PSC Falcon 4400 Series User manual

Falcon
®
4400 Series
Powered Vehicle Dock
Installation Guide

PSC Inc.
959 Terry Street
Eugene, Oregon 97402
Telephone: [phone]
Fax: [phone]
Copyright ©2004 PSC Inc. An Unpublished Work - All rights reserved. No part of the contents of this documentation or the pro-
cedures described therein may be reproduced or transmitted in any form or by any means without prior written permission of
PSC Inc. or its wholly owned subsidiaries (“PSC”). Owners of PSC products are hereby granted a non-exclusive, revocable
license to reproduce and transmit this documentation for the purchaser's own internal business purposes. Purchaser shall not
remove or alter any proprietary notices, including copyright notices, contained in this documentation and shall ensure that all
notices appear on any reproductions of the documentation.
Should future revisions of this manual be published, you can acquire printed versions by contacting PSC Customer Administra-
tion. Electronic versions will either be downloadable from the PSC web site (www.pscnet.com) or provided on appropriate
media. If you visit our web site and would like to make comments or suggestions about this or other PSC publications, please let
us know via the “Contact PSC” page.
Disclaimer
Reasonable measures have been taken to ensure that the information included in this manual is complete and accurate. How-
ever, PSC reserves the right to change any specification at any time without prior notice.
PSC is a registered trademark of PSC Inc. The PSC logo is a trademark of PSC. All other trademarks and trade names referred
to herein are property of their respective owners.
Falcon®is a registered trademark of PSC Inc. and of its wholly owned subsidiaries.
Microsoft®Windows®, Windows®2000, and Windows®XP, are registered trademarks of Microsoft Corporation.

Installation Guide i
Table of Contents
PSC Falcon
®
4400 Series
Powered Vehicle Dock
Warranty ............................................................................................................ iii
Electrical Warnings, Safety
Precautions & Regulatory Statements ................................................................ iv
Electrical Warnings ........................................................................................................ iv
Safety Precautions ........................................................................................................ iv
Introduction ........................................................................................................ 1
Manual Overview ...........................................................................................................1
Document Conventions ..................................................................................................1
About the Powered Vehicle Dock ......................................................................................2
Features of the Powered Vehicle Dock .........................................................................2
Electrical Specifications: ..................................................................................................3
Unpacking ....................................................................................................................3
Electrical Considerations ..................................................................................... 5
Electrostatic Build-up ......................................................................................................5
Ground Contact Anti-Static Straps ..............................................................................6
Electrical Accessories ......................................................................................................7
Electrical Accessory Matrix ..............................................................................................7
Electrical System Connections ..........................................................................................8
Connection to +12V .................................................................................................8
Connection to +24V, +36V and +48V Systems ............................................................9
Mounting Options .............................................................................................. 11
Ram Ball Mounting Assembly ......................................................................................... 11
Components, Materials and Tools ............................................................................. 12
Ram Ball Assembly (sold separately) ........................................................................ 12
Attaching the Ram Ball to the Vehicle Dock ................................................................ 13
Final Assembly ...................................................................................................... 13
Inserting/Removing the 4400 ........................................................................................ 14
Inserting the 4400 in the Dock ................................................................................ 14
Removing the 4400 from the Dock ........................................................................... 17
Power and Peripheral
Device Connections............................................................................................ 19
Connections on the Dock ......................................................................................... 19
Power Connection .................................................................................................. 20
Battery Charging ................................................................................................... 20
COM Port Connections ............................................................................................ 20
Appendix. Troubleshooting ................................................................................ 23
Hardware Troubleshooting ............................................................................................. 23
Issues with Power to the Dock ................................................................................. 23

ii Falcon® 4400 Series Powered Vehicle Dock
PSC Technical Support .................................................................................................. 23
Appendix. Accessories and Peripherals ............................................................. 25
Overview .................................................................................................................... 25
Index ................................................................................................................ 29

