PowerFleet VAC4S Installation manual

Enterprise VAC4 and VAC4S Hardware User’s Guide
085-00000700 Rev K
[email protected]
Page 2 of 100
EnterpriseVehicle
Management System (VMS)
Hardware User’s Guide
An operating and troubleshooting guide for the
VAC4, VAC4S, WAM, and other peripheral hardware
(some features require firmware from system release 08.05.00 or later)
123 Tice Blvd • Suite 101
Woodcliff Lake, NJ 07677
Phone [phone] • Facsimile 201.996.9144
www.powerfleet.com
©2020 PowerFleet Inc.
085-00000700 Rev K

Enterprise VAC4 and VAC4S Hardware User’s Guide
085-00000700 Rev K
[email protected]
Page 3 of 100
About this Guide
This Guide provides detailed information on the proper use and maintenance of PowerFleet
Enterprise vehicle management system (VMS), including the 4th generation Vehicle Asset
Communicator® (VAC), other vehicle peripheral hardware, and the Wireless Asset Manager (WAM).
Safety
The PowerFleet VMS is not intended for use as a primary safety device. Installation must NOT
adversely affect any vehicle safety system or safety device. The installation, configuration and
operational procedures provided in this Guide are intended for use ONLY by personnel certified on
PowerFleet VMS installation. It is the user’s responsibility to ensure that the procedures in this Guide
are completed by certified personnel ONLY, using the proper tools and following the proper safety
protocols. The procedures and recommendations in this Guide do not supersede any Federal, State
or Local regulations.
Confidentiality Notice
© 2020 PowerFleet, Inc. All rights reserved. This document contains confidential and/or proprietary
information and may be reproduced for the user’s internal training purposes ONLY. This document
may not be reproduced in part, or shown, or in any way disclosed to any third party, without the
express written consent of PowerFleet, Inc.
Disclaimer
The information contained in this Guide is subject to change without notice and should not be
construed as a specification.
Disclaimer and Limitation of Liability
PowerFleet, Inc. assumes no responsibility for any damage or loss resulting from the use of its
products or services. PowerFleet assumes no responsibility for any loss or claims by third parties,
which may arise through using its products or services.

PowerFleet®VAC4 and VAC4S Hardware User’s Guide
085-00000700 Rev K
[email protected]
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CONTENTS
INTRODUCTION....................................................................................................................................................... 8
SECTION 1: SYSTEM OVERVIEW .............................................................................................................................. 9
POWERFLEET ENTERPRISE SYSTEM DIAGRAM...........................................................................................................................................9
VAC INTERFACE:LCD, KEYPAD,ID READER AND LEDS...........................................................................................................................10
Status Indicators ......................................................................................................................................................................10
MENU SCREENS................................................................................................................................................................................14
DATA INPUT SCREENS........................................................................................................................................................................15
MULTIPLE CHOICE SELECTION SCREENS.................................................................................................................................................16
LOGIN METHODS (VARIOUS METHODS ARE BASED ON WHICH VERSION OF POWERFLEET IS PURCHASED) ............................................................17
SECTION 2: CONFIGURING THE HARDWARE............................................................................................................18
VAC CONFIGURATION .......................................................................................................................................................................18
WI-FI CONFIGURATION ON THE VAC....................................................................................................................................................19
Entering credentials on the VAC using the keypad ..................................................................................................................19
Wirelessly receiving credentials from a nearby Wi-Fi-configured VAC ....................................................................................21
Receiving credentials from a Wireless Asset Manager (WAM)................................................................................................22
VAC SYNCHRONIZATION ....................................................................................................................................................................24
Wirelessly, using Intelligent RF (IRF) ........................................................................................................................................24
Wirelessly, using Wi-Fi .............................................................................................................................................................24
IMPACT SENSOR CONFIGURATION........................................................................................................................................................24
READING VAC “INFO”SCREENS ..........................................................................................................................................................26
SECTION 3: STANDARD OPERATORS.......................................................................................................................28
LOGGING INTO THE VAC (TO START THE VEHICLE) ...................................................................................................................................28
Login Error Code Table [“Error (AXX)” plus below text when login is attempted] ...................................................................29
READING VAC “ABOUT”SCREENS .......................................................................................................................................................30
LOGGING OFF THE VAC.....................................................................................................................................................................31
ANSWERING SAFETY CHECKLISTS..........................................................................................................................................................32
Critical Shutdown.....................................................................................................................................................................34
OPERATING THE VEHICLE....................................................................................................................................................................35
Break Mode..............................................................................................................................................................................35
Idle Timeout .............................................................................................................................................................................35
Automatic Hibernate ...............................................................................................................................................................35
Motion Safety Feature .............................................................................................................................................................36
Event Shutdowns (Impact, safety non-compliance, etc.) .........................................................................................................36
Memory Status.........................................................................................................................................................................36
SECTION 4: MASTER OPERATORS (SUPERVISORS) ...................................................................................................37
Adding Temporary Users..........................................................................................................................................................37
Clearing Event Lockouts ...........................................................................................................................................................39
Checklist Administration ..........................................................................................................................................................40
Manual Vehicle Lock ................................................................................................................................................................41
Manual Vehicle Unlock ............................................................................................................................................................41
SECTION 5: MAINTENANCE OPERATORS ................................................................................................................42
Installation and Configuration .................................................................................................................................................42
VAC Timer Reset After Completed PM .....................................................................................................................................42
Diagnostic Errors......................................................................................................................................................................43
ID Optional (‘Soft’ Bypass) .......................................................................................................................................................44
Read Operator Identification ...................................................................................................................................................45
Replacing an Existing VAC........................................................................................................................................................46

