Intermec PEN*KEY 6400 User manual

6400 VehicleDock
INSTALLATION
INSTRUCTIONS
""""""""""""""""""""""""""""
PN:962-020-006
RevisionB
August1998

"NOTICETheinformationcontainedhereinisproprietaryandisprovidedsolelyforthe
purpose ofallowingcustomersto operateandserviceIntermecmanufactured
equipmentandisnot tobereleased,reproduced,orusedforanyotherpurpose
withoutwrittenpermissionofIntermec.
DisclaimerofWarranties.Thesamplesourcecodeincludedinthisdocumentis
presentedfor reference only.Thecodedoesnotnecessarilyrepresentcomplete,
tested programs.Thecodeisprovided“ASISWITHALL FAULTS.”ALL
WARRANTIESARE EXPRESSLY DISCLAIMED,INCLUDING THE
IMPLIEDWARRANTIESOFMERCHANTABILITY AND FITNESS FORA
PARTICULARPURPOSE.
Wewelcomeyour commentsconcerningthispublication.Althougheveryefforthas
beenmadetokeepitfree oferrors,somemayoccur.Whenreportingaspecific
problem,pleasedescribeitbrieflyandincludethebooktitleand partnumber,as
well astheparagraphorfigurenumberandthepagenumber.
Sendyour commentsto:
IntermecTechnologiesCorporation
PublicationsDepartment
550 SecondStreetSE
CedarRapids,IA52401
INTERMEC,NORAND,NOR*WARE,andPEN*KEYareregisteredtrademarks
ofIntermecTechnologiesCorporation.
Ó1997 IntermecTechnologiesCorporation.All rightsreserved.
Thispublicationprintedonrecycled paper.
FCC ComputerCompliance
"NOTICEThisequipmentmeetsClass AdigitaldevicelimitsperPart15 ofFCC Rules.
Theselimitsprotectagainstinterferenceinacommercialarea.Itemits,uses,and
canradiateradiofrequencyenergy.Ifyoudonotinstall andusethe equipment
accordingtoitsinstructions,itmayinterferewithradiosignals.Usingitina
residentialareaislikelytocauseinterference.Ifthisoccurs,youmustcorrect the
interferenceatyourexpense.
CanadianComputerCompliance
ThisClass Adigitalapparatusmeetsall requirementsoftheCanadianInterfer-
ence-CausingEquipmentRegulations.
Cetappareil numériquedelaclasseArespectetouteslesexigencesduReglèment
surlematerialboilleurduCanada
TelephoneInstallation Warning Notices
Thefollowingnoticesapplyto equipment thatmaybeconnectedtotelephonelines
orsystems.Foryourpersonalsafety,andtoprotect thisequipmentfrompotential
electricalorphysicaldamage,doNOTconnectequipment totelephonelinesor
datacommunicationequipmentunless thefollowingwarningshavebeenread,
understood,andcompliedwith.

