power required RF Data Only Vibration in packaging to 90 no condensation Physical Dimensions and Mounting 75mA Nom 85W Drop Test Operating Temp Storage Temp Sealing to environment Humidity 2 0kg M6 x 4x 12 deep equally spaced 137mm dia equally spaced 22mm tall approx 1 5M SR 1 0M ST Thickness Weight pair Mounting holes Mounting Hole Bolt Circle Cable Gland Cable Length Microchip Wi Fi Module Information Microchip MRF24W80MA Wi Fi Module Data 2 4GHz 802 11 Low Power Transceiver Wi Fi Certified for 802 11b RoHS compliant oo CE Comptar ooo Fcc cenie US Foc I wrozez1oozaaron _ 1C Certified IC 8248A G21ZEROG Fully Compliant with EU and meets R amp ETT Directive for Radio Spectrum Radio Type Approval Certified in Europe ETST and Japan ARIB WFA ID WFA7150 E 20cm from body see spec notes sec 10 Range Distance and alignment for optimal inductive power transfer 6mm to 25mm Over 25mm power transfer eff deterio rates Power Trans Distance 12mm Over 12mm power transfer eff deteriorates Misalignment allowance center line axis 15 deg misalignment causes power transfer eff to
3. 00 227 223 Fax 61 7 3373 7333 cascade eo eTM Cascade Corporation 2013 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 905 629 7777 Fax 905 629 7785 Cascade Africa Pty Ltd PO Box 625 Isando 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade Korea 121B 9L Namdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel 82 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 64 9 273 9137 Cascade do Brasil Rua Joao Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105 8800 Fax 55 13 2105 8899 Cascade Xiamen No 668 Yangguang Rd Xinyang Industrial Zone Haicang Xiamen City Fujian Province P R China 361026 Tel 86 592 651 2500 Fax 86 592 651 2571 Sunstream Industries Pte Ltd 18 Tuas South Street 5 Singapore 637796 Tel 65 6795 7555 Fax 65 6863 1368 08 2013 Cascade India Material Handling Private Limited No 34 Global Trade Centre 1 1 Rambaugh Colony Lal Bahadur Shastri Road Navi Peth Pune 411 030 Maharashtra India Phone 91 020 2432 5490 Fax 91 020 2433 0881 Part Number 6842818
4. Truck o gt Input Output Circuit AC2405 eps 5 Connect other functions to the input output and CAN circuits as required using appropriate Deutsch connectors See chart below SR Circuit on Carriage amp Attachment ST Circuit on Mast amp Truck CAN CAN Circuit O O gt Circuit Input Output u g gt Input Output Circuit Circuit EI Cascade Truck Battery 6075736 Oo Power 2 Legend O D Pin O O Socket 6 AC2406 eps ST UNIT Pin Socket Mating Connector Mating Connector Wire ID Function Connector No Deutsch Part No Cascade Part No Red 12V DTP04 2P P1 DTMO6 2S E007 223693 Black Truck GND WM 2P WM 2S 223695 Yellow CAN High DTMO6 2S E007 DTP04 2P 223694 Green CAN Low WM 2S WM 2P 223696 Red Jumper 12V Orange GPI 1 Blue GPO 1 DTMO06 6S E007 DTP04 6P 223672 Brown GPO 2 WM 6S WM 6P 223676 Violet GP1 2 Black Jumper Truck GND SR UNIT Pin Socket Mating Connector Mating Connector Wire ID Function Connector No Deutsch Part No Cascade Part No Red Battery DTP04 2P P1 DTMO6 2S E007 223693 Black Batter WM 2P WM 2S 223695 Yellow CAN High DTMO06 2S E007 DTP04 2P 223694 Green CAN Low WM 2S WM 2P 223696 GPO 1 DTP04 6P DTMO6 6S E007 223671 GPO 2 WM 6P WM 6S 223675 GPI 2 LOAD GND Test Procedure Perform by Qualif