PowerFleet®VAC4 and VAC4S Hardware User’s Guide
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Checking VAC Synchronization Status......................................................................................................................................47
Reset VAC Synchronization ......................................................................................................................................................48
Changing the VAC Facility ID....................................................................................................................................................49
Forcing the VAC to Low Power Mode (Hibernate) ...................................................................................................................49
Checking VAC Internal Backup Battery (not applicable for all VAC types)...............................................................................50
Changing the VAC Data Transmission Settings........................................................................................................................51
Checking and Changing the VAC Usage Totals ........................................................................................................................52
Testing the BLU wire connection prior to VAC configuration...................................................................................................53
Understand and Manually Set “Motion” for Electric Vehicles .................................................................................................54
Understand and Manually Set “Idling” for Internal Combustion Vehicles ...............................................................................55
Understand and Manually Set “Motion” for Internal Combustion Vehicles ............................................................................56
Current VAC Configuration (“States” Screen) ..........................................................................................................................57
Last VAC Configuration (“InsReport” Screen)...........................................................................................................................60
Impact Sensor Troubleshooting ...............................................................................................................................................62
Manually Enabling Impact Calibration ....................................................................................................................................63
Check Vehicle Battery Voltage Monitoring ..............................................................................................................................63
SECTION 6: WAM USE AND TROUBLESHOOTING ....................................................................................................64
WAM Use .................................................................................................................................................................................64
WAM LEDs Explained ...............................................................................................................................................................64
WAM Troubleshooting.............................................................................................................................................................65
.................................................................................................................................................................................................65
Multitech Modem LEDs Explained ...........................................................................................................................................65
Cradlepoint Modem LEDs Explained ........................................................................................................................................66
Modem Troubleshooting..........................................................................................................................................................66
SECTION 7: VAC TROUBLESHOOTING .....................................................................................................................67
Recommended maintenance tool list.......................................................................................................................................67
VAC to Wired vehicle cable pinout and fuses...........................................................................................................................67
VAC screen and LEDs do not illuminate ...................................................................................................................................67
SECTION 8: SENSOR HUB ERRORS ..........................................................................................................................68
Pinout Diagram........................................................................................................................................................................68
Sensor Hub LED Indicators .......................................................................................................................................................68
Troubleshooting.......................................................................................................................................................................68
SECTION 9: SELF-DIAGNOSTIC ERROR CODES..........................................................................................................69
SECTION 10: SYSTEM SUPPORT INFORMATION ......................................................................................................94
TECHNICAL SPECIFICATIONS –VAC4S AND VAC4 ..................................................................................................................................94
Electrical Specifications............................................................................................................................................................94
Processor/Memory/Other Specifications.................................................................................................................................94
Communication Specifications.................................................................................................................................................95
User Interface Specifications....................................................................................................................................................95
Mounting Specifications ..........................................................................................................................................................96
Sensor Specifications................................................................................................................................................................96
Regulatory and Product Certifications .....................................................................................................................................97
CUSTOMER SUPPORT AND RETURN MERCHANDISE AUTHORIZATION (RMA) POLICY AND PROCEDURES ............................................................99
APPENDIX A(RMA REQUEST FORM)..................................................................................................................................................100
APPENDIX B(HARD-BYPASS POWERFLEET®ACCESS CONTROL) ................................................................................................................101
APPENDIX C(USING THE POWERFLEET WI-FI TEST TOOL)......................................................................................................................102