"Neverinstall telephonewiringduringalightningstorm.
"Neverinstall telephonejacksinwetlocationsunless thejackis specifi-
callydesignedforwetlocations.
"Nevertouch uninsulatedtelephonewiresorterminalsunless thetele-
phonelinehasbeendisconnectedat thenetworkinterface.
"Usecautionwheninstallingormodifyingtelephonelines.
"Avoidusingatelephone(otherthancordless type)duringanelectrical
storm.Theremaybearemoteriskofelectricshockfromlightning.
"Donotusethetelephonetoreportagasleakinthevicinityoftheleak.
Installation du téléphone:avertissements
Lesavertissementsquisuivents’appliquentàtoutéquipementquipeutêtre
branchéauxlignesousystèmestéléphoniques.Pourvotresécuritépersonnelle et
pourprotégerl’équipementdetoutdommage électrique ouphysiquepotentiel,NE
PASbrancherun ordinateurtablette électronique ousespériphériquesauxlignes
téléphoniquesouéquipementsavantquelesavertissements suivantsaientétélus,
comprisetobservés:
"Nejamaisinstallerdecâblagetéléphoniquependantun orage électrique.
"Nejamaisinstallerdeprisetéléphoniquedansun endroithumideà
moinsquelapriseaitétéspécifiquementconçuepourêtreutilisée dans
lesendroitshumides.
"Nejamaistoucherlesfilsdetéléphone oudel’équipement terminalnon
isolésàmoinsquelalignetéléphoniquen’aitétédébranchée del’inter-
faceréseau.
"Userdeprudencelorsdel’installationoudelamodificationdelignes
téléphoniques.
"Éviterd’utiliserun téléphone(autrequ’un appareil téléphoniquesans
fil)pendantun orage électrique.Ilpourraityavoirun faiblerisqued’é-
lectrocutionparlafoudre.
"Nepasutiliserletéléphoneafindesignalerunefuitedegazàproximité
delafuite.
BCAUTION:Intermec Technologies Corporation suggests you buy cables fromus
toconnectwith otherdevices.Ourcables are safe,meetFCC rules,
and suitourproducts.Othercables may notbetested.They may
cause problemsfromelectrostaticdischargeorinducedenergy.Our
warranties do notcoverloss, injury,ordamagefromothercables.
BCAUTION:Intermec Technologies Corporation recommendsthatyou only
purchase Norand MobileSystemsDivision certifiedmodems.
Intermec does notcertify all modems availableinthemarketplace.
Intermec does notwarrantnoncertifiedmodems; furthermore,these
modemsmay cause problemsfromelectrostaticdischarge and may
notconformto FCC regulations.ForalistofNorand MobileSystems
Division certifiedmodems call CustomerSupportat1-800-221-9236.

6400 VehicleDockInstallationInstructionsii
CCOONNTTEENNTTSS
""""""""""""""""""""""""""""
SSEECCTTIIOONN 11
GeneralInformation
VehicleDockDescription1-1...................................
Specifications1-1..........................................
DC-DCPowerConverter1-3....................................
ConnectorPin-Outs1-4........................................
VehicleDock3-PinMalePowerConnector1-4.................
VehicleDockVoltageContacts1-4...........................
SSEECCTTIIOONN 22
Installation
Introduction2-1...............................................
InstallationGuidelines2-2......................................
ToolsRequired2-3........................................
VehicleInstallation2-4.........................................
Installing theCables2-4....................................
Routing theCables2-4.....................................
PowerCableAssembly 2-6......................................
Assembling theIn-lineFuseHolder2-6.......................
Terminating WireEnds2-8.................................
Connecting theFuseHolder2-9.............................
SideMountBatteryConnection2-10..............................
Top MountBatteryConnection2-12...............................
DockInstallationKits2-14.......................................
Installing theDC-DCPowerConverter2-15........................
FinalCableConnections2-15....................................
ConvertertoPowerSourceCable 2-15.........................
ConvertertoDockCable 2-16................................
Using theVehicleDock2-18.....................................

CCOONNTTEENNTTSS "
iiii 6400 VehicleDockInstallationInstructions
Inserting YourComputerintotheVehicleDock2-19.............
JumpStarting YourVehicle 2-22..................................
FFIIGGUURREESS
Figure 1-1VehicleDock SideView1-2............................
Figure 1-2DC-DCPowerConverter1-3...........................
Figure 1-3VehicleDock3-PinMalePowerConnector1-4............
Figure 1-4VehicleDockTop View1-4............................
Figure 2-1Stripping thePowerCableJacket2-5....................
Figure 2-2Assembling theIn-lineFuseHolder2-7..................
Figure 2-3Terminating WireEnds2-8............................
Figure 2-4PrepareCableEnds2-9...............................
Figure 2-5Side-MountBatteryTerminals2-11......................
Figure 2-6Top-MountBatteryTerminals2-13.......................
Figure 2-7VehicleDockwithFree Standing Mounting Plate 2-14.......
Figure 2-8ConvertertoBatteryCable 2-16.........................
Figure 2-9PowerConvertertoDockCable 2-16.....................
Figure 2-10 Connecting thePowerCabletotheVehicleDock2-17......
Figure 2-11 VehicleDockComponents2-18........................
Figure 2-12 Rotating theBumperPad2-19..........................
Figure 2-13 Inserting theComputerintotheVehicleDock2-20........
Figure 2-14 Putting aComputerwithScannerHandleinVehicleDock2-21
TTAABBLLEESS
Table 2-1FuselinePowerKit203-472-001 2-4......................
Table 2-2Free Standing Mounting BracketKit203-470-001 2-14.......
Table 2-3VehicleMounting Kit203-471-001 2-15....................

