PSC Falcon 4220 User manual

Falcon
®
4220
Powered Vehicle Dock
Installation Guide

PSC Inc
959 Terry Street
Eugene, Oregon 97402
Telephone: [phone]
Fax: [phone]
An Unpublished Work - All rights reserved. No part of the contents of this documentation or the procedures 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 reproduc-
tions of the documentation.
Should future revisions of this manual be published, you can acquire printed versions by contacting your PSC representative.
Electronic versions may either be downloadable from the PSC website (www.psc.com) or provided on appropriate media. If you
visit our website and would like to make comments or suggestions about this or other PSC publications, please let us know via
the “Contact PSC” page.
Disclaimer
PSC has taken reasonable measures to provide information in this manual that is complete and accurate, however, 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® 4220
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 and +24V Systems ......................................................................8
Connection to +36V and +48V Systems ......................................................................9
Power and Peripheral
Device Connections............................................................................................ 11
Connections on the Dock ......................................................................................... 11
Power Connection .................................................................................................. 12
Battery Charging ................................................................................................... 12
COM Port Connections ........................................................................................... 12
Mounting the Dock............................................................................................. 15
Mounting Assembly ...................................................................................................... 15
Mounting Options ......................................................................................................... 16
Components, Materials and Tools ............................................................................. 16
Ram Ball Assembly ................................................................................................. 16
Attaching the Ram Ball to the Vehicle Dock ................................................................ 17

ii Falcon® 4220 Powered Vehicle Dock
Final Assembly ...................................................................................................... 18
Inserting/Removing the 4220 ........................................................................................ 19
Inserting the 4220 into the Dock .............................................................................. 19
Removing the 4220 from the Dock ........................................................................... 20
Appendix. Troubleshooting ............................................................................... 21
Hardware Troubleshooting ............................................................................................. 21
Issues with Power to the Dock ................................................................................. 21
Technical Support ........................................................................................................ 21
PSC Website Support .............................................................................................. 21
PSC Website TekForum ........................................................................................... 21
Reseller Technical Support ...................................................................................... 21
Telephone Technical Support ................................................................................... 22

Installation Guide iii
PSC Falcon
®
4220
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® 4420 Powered Vehicle Dock
Electrical Warnings, Safety
Precautions & Regulatory Statements
Electrical Warnings
Safety Precautions
The Falcon®4220 is PSC’s latest generation PDA device, combining a com-
pact, ruggedized form factor with the flexibility of Microsoft’s CE .NET oper-
ating system. The 4220 is ready for installation in mobile environments using
the Powered Vehicle Dock. However, there are some safety precautions you
should take to protect the PDA from unnecessary damage.
Compliance Statement
This device complies with Part 15 rules. Operation is subject to the following
conditions:
1. This device may not cause harmful interference; and
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 PDA near a television or radio receiver.
Keep the PDA away from magnets and from magnetic fields.

Safety Precautions
Installation Guide v
2. This device must accept any interference received, including interference
that may cause undesired operation.
This Class A digital apparatus complies with Canadian ICES -003.
Cet appareil numérique de la classe A est confrome à la norme NMB-003 du Canada.
This device complies with Automotive Directive 95/54/EEC.

Electrical Warnings, Safety Precautions & Regulatory Statements
vi Falcon® 4420 Powered Vehicle Dock
NOTES

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®4220 Powered Vehicle Dock
About the Powered Vehicle Dock
The 4220 Powered Vehicle Dock (PVD) is a rugged cradle for Falcon®4220
Win CE .NET ruggedized PDAs, 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
• Provides power for battery charging of the Falcon terminal
• Versatile mounting options
• Two serial port connections for peripherals (with power available)
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 Powered Vehicle Dock
Electrical Specifications:
• Input voltage range: +9 to +28vdc
• Power consumption: Less than 100ma without 4220 installed, max 3.5
amps with 4220 PDA charging and both COM ports supplying power
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
•PowerCable
• Installation Guide
Serial Port
Connections
Power-On
Indicator
Mounting
Assembly
Power Port