5. cade Corporation 2501 Sheridan Ave Springfield OH 45505 Kit Installation Perform by Qualified Personnel only gt 1 Mount the ST and SR units so that the faces gt are parallel and 25 1 00 in 6 25 mm apart E Soe Orient the cables as required al If mounting hardware is included modifications ie may be required for your installation ca Mount the SR slider mechanism fixed to the carriage Use the load backrest holes if possible Make sure the top of the slider is not above the carriage or attachment and the bottom is hidden behind the frame or high enough to avoid hitting the ground i Mount ST unit and bracket to mast Attachment Mount the ST unit bracket to the mast so that Connections when the carriage is in its lowest position the SR unit is supported near the top of the slider i rail Check for clearance through the full range of slide movement while tilting forward and fully i back 25 1 00 in 6 25 mm D uam Connections 2 Anchor cable Mount SR slider mechanism to carriage AC2417 eps AC2418 eps a Pa Ns Remove cable from negative battery 2 Route the SR unit cable so movement of the SR along the ld terminal guide does not bind or snag Anchor the cable as required 3 Disconnect the negative battery terminal as directed by the truck OEM NOTE UL Classified kits require installation by qualifie
6. cascade cem CITM Wireless Power and Installation amp Communication Kits 6842546 12V User Manual 6842547 24V 48V This manual provides installation instructions for Cascade Wireless Power and Communications Kits These kits allow 12W of inductive power transfer when the ST and SR units are 2A Fuse in alignment At all times a 2 4 Ghz RF signal provides two digital switch input and outputs 5A total each direction as well as providing a generic CAN bus node The RF features have a 10 M range and meet EMC EN 12895 and FCC standards 12V 5A Fuse S DP Configuration A Voltage Filter S o A o 24V 48V f Configuration ee 24V 48V gt 12V g CAN Voltage Converter Truck Side d Battery G CAN lt A Input Output ST and SR Wireless Devices Attachment Side NOTE Kits are UL Classified File AU3546 for safety in Electric Battery UL 583 and IC Engine UL 558 Indust Truck type E ES G GS G LP GS LPS LP LPS D and DS NOTE UL Classified Kits require installation by qualified personnel only without major disturbance cutting splicing AC2415 eps or soldering of factory installed wiring cascade GRO aca Corporation Ee No AUSES For Technical Support To Order Paris Call 1 800 227 2233 Fax 1 888 329 8207 Call 1 888 227 2233 Fax 1 888 329 0234 Internet www cascorp com Internet www cascorp com Write Cascade Corporation PO Box 20187 Portland OR 97294 Write Cas
7. d personnel only without major disturbance of cutting splicing or soldering of factory installed wiring CAUTION Consult the Lift Truck OEM for proper power source connection GA0436 eps 4 Connect cable ends to the components as shown 12V Systems Connect the fused positive wire from the cable harness to a 12V switched power source and the negative wire to a ground 24V 48V Systems Connect the power wire harness to the DC to DC Converter Kit Connector Connect converter kit inputs to a 24V 48V switched power source Check the cable routing for pinch points and clearance Use wire ties as needed NOTE When installing on electric trucks voltage filter 6061953 must be installed Failure to install voltage filter can cause damage to electrical components WARNING To reduce risk of fire replace only with the same type and ratings of fuse The fused power cable is polarity sensitive The positive wire must be connected to a positive power source Cascade Battery 6075736 SR Circuit on Carriage amp Attachment Attachment CAN amp O Circuit Attachment Input Output o Circuit 24 48V Voltage Voltage Filter Converter _ Truck Battery IC Trucks Use chassis ground Electric Trucks Use battery ground ST Circuit on Mast amp Truck Truck CAN Circuit Switched Truck Fuse Block Truck Battery