6400 VehicleDockInstallationInstructions11--11
SSeeccttiioonn 11
GeneralInformation
""""""""""""""""""""""""""""
VVeehhiiccllee DDoocckk DDeessccrriippttiioonn
Figure 1-1onpage 1-2showsthekey featuresoftheVehicleDock.
"Keylocktolockinyourcomputer.
"Keyedcableconnectorforsecuring thepowercablecoming
fromtheconverterorpowersource.
"Pushtoreleaseleverstoreleasethecomputerfromthedock.
"Bumperpadsto protectand brace yourcomputerwhenitis se-
curedinthedock.Thepadassemblycan berotatedtoaccommo-
date yourcomputerwithanoptionalscannerhandle.
"Rotating swivelstand
SSppeecciiffiiccaattiioonnss
"Weight:5lbs.(22.68 kg)
"Dimensions:
"Length:Withkey installed6.75inches(17.15 cm)
"Width:Mountedwithswivelstand inthevertical
position,6inches(15.24 cm)
Mountedwithswivelstand inthehorizontal
position,8.5inches(21.59 cm)
"Height:Dockonly 9.25 inches(23.50 cm)
Dockwith hand-heldcomputer
13.0inches(33.02 cm)

SSEECCTTIIOONN 11 "GeneralInformation
11--22 6400 VehicleDockInstallationInstructions
Figure1-1
VVeehhiiccllee DDoocckk SSiiddee VViieeww
1
1.Pivotingcomputerbumpersupports
2.Computer releaselevers
3.Rotatingswivelbase
4.Releaseleverforswivelbase
5.Keylock
6.Powercable
7.Keyed powerconnector
8.Computerholder
2
3
4
5
7
6
8

SSEECCTTIIOONN 11 "GeneralInformation
6400 VehicleDockInstallationInstructions11--33
DDCC--DDCC PPoowweerr CCoonnvveerrtteerr
TheDC-DCPowerConverteris showninFigure 1-2.Thelargemag-
netsonthebottomoftheconverteraidinmounting theunit.
Figure1-2
DDCC--DDCC PPoowweerr CCoonnvveerrtteerr
1
1.Convertertodockcable
2.Magnet
3.On/Off switch
4.Fuseholder
5.Convertertopowersourcecables
BottomViewEnd View
5
2
34

SSEECCTTIIOONN 11 "GeneralInformation
11--44 6400 VehicleDockInstallationInstructions
CCoonnnneeccttoorr PPiinn--OOuuttss
VVeehhiiccllee DDoocckk 33--PPiinn MMaallee PPoowweerr CCoonnnneeccttoorr
Figure1-3
VVeehhiiccllee DDoocckk 33--PPiinn MMaallee PPoowweerr CCoonnnneeccttoorr
Pin1,chassisground(greenwire)
Pin3,ground(whitewire)
Pin2,12 volts(blackwire)
VVeehhiiccllee DDoocckk VVoollttaaggee CCoonnttaaccttss
Figure1-4
VVeehhiiccllee DDoocckk TToopp VViieeww
1
2
1.Negativevoltagecontact
2.Positivevoltagecontact