Installation Guide iii
PSC Falcon
®
4400 Series
Powered Vehicle Dock
Warranty
Warranty
Falcon products are guaranteed against defects in materials and workmanship for the period specified at the time of sale. This warranty shall apply to Falcon
Portable Data Terminals (PDT's), Base Stations for the Falcon and Chargers for the Falcon. Cables, mounts and other accessory items are specifically war-
ranted for a period of 90-days from product purchase. Customer must notify PSC of the claimed defect before the expiration of the Warranty period and
obtain from PSC a return authorization number for return of the product to designated PSC service center. If PSC determines Customer’s claim is valid, PSC
will repair or replace product without additional charge for parts and labor. Customer shall be responsible for packaging and shipping the product to the des-
ignated PSC service center, with shipping charges prepaid. PSC shall pay for the return of the product to Customer if the shipment is to a location within the
country in which the PSC service center is located. Customer shall be responsible for paying all shipping charges, duties, taxes, and any other charges for
products returned to any other locations.
Warranty is subject to the limitations and exclusions set forth in the paragraphs that follow.
WARRANTY SET FORTH ABOVE IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING MERCHANTABILITY AND FITNESS.
Exclusions
Warranty coverage shall not apply to any claimed defect, failure or damage which PSC determines was caused by: abuse, neglect, improper use of product;
failure to provide product maintenance, including but not limited to cleaning of the display in accordance with product reference guide; installation or service
of product by other than PSC representatives; use of product with any other instrument, equipment or apparatus; modification or alteration of product or units
with Warranty Void labels that have been tampered with. External cables and replacement of upper window/cartridge due to scratching, stains or other deg-
radation will not be covered under the Warranty. External power supplies returned for service must be accompanied by the original product for performance
of service.
Returned products that PSC inc. has determined are not covered by Warranty, will be charged PSC Inc. standard repair rates then in effect for repair of prod-
uct. Replacement of display due to scratching, stains or other degradation will not be covered under Warranty. If a product is determined to be not repairable
customer will be notified and product may be returned to customer at their request. A minimum repair fee may be charged.
Limitation of Liability
PSC's REPAIR OR REPLACEMENT OF DEFECTIVE PRODUCT AS SET FORTH ABOVE IS THE CUSTOMER’S SOLE AND EXCLUSIVE REMEDY ON
ACCOUNT OF CLAIMS OF BREACH OF WARRANTY OR PRODUCT DEFECT. UNDER NO CIRCUMSTANCES WILL PSC BE LIABLE TO CUSTOMER
OR ANY THIRD PARTY FOR ANY LOST PROFITS, OR ANY INCIDENTAL, CONSEQUENTIAL IN-DIRECT, SPECIAL OR CONTINGENT DAMAGES
REGARDLESS OF WHETHER PSC HAD ADVANCE NOTICE OF THE POSSIBILITY OF SUCH DAMAGES.
Assignment
Customer may not assign or otherwise transfer its rights or obligations under Warranty except to a purchaser or transferee of product. No attempted assign-
ment or transfer in violation of this provision shall be valid or binding upon PSC.
Risk of Loss
Customer shall bear risk of loss or damage for product in transit to PSC. PSC shall assume risk of loss or damage for product in PSC's possession or product
being returned to Customer by PSC, except such loss or damage as may be caused by the negligence of Customer, its agents or employees. In the absence
of specific written instructions for the return of product to Customer, PSC will select the carrier, but PSC shall not thereby assume any liability in connection
with the return shipment.

Electrical Warnings, Safety Precautions & Regulatory Statements
iv Falcon®4400 Series Powered Vehicle Dock
Electrical Warnings, Safety
Precautions & Regulatory Statements
Electrical Warnings
Safety Precautions
The PSC Falcon 4400 Series is a powerful, compact, rugged data terminal,
ready for installation in mobile environments using the Powered Vehicle
Dock. However, there are some safety precautions you should take to protect
the terminal from unnecessary damage.
WARNING
To ensure safe operation when using the standard 110/220 VAC Power supply, the
three prong electrical plug must be inserted into a standard three prong electrical
power plug. The power plug should be grounded through the normal wiring.
During installation, make sure that the main outlet socket is easily accessible; this
allows users to remove the dock from the power supply by unplugging the unit.
Only three-prong, grounded extension cords should be used. Improperly wired
extension cords are a major cause of fatalities!
Only use PSC approved accessories and peripherals.
CAUTION
Do not place the terminal near a television or radio receiver.
Keep the terminal away from magnets and from magnetic fields.

