Sm-7022

Transcript

IUNION SWITCH & SIGNALI~ A member of the ANSALDO Group 5800 Corporate Drive, Pittsburgh, PA 15237 SERVICE MANUAL 7022 Delivery/Acceptance, Operation and Field Maintenance MODEL 6632 BATTERY ANALYZER Formerly Dynamic Sciences Limited Document Reference 176-0005-00 November, 1990 A-2/93-2994-1 COPYRIGHT 1993. UNION SWITCH & SIGNAL INC. PRINTED IN USA ANSALDO Trasporti NOTICE Effective July, 1992, this document became the property of Union Switch & Signal Inc. All references to "Dynamic Sciences Limited" and "DSL" apply to Union Switch & Signal Inc. For service on this Union Switch & Signal product, please contact: Union Switch & Signal Inc. The Service Shop 645 Russell St. Batesburg, SC 29006 Toll-Free Phone: 1-800-652-7276 Fax: 803-532-2940 This page left blank intentionally. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 2 of 95 90-Nov-12 PROPRIETARY CONFIDENTIAL INFORMATION This document contains commercial and technical data and designs which are the exclusive property of DSL Dynamic Sciences Limited (DSL) and may contain proprietary information of others, which shall not be used, copied or disclosed in any way to any third party without the prior written consent of the Manager of Contracts of DSL. The recipient of this document, by its retention and use, agrees to maintain it in confidence using the same safeguards as it uses to protect its own confidential information. PATENT INFORMATION Patents are issued on the equipment described in this manual. In the USA, the following patent is issued: Rechargeable Battery, Patent 4,554,221 In Canada, the following patent is issued: Rechargeable Battery, Patent 1,230,653 REGISTERED TRADEMARK DIGITAIR is a registered trademark of DSL Dynamic Sciences Limited (United states Trademark Registration No. 1,293,9961 Canadian Trademark Registration No. 296,425). DIGITAIR is also a registered trademark of DSL in Australia, Germany, France, Great Britain, and Italy. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 3 of 95 90-Nov-12 PREFACE INTENT OF MANUAL: The intent of this document is to assist in repair and service. Service should be attempted by qualified service personnel only if the manual is clearly understood. FURTHER SUPPORT: Questions regarding the manual should be directed to: Marketing Services Department DSL DYNAMIC SCIENCES LIMITED 359 Ste Croix Blvd. st. Laurent, Quebec Canada H4N 2L3 Telephone: Fax: Telex: (514) 744-5571 (514) 744-0053 05-825803 Servicing is available from DSL Headquarters at the address given above and from the following DSL Service Offices: DSL Vancouver 2820 Production Way Burnaby, B.C. Canada V5A 4T6 Telephone: From u.s: Fax: Telex: (604) 444-4122 (800) 663-8667 (604) 444-4923 04-352848 Ver DSL Hershey 1421 Fishburn Road Hershey, PA. USA 17033 Telephone: From U .s.: Fax: (717) 533-4618 (800) 544-8879 (717) 533-4468 Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 4 of 95 90-Nov-12 WARRANTY (a) Seller's liability in respect of any defect in or failure of the Products supplied hereunder, or for any loss, damage or injury attributable thereto, is limited to making good by repair or replacement, at Seller's discretion, defects which under proper use, care and maintenance, appear therein and arise solely from defective design, materials or workmanship, within a period of twelve (12) months from delivery, PROVIDED ALWAYS THAT: (i) Buyer advises Seller of any such defect or failure within thirty (30) days of its occurrence; and (ii) Buyer obtains Seller's authorization to return, at Buyer's expense, the defective Product or part, in the following way; upon receipt by Seller of the serial number and proper identification of the defective Product, Seller shall issue to Buyer a return authorization number which must appear on labels and documents accompanying the returned Product. A full description of the fault must also accompany each return. (b) Seller shall return the repaired unit or a replacement thereof prepaid to Buyer. (c) Repair, attempted repair or alteration, by other than Seller or its authorized representative, without prior authorization in writing by Seller, or alteration or effacement of any part of Seller's nameplate or marking affixed to a Product supplied by Seller, shall void this Warranty. (d) Products not identified by Seller's nameplate are expressly excluded from this Warranty. However, Seller will pass on to Buyer the warranties, received from its suppliers, if any and to the extent it is permitted to do so, but only so far as to not impose on Seller a liability greater than that imposed on Seller by this Warranty. (e) No warranty is given in respect of any consumable items. (f) NO WARRANTIES, WHETHER STATUTORY, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE, OTHER