6400 VehicleDockInstallationInstructions22--11
SSeeccttiioonn 22
Installation
""""""""""""""""""""""""""""
IInnttrroodduuccttiioonn
This sectionprovidesdetailedinstructionsformounting thevehicle
dockontoamotorizedload-handling pieceofequipmentsuchasa
forklift.During thisinstallationthepowercableiswired directlytothe
vehiclebatteryorbank ofbatteries.
Whentheinstallationiscomplete,youwill haveasecureplacetostore
thecomputer.Inaddition,thevehicle electricalsystemprovidespower
torechargethebatteriesinyourhand-heldcomputer.
"NOTE:NorandCorporationisnotresponsibleforloss ordamagetothehand-held
computersordocksresulting fromimproperinstallation.
"NOTE:Mountingbracketand bracketinstallation hardwarearenotprovidedinthiskit.
Twoseparateautoranging dc-dcpowersupplyconvertersareavailable
toacceptawiderange(12 Vdcor24.0-48 Vdc)ofinputvoltages.In
general,thelow-rangeconverterisintendedforpropane-fueledfork-
lifts,ordeliveryvehicleswith12 voltpowersystem,whilethehigh-
rangeconverterisintendedforothermodels.
BCAUTION:Iftheoverall vehiclevoltage exceeds48 volts,youmust tap intothebankof
batteriesata point thatis48 voltsorless.

SSEECCTTIIOONN 22 "
I
n
s
t
a
l
l
a
t
i
o
n
22--22 6400 VehicleDockInstallationInstructions
IInnssttaallllaattiioonn GGuuiiddeelliinneess
Since eachsituationorequipment typemayposeuniquerequirements,
mounting hardwareselectionand mechanical installationofthevehicle
dockshall betheresponsibilityoftheinstaller.Norand recommends
using 3/8-inchterminalringsforconnecting the electricalcabledirect-
lytothevehiclebattery.Awaterproofin-linefuseholdermustbe
installed betweenthepositivebatteryterminaland theblackwirein
thepowercable.
Theinstallation kitcontainsnuts,bolts,washers,batteryterminal
rings,and afuselink forconnecting thebatterycabledirectlytothe
vehiclebattery.Italsocontainsadjustablewireclampstosecurethe
cableinplace.
Yourtasksareto:
"Install thevehicledock
"Install thedc-dc converterontothevehicle
"Connect thepowercablefromtheconvertertothedock
"Connect thepowercabletothevehiclebatteryterminals
Thedockmounting locationmustnotrestrict thedriversview.Mount
thedockand cablesawayfromthebrakepedal,accelerator,steering
wheel,emergencybrake,gearshift,and anyotherareathatinterferes
withsafeoperationofthevehicle.Decidewhere youwill mount the
vehicledock,thenproceedwiththefollowing instructions.
Thevehicledockand associatedelectricalwiring should beinstalled
underthesupervisionofproperlytrainedand qualifiedpersonnel.Fol-
lowtheseinstallationinstructionscloselytoensuresafe,reliableper-
formanceforyourequipment.
Thevehicle’selectricalsystem mustbeinexcellentcondition.This
meansthecharging circuitmustworkproperlyand thatvehicle-gener-
atedelectrical“noise”mustbeminimizedand withinspecifications
(SAE J113).
BCAUTION:Thevehiclechargingcircuitmustneitherunderchargenoroverchargethe
vehiclebattery.Eitherfaultconditioninthevehicle electricalsystemcancause
ano-chargeconditionintheterminalbattery.

SSEECCTTIIOONN 22 "
I
n
s
t
a
l
l
a
t
i
o
n
6400 VehicleDockInstallationInstructions22--33
Excess electricalnoisecan besevere enoughtodefeat the electrical
filtering thatisbuiltintoyourequipment.Defectiveignitionwiring,
damagedinsulation,orafaultyvehicle electricalcomponentcancause
electricalnoise.Whenthishappens,computersand otherequipment
can behaveunpredictably.
TToooollss RReeqquuiirreedd
"Wirecrimping and stripping tool
"Anelectricdrill,#26 drill bit
"Commonhand tools(3/8”wrench,flatbladescrewdriver,
phillips screwdriver,and small punch)