Installation Guide 1
Chapter 1
Introduction
Manual Overview
• Chapter 1 provides an introduction to the features of the Powered Vehi-
cle Dock.
• Chapter 2 specifies important electrical considerations to observe when
installing the unit.
• Chapter 3 describes the various peripheral connections made to the
Dock, and their functions.
• Chapter 4 contains instructions for mounting.
Document Conventions
Formatting conventions are used throughout this guide to provide a consistent
method for representing the user interface and vehicle mount dock. This guide
also provides special conventions for information of high interest, in the form
of notes, cautions, and warnings.
Notes contain information that is helpful and recommended. They provide information
that is critical to operations and/or procedures described in this manual.
CAUTION
Cautions inform you that proper handling (adherence to the procedures described) is
required to avoid damage to equipment and/or property.
WARNING
Warnings alert you to potential physical harm or injury. These statements do not
include potentially fatal hazards, which would be designated as ‘DANGER’ blocks.
Use of this product does not warrant the need for a DANGER block.

Introduction
2Falcon®4400 Series Powered Vehicle Dock
About the Powered Vehicle Dock
The Powered Vehicle Dock (PVD) is a rugged cradle for Falcon 4400 Series
Win CE .NET data terminals, for use on mobile vehicle applications. This
guide is intended to address some of the factors to consider when installing the
PVD on gas, diesel, propane or electric powered forklifts.
Features of the Powered Vehicle Dock
•PowerOnIndicator
• Rugged holder for the Falcon terminal
• Battery charging for the Falcon terminal
• Versatile mounting options
• Two serial port connections for peripherals (with power available)
• Additional styluses included
To ensure you have the latest version of manuals and instructions for this product,
download them from the PSC website listed on the back cover of this manual.
The procedures describe installation for most standard mounting applications;
however, if your target installation does not generally match any of the mounting
options detailed, contact PSC for technical support regarding a custom installation.

Electrical Specifications:
Installation Guide 3
Figure 1. Features of the F4400 Powered Vehicle Dock
Electrical Specifications:
• Input voltage range: +12 to +18V
• Power consumption: <50 MA with no load
• +12v available on COM A and COM B ports
Unpacking
Unpack the unit carefully and ensure you received everything you ordered.
Refer to your packing slip for an exact list of items delivered, which may
include some or all of the following items:
• Powered Vehicle Dock
•PowerChargingCable
• Installation Guide
Stylus
Power-On
Indicator
Serial Port
Connections

Introduction
4Falcon®4400 Series Powered Vehicle Dock
•RamBallMountKit
• Ram Ball Assembly
• Assorted Screws
• Any additional accessories required for your installation
If any parts are missing, please contact your dealer or refer to “Troubleshoot-
ing” on page 23 for PSC Technical Support contact information.

Installation Guide 5
Chapter 2
Electrical Considerations
Electrostatic Build-up
One common characteristic of forklifts is the possibility of producing high lev-
els of electrostatic voltage. Static is created by the wheels as they move about
the floor and can also be generated when an operator slides on or off of a vehi-
cle's cloth-covered seat. Static buildup on the forklift frame can be as high as
several thousand volts (see Figure 2). At these levels of high voltage, a discharge
can cause severe damage to electronic devices.
Figure 2. Static Build-up on a Forklift Frame
There are several factors which affect the levels of static buildup on a forklift.
For instance, the type of materials used to make the wheels can help to reduce
static, as well the conductive properties of the flooring and the relative humid-
ity in the air. Static buildup will remain on the vehicle until it can be dissi-
pated. Lowering the front forks to make contact to the floor surface can
typically do this. However, eliminating the potential for static buildup is the
best means of protection for both operator and equipment.
Positive Charge (+)
Negative Charge (-)

Electrical Considerations
6Falcon®4400 Series Powered Vehicle Dock
Ground Contact Anti-Static Straps
The recommended method of reducing static buildup is to install ground con-
tacting anti-static straps or conductors to the frame of the forklift (refer to Fig-
ure 3).
Contact your forklift parts provider for availability.
Figure 3. Installing Ground Contact Anti-Static Straps
It is recommended that more than one strap be installed on each vehicle to
help eliminate or reduce the potential for static buildup while the vehicle is in
motion. This will provide an adequate level of redundancy, should one of the
straps become dislodged from the lift.
Ground Contact
Anti-Static Straps
Ground Contact Anti-Static Straps should be checked at regular intervals to
ensure proper installation or identify need for replacement.