Introduction
4Falcon®4220 Powered Vehicle Dock
• Ram Ball Mount Kit (ordered separately)
• 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 21 for PSC 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®4220 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.
DC/DC Converter. Voltage step down device used to power the PDA from
+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 Optional* Required Required
DC Conditioner/UPS Optional* Not Required Not Required Not Required
Delay Timer Optional* Optional* N/A N/A
Noise Spike/RF Filter Required Required Required Required
5-Amp Dock In-line
fuse Required Required Required Required

Electrical Considerations
8Falcon®4220 Powered Vehicle Dock
Electrical System Connections
This section covers electrical connection to +12V, +24V, +36V and +48V sys-
tems.
Connection to +12V and +24V Systems
Figure 4 illustrates a typical wiring connection for a +12 volt and +24 volt sys-
tem. The input voltage operating range of the dock will allow direct connec-
tion to the battery terminals. However, the use of a 5-Amp fuse is required (as
shown in Figure 4), and use of a Noise Spike/RF filter is required.
Accessory equipment may also be required depending on your application,
Refer to Table 1 on page 2-7. For each accessory, read and follow the manufac-
turer’s installation instructions carefully.
Figure 4. Wiring Diagram for +12V and +24V 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
(Required)
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 +36V and +48V Systems
Figure 5 illustrates a wiring diagram for +36 and +48 volt systems. The use of
a DC/DC converter is required to step down the battery voltage for use by the
PDA.
When using any optional equipment caution must be taken to ensure that +36
or +48VDC does not exceed any voltage rating for these devices. Follow all
manufacturer's installation instructions carefully. For any accessories, follow
manufacturer’s recommendations for fuse protection.
Some DC/DC converters provide internal Noise Spike/RF filtering. However,
the use of an additional filter is required.
Figure 5. Wiring Diagram for +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)
5 Amp In-Line Fuse
(Required)
DC/DC
Converter
(Required)
Use crimp connectors
for all wire connections
White (N/C)** Dock
Power Cord
Red (Pos)
Black (Neg)
Pos
Neg
+
-
IN OUT
DO NOT connect the white wire. Either cut it or
ensure it isproperly isolated.
**
Noise/Spike Filter
(Required)
Fuse each device accordingto
manufacturer’s recommendation
Pos
+
Neg
-

Electrical Considerations
10 Falcon®4220 Powered Vehicle Dock
NOTES

Installation Guide 11
Chapter 3
Power and Peripheral
Device Connections
This chapter describes connection of peripheral devices that are provided with
or available for the Falcon®4220 Powered Vehicle Dock system. For more on
power connections, see “Electrical Considerations” starting on page 5.
Connections on the Dock
Figure 6 shows the connection located on the back side of the dock. See the
following pages for more information about these connections.
Figure 6. Cable Connections
Printer
COM Port
Input Power
Connection
Scanner
COM Port

Power and Peripheral Device Connections
12 Falcon®4220 Powered Vehicle Dock
Power Connection
Insert the DC power cord at the power port with the arrow on the connector
facing up, toward the rear of the dock. When power is applied to the dock, the
Power-On LED will light. When the PDA is inserted into a powered dock, the
Power On/Charging LED on the PDA will also be lit.
Also refer to “Electrical Considerations” starting on page 5 for complete infor-
mation and wiring diagrams detailing power connection.
Battery Charging
The PVD provides battery charging for the Falcon terminal when powered.
COM Port Connections
The PVD includes two powered DTE serial port connections to allow the Fal-
con terminal to communicate with peripherals, such as a PowerScan®hand-
held scanner or a portable printer. +12v is available on pin 9 of each port
connector for power to a peripheral. However, since the Falcon terminal can
Insert connector
with arrow
facing up
For non-mobile applications, an AC power supply adapter is available to power
the PVD. Contact your local distributor or PSC sales for additional information.
You must have the Falcon 4220 PDA attached to the Vehicle Dock and powered
on in order for the COM ports to function.