SSEECCTTIIOONN 22 "
I
n
s
t
a
l
l
a
t
i
o
n
22--44 6400 VehicleDockInstallationInstructions
VVeehhiiccllee IInnssttaallllaattiioonn
Table2-1
FFuusseelliinnee PPoowweerr KKiitt 220033--447722--000011
DescriptionNPNQty
Fuseholder315-062-001 1
Fuse(15 amp,250 volt)315-064-001 1
Selftaping screw#6 800-008-001 8
Bolt3/8”800-099-001 2
Brass Nut802-099-001 4
FlatWasher803-099-001 4
Adjustablecordclip808-011-001 8
Terminalring (3/8”) 809-083-027 2
IInnssttaalllliinngg tthhee CCaabblleess
Usecableclampsorwire-tiesatleastevery18incheswheninstalling
cablesona vehicle.Thiseliminateslooseorsagging cables,guarding
againstbreakageand ensuring that they donotposeahazardtothe
vehicleoperatororto otherworkers.
RRoouuttiinngg tthhee CCaabblleess
Decidethemounting locationforthevehicledock,dc-dcpowercon-
verter,and thecables.Whenyouarecertainyourarrangementworks
and thatcableswill reachfromthebatteriestothepowerconverterto
thedock,proceedwiththeinstructionsbelow.
1.Completelyinstall thecablethatconnectstothevehiclebattery
beforeconnecting thedc-dc converter.
2.Routethecablefromthevehiclebatterytowardthegeneralarea
wherethecomputerwill bemounted.
TTaakkee eexxttrraa ccaarree ttoo mmaakkee ssuurree tthhee ccaabblliinngg::
"Doesnotendangertheoperator.
"Isnotinthepathofmoving vehicleparts.
"Will notharmotherequipment.

SSEECCTTIIOONN 22 "
I
n
s
t
a
l
l
a
t
i
o
n
6400 VehicleDockInstallationInstructions22--55
"Doesnotinvitedamagetothecable.
"Doesnotsnagonfixturesoranypassing equipment.
3.Cut thepowercablenearthebatterytoeliminatetheneedfor
coiling excess cable.
"NOTE:Donotcut thecabletoo short toreachthebatteryterminals.
4.Stripthepowercablejacketback12-14 inches.
1
2
3
1.Whitewire(negative)
2.Black wire(positive)
3.Powercable
Figure2-1
SSttrriippppiinngg tthhee PPoowweerr CCaabbllee JJaacckkeett

SSEECCTTIIOONN 22 "
I
n
s
t
a
l
l
a
t
i
o
n
22--66 6400 VehicleDockInstallationInstructions
PPoowweerr CCaabbllee AAsssseemmbbllyy
Thepowercablemusthaveanin-linefuseinstalled beforemaking final
connectionstothevehiclebattery.Youmustalsocrimpa3/8inchter-
minalring tothe end ofthewhitewire.
AAsssseemmbblliinngg tthhee IInn--lliinnee FFuussee HHoollddeerr
RefertoFigure 2-2forhelpwithcompleting thisprocedure.Thein-line
fuseholderconsistsofarubberboot,twocrimp-typefuseclips,and a
fuse.
Thisfuseholdermaybepreassembled,inwhichcase youshouldskip
thefollowing fuseholderassemblyproceduresand gotothenextset
ofinstructions,ConnectingtheFuseHolderonpage 2-9.
Ifthefuseholderisnotpreassembled,carefullyfollowtheseinstruc-
tionstoassemblethein-linefuseholder.
1.Locatethein-linefuseholdercomponents.
2.Cut theblackwireinthepowercablemidwaybetweenitsend
and thecablejacket.Savethe 6-7inchlengthofblackwire.
3.Strip1/4-inchofinsulationfromtheblackwirethatextendsfrom
thepowercable;alsostrip1/4-inchofinsulationfrombothends
ofthe6inchlengthofblackwiresavedinstep2.
4.Slidethelongerportionofthein-linefuseholderboot(yellow
rubber) overtheblackwirethatextendsfromthepowercable.
5.Slipafuseclip ontothiswireand crimptheclip ontothewire.
6.Sliptheremaining fuseclip onto one end ofthe 6 inchwiresaved
fromstep2and crimpsecurely.
7.Slidethiswireintotheotherhalfofthefuseholderboot.Insert
thefuseintothefuseclipsand snapthehalvesofthefuseholder
boot together.
8.GotoTerminatingtheWireEnds.