Electrical Accessories
Installation Guide 7
Electrical Accessories
Installation of the PVD may require accessory electronic equipment for proper
and safe operation. Some of this equipment may not be available through
PSC, but could be available through your dealer, forklift parts provider, or
other suppliers. See Appendix A, “Accessories and Peripherals” on page 25.
DC/DC Converter. Voltage step down device used to power the terminal
from +24, +36 and +48 volt battery systems.
DC Conditioner/UPS. Used to provide backup DC power during sags or
interruptions in battery voltage due to peak loads or disconnect.
Delay Timer. Provides automatic shut-off of power to a terminal or other
equipment, to reduce battery drain.
Noise Spike/RF Filter. Used to suppress high voltage and RF voltage
spikes on the power system.
Electrical Accessory Matrix
Table 1 summarizes the accessory recommendations and options available
depending on the forklift voltage application. This matrix should be used only
as a reference and may not include accessories for all applications.
Table 1. Electrical Accessories
*Ensure that the device being installed is properly rated for use on your vehicle.
Accessory
Forklift System Voltage
12 volt 24 volt 36 volt 48 volt
DC/DC Converter Not Required Required Required Required
DC Conditioner/UPS Optional* Not Required Not Required Not Required
Delay Timer Optional* Optional* N/A N/A
Noise Spike/RF Filter Recommended Recommended Recommended Recommended
5-Amp Dock In-Line Fuse Required Required Required Required

Electrical Considerations
8Falcon®4400 Series Powered Vehicle Dock
Electrical System Connections
This section covers electrical connection to +12V, +24V, +36V and +48V sys-
tems.
Connection to +12V
Figure 4 illustrates a typical wiring connection for a +12 volt system. The
input voltage operating range of the dock will allow direct connection to the
battery terminals. However, the use of a 5-Amp fuse is required, and a Noise
Spike/RF filter is highly recommended.
Accessory equipment may also be required depending on your application,
Refer to Table 1 on page 2-7. Read and follow all manufacturer's installation
instructions carefully.
Figure 4. Wiring Diagram for +12V Systems
CAUTION
Proper installation requires that source power connections be made directly to
the vehicle's positive and negative battery terminals. It is important to maintain
electrical isolation when installing the powered vehicle dock and any accessory
equipment, to ensure safe and proper operation. Do not make any electrical
connections directly to the chassis of the forklift.
Noise/Spike Filter
(Recommended)
DC Conditioner/UPS
(Optional)
Delay Timer
(Optional)*
Use crimp connectors
for all wire connections
** White (N/C)
Dock
Power Cord
Red (Pos)
Black (Neg)
Pos
+
Neg
-
5-Amp In-Line Fuse
(Required)
DO NOT connect the white wire.
Either cut it or ensure it isproperly
isolated.
**
ENSURE that the device being
installed isproperly rated for use
on your vehicle
*
Fuse each device accordingto
manufacturer’srecommendation

