Hey diad dude, from a support standpoint, the new racks suck and so do the boards. Major comm issues, pc adapter failures and general lock ups. How about something that is actually what we pay for? It seems ridiculous the amount these boards cost, only to have it go out on drivers while in middle of a route. They need a general improvement in the software that is running on the device.
Trust me when I say that your complaints are not falling on deaf ears. Much of this has been known since early on in the life of DIAD 4, and hopefully strides are being made to fix what can be fixed. Here's what I can tell you about the individual things you called out.
The Rack: It is certainly not as well engineered as the previous DIAD rack. It will be difficult/impossible to make any changes to the rack design for DIAD 4. The best thing you can do is to keep them clean and cool. There are also a lot of people that believe that tilting the rack by shimming the bottom away from the wall could have benefits in keeping the DIADs in contact with the charging pins.
The Board: The DIAD 4 is a major change from the DIAD II/III boards of the past. Not only is it all new technology, but it was also a new vendor. Symbol did the best they could to understand UPS's needs and the environment that the boards would be used in. It is apparent now that some QA/engineering things could have gone better in DIAD 4. Symbol continues to work with UPS (at great expense to themselves) to try to make DIAD 4 better. Hopefully lessons learned from DIAD 4 can improve the process for DIAD 5 with whatever vendor is chosen.
Comm Issues: There was a major change to the communications method in 07.06 to address Comm Fails while talking to the DCS. It is believed that a significant reduction in Comm Fails has been achieved. Some Comm Fails are results of things that are outside the control of the DIAD itself. Several issues have been identified and several UPS groups continue to look for and find ways to improve communications.
PC Adapter Failures: These are almost always hardware related. Symbol believes they may have an idea as to why they occur. If this theory proves true, changes will be made in a future relaease of the DIAD/DCS software to try to reduce these.
General Lock Ups: "Lock ups" as described by most UPSers fall into 3 categories:
Battery Failures: There is software that is currently planned for release before the end of peak which will improve battery life.
Locked up in the rack: Several changes were made in 07.06 which have virtually eliminated this problem which plagued 06.05 DIADs.
Locked up on road: These are a topic of much concern and a lot of investigation has been done into the root cause of these issues. A couple theories exist, but nothing has been found to be a "smoking gun" at this point. It is unclear at this point if this problem is more prevalent since the 07.06 release of the DIAD software.
General software improvement: There is currently an effort underway to re-evaluate the DIAD software interface and possibly update it with a more user-friendly interface. I don't expect this to actually see release for several years.