8. erse Input Voltage at ST only High Voltage protected ST Short Circuit protection at GPO s ST and SR 1 6A reset 5A typical total 2 5A 1 2A shutdown with auto reset Recommended Limits 3A on any one channel alone tested to 17 duty cycle 1 5A channel simultaneous recommended tested to 80 duty cycle shutdown with auto ESD 8kV any contact and 15kV air E to case 14 4 volts ST ps o SAE J1455 Double Jump 28 7V Surge Limit 41V Use appropriate dc dc converter and filters Protected Auto reset Local voltage 3A per channel or 5A total Outputs ST input voltage SR see Load Line amp GPO voltage above eo 45ms avg 80ms max None GPO s un latch after 1 5s GPO Latching Voltage goes Low after 1 5s when power goes off Battery Information 3 cell 11 1V 2200 mAH 12 54V 9 8V 2200 mAH 6 5A current load limited Shuts down when voltage is less than 9 8v 27 hrs RF full time No GRO load SR ON 120 hrs uninterrupted sleep mode SR OFF Use only Cascade Li lon Battery pn 6075736 Battery Rating Battery Life out or Range Inductive Power at optimal range Fully charge in 2 5 hrs at optimal alignment Battery Voltage 14 4V Cascade Li lon Batt charging circuit Seamless Transition between Battery Inductive Power Specifications SR Power Management 12W Unused Power is charging the Battery Demand over 12W draws additional power
9. he Cascade Battery as well as a 16W load line for remote sensor controller power Two main components include ST Transmitter typically located on the host device and the SR Receiver typically located remotely and requires a Cascade Battery for out of range power Actual power available depends on battery condition 9V to 16V DC 12V DC Nominal ST Typical operating lt 3A Note Input is fused at current 5A per UL requirements ST Max power required lee g Transfer 12W nom 12V DC 1A ST Input Voltage ST Start Up current requirement in Range SR Input Voltage ES Battery Voltage only pa load a amp GPO voltage 14 4V 5 in Range SR load Line amp GPO voltage Cascade Battery ne out of Range 12 5V to 10 0V min CAN message A O E 10m in typical truck pe ange application Not LOS 1Mbps Operating Freq 2 4 2 4835GHz Protocol independent RF CANbus node bi i directional J1939 CANopen and DeviceNet supported FFCO to FFC1 inclusive FFOO to FF34 inclusive Note PNG address will be allowed in either direction FFO1 message is sent every 1 second CAN PNG Address Limits factory set Performance SR Power required RF Data Only 75mA nom 85W 2x Input and 2 x Output at each PNP Sensors suitable inputs Input voltage 9 to 24 VDC SR Load Line Over Current Protection OCP GPO Over Current Protection OCP Protection Rev
10. ied Personnel only At the SR unit connect only Cascade Battery 6075736 to the connector marked BATTERY With power ON at the ST unit e Align SR and ST units and verify inductive power yields 14 4V min at SR 6 pin LOAD line connector Pin 1 and Pin 6 e Move units out of alignment and verify LOAD line voltage drops to the battery voltage e Turn off power tp ST unit wait 5 minutes do not vibrate or bump the SR unit and verify that the LOAD line voltage drops to near OV 24V 48V Configuration Voltage Filter 7 Pa Voltage Converter i 12V P Configuration a 5 Wireless Power and Communication Kits 12V EF REF QTY PART NO DESCRIPTION 6842546 Wireless Power Comm Kit 12V 1 1 6829906 Wireless Power Comm Device 2 1 6842851 Seal Plug 3 1 6806708 Fuse 5 Amp 5 1 6048139 Cable Harness 24V 48V REF QTY PART NO DESCRIPTION 6842547 Wireless Power Comm Kit 24V 48V 1 1 6829906 Wireless Power Comm Device Epa 2 1 6842851 Seal Plug 4 1 6806701 Fuse 2 Amp 6 1 6816341 Voltage Converter Kit AC2410 eps Specifications Description and Operation A three function device providing 1 Inductive battery charger for Cascade Li lon battery s 2 RF CAN bus node with 10m range and 3 RF digital switching device with two remote inputs and two remote outputs with 60W limited by OCP of switching power provided by t
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