PowerFleet®VAC4 and VAC4S Hardware User’s Guide
085-00000700 Rev K
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INTRODUCTION
This Guide provides the information needed to configure, use, and maintain the hardware included with PowerFleet’s
Enterprise Vehicle Management System (VMS):
VAC
Vehicle Asset Communicator
WAM *
Wireless Asset Manager
Related peripherals
* WAM not required for Wi-Fi deployments.
In addition to this guide, PowerFleet offers many other ways to learn the system including but not limited to:
•Live training webinars
•Interactive self-paced learning modules
•How-to videos
•Technician Certification programs (visit http://go.powerfleet.com/powerfleet-university)
Related Documents
This detailed Guide is a supplement to the following PowerFleet system documents:
Title
Description
PowerFleet Enterprise Getting Started Guide
General system instructions for the site coordinator.
PowerFleet Enterprise Installation Guide
Installation instructions for vehicle hardware.
(Cellular) Wireless Asset Manager Installation Guide
Installation instructions for the WAM.
I.D. Registration form
Associate each operator with assigned fob
Note: The VAC is an interactive mini-computer designed for installation on industrial vehicles. Since vehicle designs vary
widely, this Guide cannot provide precise instructions for each specific vehicle model. Instead, this Guide provides the
basic knowledge needed for a certified installer with a typical installation.
Note: The installation, configuration and operational procedures provided in this document are intended for use by
authorized, certified personnel only. It is the responsibility of the supervisor to ensure that the procedures in this
publication are only completed by trained/certified personnel, using the proper equipment and following the proper
safety protocols.

PowerFleet®VAC4 and VAC4S Hardware User’s Guide
085-00000700 Rev K
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SECTION 1: SYSTEM OVERVIEW
PowerFleet Enterprise System Diagram
Placement of a VAC on a vehicle
•VAC must be mounted on the
vehicle where it can be
accessed by the operator
without interfering with any
vehicle operation.
•VAC interfaces with the
vehicle for power, ignition/
access control, and usage
monitoring using an 18-foot
cable harness.
•VAC interfaces with operators
through Access ID readers,
LEDs, a keypad, and a backlit
LCD display.
•VAC communicates
automatically with remotely
hosted software via a WAM
or Access Point, but operates
seamlessly, even when not in
coverage range.
or
Hotspot

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VAC Interface: LCD, Keypad, ID Reader and LEDs
The VAC incorporates a 20-key keypad that is easy to read and operate. The graphical LCD screen remains backlit for
15 seconds after any key is pressed on the keypad. The VAC integrates an electronic identification reader for vehicle
access control. Operators use individual access identification “keys” to the vehicle. (i.e., iButton fobs, prox cards, etc.).
Vehicle keys may still be required, depending on wiring and can be safely left in the vehicle.
Keypad
LEDs
•Access
•Numbers for PIN entry and
menu selection
•Message
•Letters for configuration
inputs
•Checklist
•ARROW keys for scrolling
LCD screen
•ENTER and ESC key - menu
navigation
•Status Header
•Function key
•Alerts/ Icons
•Shortcut keys
•Text
•VAC menu screens
displays: menu
options
Access ID Reader
•Touch ID to log on or log off and assign a Temporary User
Status Indicators
When the VAC is powered, the VAC has three integrated LEDs for operator and supervisor status indication.
LED
Message
LED State
Indication
Access
Off
No one logged in and the vehicle is in Registered ID or Any ID mode
(operators must log in to operate the vehicle).
Blinking
Green
No one logged in and the vehicle is in ID Optional mode
(Anyone can use the vehicle without logging in).
Solid
Green
An operator is logged in
(The vehicle should NOT be left unattended in this state).
Blinking
Green/Orange
The vehicle is locked or about to be locked for certain operator levels
(This occurs due to a vehicle impact or other event).
Message
Off
There are no incomplete tasks, no unread text messages, and no active errors.
Blinking Red
The vehicle has an unread message, task or an active diagnostic error.
Checklist
Off
No one logged in and/or the vehicle is compliant for all configured checklists.
Blinking
Yellow
There is a checklist that needs to be completed.
Note: When the Access, Message, and Checklist LEDs blink in sequence, the VAC is in ‘programming’ mode and cannot
be used by operators. Call PowerFleet’s Support if this condition persists for more than twenty-five minutes.