SSEECCTTIIOONN 22 "
I
n
s
t
a
l
l
a
t
i
o
n
6400 VehicleDockInstallationInstructions22--77
Figure2-2
AAsssseemmbblliinngg tthhee IInn--lliinnee FFuussee HHoollddeerr
1.Fuseclips
2.Blackwire(6-7inches)
3.Fuseholder”boot”
4.Blackwire
5.Powercable
6.Whitewire
1
2
3
4
6
5

SSEECCTTIIOONN 22 "
I
n
s
t
a
l
l
a
t
i
o
n
22--88 6400 VehicleDockInstallationInstructions
TTeerrmmiinnaattiinngg WWiirree EEnnddss
Crimp3/8-inchterminalringstothestrippedend ofthewhitewireand
totheblackwirefromthefuseholder.See thebatterydrawing and
instructionsfor recommendedassemblytoconnect thecabletothe
vehiclebattery.
1.Stripapproximately 1/4”ofinsulationfromthewhitewireonthe
powercable.
2.Crimpthe 3/8”terminalring ontothiswire.
3.Crimpa3/8”terminalring ontotheblackwirefromthe end of
thein-linefuseholder
--
+
Figure2-3
TTeerrmmiinnaattiinngg WWiirree EEnnddss

SSEECCTTIIOONN 22 "
I
n
s
t
a
l
l
a
t
i
o
n
6400 VehicleDockInstallationInstructions22--99
CCoonnnneeccttiinngg tthhee FFuussee HHoollddeerr
Iftheinstallation kitcontainsapreassembledin-linefuseholder,you
mustcrimpitontheblackwirefromthepowercable.Followthe
instructionsbelowtoterminatethe endsofthepowercablewhenyour
kitincludesapreassembledfuseholder.
1.Stripthewhitewire.
2.Crimpthe 3/8”terminalring (1)ontothewhitewire.
3.Locatethefuselink (2):itattachestotheblackwire.
4.Shortentheblackwireifdesired.
5.Then,strip1/4”ofinsulationfromtheblackwire.
6.Securelycrimpthefuselink splice(3)ontotheblackwire.
1.3/8”terminalring
2.Fuselinkassembly
3.Fuselinksplice
4.Access cable
Figure2-4
PPrreeppaarree CCaabbllee EEnnddss
1.Stripwire
2.Install terminalring
RedWire
Black(orBrown)Wire
Crimp
Here
1
2
3
4

SSEECCTTIIOONN 22 "
I
n
s
t
a
l
l
a
t
i
o
n
22--1100 6400 VehicleDockInstallationInstructions
SSiiddee MMoouunntt BBaatttteerryy CCoonnnneeccttiioonn
WARNING:Itisveryimportant tomakesurethatyoumakethe correctcabletobattery
connections,because electricalenergyfromvehiclebatteriescan harm
equipmentand people.
1.Removebothbatteryterminalboltsfromthevehiclebattery.
2.Screwa3/8inchnut(10)asfarasitwill go ontoa3/8”x1 1/2”
bolt(9)furnishedin kit.
3.Slipa3/8inchwasher(8)ontothebatteryterminalbolt.
4.Slidethepositive(redwire/fuselink (7))terminalring fromthe
batterycableontothepositive(+)batteryterminalbolt.
5.Slipasecond 3/8inchwasher(8)ontothebatteryterminalbolt.
6.Slidethevehiclepositivebatterycable(3)ontothebatterytermi-
nalbolt.
7.Threadtheboltassembly(steps2-6,above)intothepositivebat-
teryterminal.Tightenthebatteryterminalboltsecurely.
8.Tightenthenut(9)installedinstep2tosecurewashers(8)and
cablesfirmlyinplace.
Repeatsteps2through8forthenegativewire(blackorbrown)from
thebatterycable,hooking upthenegativecablestothenegative(-)
batteryterminal.