Electrical System Connections
Installation Guide 9
Connection to +24V, +36V and +48V Systems
Figure 5 illustrates a wiring diagram for +24, +36 and +48 volt systems. The
use of a DC/DC converter is required to step down the battery voltage for use
by the terminal.
When using any optional equipment caution must be taken to ensure that
+24, +36 or +48VDC does not exceed any voltage rating for these devices. Fol-
low all manufacturer's installation instructions carefully.
Some DC/DC converters provide internal Noise Spike/RF filtering. The use
of an additional filter is optional.
Figure 5. Wiring Diagram for +24V, +36V and +48V Systems
CAUTION
Proper installation requires that source power connections be made directly to
the vehicle's positive and negative battery terminals. It is important to maintain
electrical isolation when installing the PVD and any accessory equipment, to
ensure safe and proper operation. Do not make any electrical connections
directly to the chassis of the forklift.
In-Line Fuse
(integral to converter)
DC/DC
Converter
(Required)
Use crimp connectors
for all wire connections
White (N/C)* Power Cord
Red (Pos)
Black (Neg)
Pos
+
Neg
-
Pos
Neg
+
-
IN OUT
DO NOT connect the white wire.
Either cut it or ensure it isproperly
isolated.
*
5 Amp In-Line Fuse
(Required)

Electrical Considerations
10 Falcon®4400 Series Powered Vehicle Dock
NOTES

Installation Guide 11
Chapter 3
Mounting Options
Ram Ball Mounting Assembly
This chapter outlines the steps needed to assemble and mount the Powered
Vehicle Dock using the Ram Ball mount accessory. The Ram Ball and mount-
ing assembly, shown in Figure 6, combine to form an extremely a flexible
mounting assembly. This assembly allows wide range of rotation for the Vehi-
cle Dock. It can be mounted on any flat horizontal or vertical surface.
Figure 6. The Ram Ball Mount
Ram Ball
Mounting
Assembly
CAUTION
Install only on properly grounded vehicles. If this Dock is used on an electric vehicle,
ensure that no part of the PVD and PDA can come into contact with the vehicle
chassis. Electrical discharges can develop on these vehicles, which can damage the
PVD and/or PDA. Refer to “Electrical Considerations” starting on page 5for important
information.

Mounting Options
12 Falcon®4400 Series Powered Vehicle Dock
Components, Materials and Tools
• Ram Ball Assembly (sold separately)
• 8 screws and nuts for mounting Ram Ball (supplied)
• Phillips head screwdriver
Ram Ball Assembly (sold separately)
1. Loosen the large adjustment knob handle on the Ram Ball assembly.
2. Remove both Ram Balls from the mount as demonstrated in Figure 7.
Figure 7. Ram Ball Assembly
3. Use four screws (customer supplied) to secure one of the Ram balls to
the desired mounting surface. Set the other Ram ball aside to use later in
the assembly process.
4. Re-attach the Ram Ball Assembly to the Ram Ball you just affixed to the
mounting surface.
Ram Balls Adju stment
Knob
Screws

Ram Ball Mounting Assembly
Installation Guide 13
Attaching the Ram Ball to the Vehicle Dock
1. Align the second Ram Ball with the four screw holes on the rear of the
Vehicle Dock as shown in Figure 8.
Figure 8. Installing the Ram Ball on the Vehicle Dock
Secure the Ram Ball to the mounting area using the four supplied 10-24 x
5/8” Phillips head screws and four supplied 10-24 hex nuts.
Final Assembly
1. Insert the Ram Ball, mounted to the rear of the Vehicle Dock assembly,
into the Ram Ball assembly you earlier affixed to the mounting surface
(see Figure 9). Tighten the adjustment knob to secure the Ram Ball in
place.

Mounting Options
14 Falcon®4400 Series Powered Vehicle Dock
Figure 9. Installing the Vehicle Dock Assembly on the Mount
2. Loosen the Adjustment Knob slightly to tilt the Vehicle Dock to the
desired mounting angle. Re-tighten the Adjustment Knob securely.
3. Route and connect all cables (see “Power and Peripheral Device Connec-
tions” starting on page 19 for more on connections). If you haven’t
already prepared the power connection, reference “Electrical Consider-
ations” starting on page 5 for wiring information.
Inserting/Removing the 4400
Inserting the 4400 in the Dock
To insert a 4400 terminal into the Powered Vehicle Dock, perform the follow-
ing steps:
1. Slide the Falcon up under the top of the Powered Vehicle Dock.
2. Push upwards to lift the spring-loaded top to allow insertion of the Fal-
con as shown in Figure 10 on page 15.
Ram Ball
Ram Ball
Assembly
Adjustment
Knob