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The VAC screen displays the current time, text, status icons (top row) and menu options.
Some icons are described as follows:
Icon
Meaning
Indication
Reception Bars
Reception bars provide an indication of signal strength the VAC is currently
experiencing for the wireless communication method which is affected by the
proximity to nearby WAMs or AP’s.
(X without bars = no coverage, 1 bar = weakest, 3 bars = strongest)
IRF Communication
IRF communication icon indicates that the VAC is ready to use or is using
Intelligent RF (IRF) to communicate with the system. If inverted, the VAC has data
to send to a WAM but is unable to do so using IRF. IRF is a proprietary 868/915
MHz technology. Refer to reception bars to determine communication strength.
Wi-Fi
Communication
Wi-Fi communication icon indicates that the VAC is ready to use or is using Wi-Fi
to communicate with the server. If inverted, the VAC has data to send to the
server but is unable to do so using Wi-Fi. Refer to the reception bars to determine
the strength of the communication.
GPS Triangulation
GPS triangulation icon indicates that the VAC has triangulated its location with
GPS satellites. Direction is found through this navigational aid.
OEM CAN
Communication
OEM CAN communication icon indicates that the VAC is configured to
communicate with a CAN equipped vehicle. If only the arrow pointed to the right
is visible, the VAC has not recently received data from the CAN (such as when
the key is off). If only the arrow pointed to the left is visible,
communication with the CAN is failing.
Time Clock
The time clock (bracketed) indicates the current local time (24-hour clock format).
The time is replaced by a countdown when a safety checklist has to be
completed. If the time is blank [--:--], the VAC does not yet know the local time
zone such as when it is first installed and yet to communicate to the system.
Logged-in Operator
Authorization Level
Logged-in operator authorization level indicators are inverted icons (black on
white) when the operator is not recognized in the system software (i.e. new
IDs in “Any ID” mode)
Operator - 1 box
STANDARD
The Standard operator logged in.
Operator - 2 Boxes
MASTER
The Master operator logged in.
Operator - 3 Boxes
MAINTENANCE
The Maintenance operator logged in.
Operator - 4 Boxes
ADMINISTRATION
The Administrator logged in (IDSY personnel only).
Operator - IT
IT
An IT operator logged in.
Diagnostic
Error
The Diagnostic Error icon is accompanied by a flashing red LED on top of the VAC.
At least one REFERENCE or FUNCTIONAL diagnostic error (i.e. Impact sensor
error) is active on the vehicle. However, these errors Do Not lock the vehicle or
prevent operator use of the VAC.
Diagnostic
Error
(Lockout)
The Diagnostic Error icon is accompanied by a flashing red LED on top of the VAC.
The vehicle is Locked Out for all operators except Maintenance users. At least one
SAFETY/ SHUTDOWN diagnostic error (i.e. Vehicle not correctly configured for
motion) is active on the vehicle and there is a driver safety risk.

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The VAC indicates different vehicle and VMS system conditions in the main screen using text as well as iconography
(some with animation). Common icons include the following:
Icon
Meaning
Indication
Battery
The Hourglass icon:
New battery request is being processed.
Break
The vehicle is in Break mode.
This feature is used to keep the vehicle from being borrowed during short
breaks. The break time is typically 15 minutes. The one operator sets the
vehicle in Break mode and only a Master operator or a Maintenance operator
can log in until the Break time expires.
Checklist
The Checklist icon is accompanied by a blinking yellow indicator LED. The
checklist icon is also sometimes accompanied by a grace period timer
indicating how long (in minutes) before a non-compliance event is created.
The same countdown will also appear in the Status Header. The vehicle has an
active checklist that requires a Standard operator to complete.
Diagnostics
The blinking Diagnostic icon is accompanied by a blinking red LED.
The vehicle has active Diagnostic errors. A Maintenance operator must correct
and clear the error, or, in some cases, the error will clear itself.
See section 7, VAC Troubleshooting, for more details on diagnostic errors.
GPS
When the GPS icon is displayed, the vehicle cannot determine location using
the GPS sensor.
Make sure the GPS sensor is connected and configured properly and that the
GPS receiver has a clear line of site to a satellite symbol.
Impact
The Impact icon is accompanied by a blinking yellow indicator LED.
The vehicle has an active impact event. When displayed on its own, the impact
event did not result in a lockout and standard operator feedback is required by
completing a checklist.
Lockout
The Lockout icon is accompanied by an alternating, blinking Green/ Orange
LEDs.
The vehicle is locked and can only be logged into using Master or Maintenance
operator credentials.

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Common icons include the following:
Icon
Meaning
Indication
Low
Battery
The Low Battery icon:
The vehicle battery is low and requires a charge.
Low Oil Pressure
High Engine
Temperature
The Engine icon:
The oil pressure or engine temperature inputs (VIMs 10 and 11) are outside the
normal range. Check the engine for low oil or coolant.
Maintenance
The Maintenance icon is accompanied by an alternating, blinking Green/
Orange LEDs.
The vehicle is locked and can only be logged into using a Maintenance operator
credentials.
Master
The Master icon is accompanied by a blinking yellow LED.
The vehicle has an active checklist that requires a Master or Maintenance
operator to complete.
New
Message
The New Message icon is accompanied by a blinking red LED.
A new message was received for the vehicle and/or operator. Once the
message is read, the icon disappears.
Shield
The blinking Shield icon:
The vehicle is in Emergency Access mode, indicating that any operator can
access and operate the vehicle without logging in through the VAC.
Speeding
The Speeding icon:
The operator was driving over the configured speed limit. The icon will
disappear once the vehicle decelerates to an acceptable speed level.
Zone
The Zone icon:
The operator has driven the vehicle inside a restricted area. Drive the vehicle
out of the restricted area to clear the icon.