THAN THOSE EXPRESSED IN THIS ARTICLE SHALL APPLY TO THE PRODUCT OR SERVICE AND, IN ANY EVENT, SELLER SHALL NOT BE LIABLE TO BUYER OR ANY OTHER PERSON FOR ANY DAMAGE, INJURY OR LOSS, INCLUDING WITHOUT BEING LIMITATIVE, LOSS OF USE, REVENUE OR PROFIT, OR ANY OTHER ECONOMIC LOSSES, OR FOR ANY DIRECT OR INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 5 of 95 90-Nov-12 CAUTION o The Model 6632 Analyzer is intended for DSL DIGITAIR batteries only. Attempts to analyze other batteries may damage the batteries and/or the Analyzer. o Analyze batteries only ihen the empergture of the ba teries is between 10 c and 30 c (50 F and 86 F). Temperatures outside this range may affect battery performance. Always allow a hot battery to cool down before recharging or analysis. CHARGING BATTERIES THAT ARE TOO HOT OR TOO COLD MAY BE HAZARDOUS. 5 5 o Do not cover or restrict air circulation around the Analyzer. o To ensure good electrical connections, clean the battery contacts before servicing. o Only qualified technicians who thoroughly understand this manual should open the Analyzer or Display Unit or attempt to service them. Always disconnect power before opening case. o Do not expose the liquid crystal display (LCD) to prolonged direct sunlight. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 6 of 95 90-Nov-12 TABLE OF CONTENTS SECTION TITLE 1. PURPOSE OF THE ANALYZER 2. 2.1 2.2 SPECIFICATIONS Model 6632 Battery Analyzer Model 6633 Display Unit (optional) 11 11 13 3. 3.1 3.2 3.3 3.4 DESCRIPTION OF THE EQUIPMENT Overview Model 6632 Analyzer Model 6633 Display Unit Options 15 15 15 16 16 4. 4.1 4.2 4.3 4.4 4.5 ON RECEIVING AN ANALYZER General Packaging Receiving Procedure General Test Operational Tests 17 17 17 17 17 17 5. 5.1 5.2 5.3 5.4 5.5 FUNCTIONAL DESCRIPTION Programs Prime Charge Auto Standby Feature 21 21 21 21 23 24 6. 6.1 6.2 6.3 6.4 6.5 6.6 OPERATION General Power-Up Target Selector Switch Analyzing Batteries Evaluating Batteries Fault Codes 27 27 27 28 29 30 30 7. 7.1 7.2 7.3 SELECTING THE APPROPRIATE PROGRAM Preparing New Batteries Batteries in Regular Use Maintenance and Service of Batteries 33 33 35 36 8. 8.1 8.2 8.3 8.4 8.5 STATUS INDICATORS Overview Lamps on the Analyzer Liquid Crystal Display (LCD) Audible Indicators Summary Tables of Indicators 39 39 39 39 42 42 PAGE 9 Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 7 of 95 90-Nov-12 SECTION TITLE PAGE 9. 9.1 9.2 9.3 9.4 9.5 9.6 FAULT CODES General Conditional Faults Battery Voltage Faults Timing Faults Hot Battery Corrected Faults 45 45 45 45 47 47 48 10. 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 THEORY OF OPERATION General Power Supply Auxiliary Circuits Logic Control Section Battery station Drivers Model 6633 Display Unit Auxiliary Jack Factory Jumper 49 49 49 49 50 54 56 57 58 11. 11.1 11.2 11. 3 11.4 11.5 11.6 SELECTION OF COMPONENTS General Fast Charge Circuit Trickle Charge Circuit Discharge Current Reverse Load Circuit Recondition Circuit 59 59 59 59 59 59 59 12. 12.1 12.2 12.3 SERVICING - GENERAL PRECAUTIONS & PROCEDURES Service Procedures Firmware Update Electrostatic Precautions 61 61 61 61 13. 13.1 13.2 13.3 13.4 CALIBRATION PROCEDURE Equipment Required Voltage Regulator Calibration v-sense Calibration Discharge Current Adjustment 63 63 63 63 63 14. TROUBLESHOOTING 65 Appendices A. B. c. D. STATUS MESSAGES AND CODES GLOSSARY OF TERMS PARTS LIST DRAWINGS 69 73 75 85 Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 8 of 95 90-Nov-12 1. PURPOSE OF THE MODEL 6632 ANALYZER The Model 6632 Analyzer, shown at the top of the following page, is intended to assist in the maintenance of DIGITAIR batteries as used in DSL DIGITAIR systems. The Analyzer can diagnose, recharge, exercise, or recondition up to four batteries at once. The Analyzer will: o o o o prepare new batteries for initial use; recondition weak batteries; charge batteries; and ensure that all serviceable batteries achieve a capacity at least equal to a preselected minimum. Optionally, the Analyzer may be equipped with a Model 6633 Display Unit, shown at the bottom of the following page. The Display Unit provides more detailed information than does the Analyzer by itself. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 9 of 95 90-Nov-12 Model 6632 Battery Analyzer BATIERY STATION NUMBER 2 3 4 3 4 BATIERY STATION SELECT • 6633 DISPLAY UNIT Model 6633 Display Unit Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 10 of 95 90-Nov-12 2. SPECIFICATIONS Note: Specifications notice. 2.1 subject are to change without Model 6632 Battery Analyzer Power Requirement: 115VAC +/-15%, 60 Hz. International alternatives available on request Dimensions (WxDxH): 240mm x 250mm x 100mm (9.5"x10"x4") Weight: 4.5 kg (10 lb) approximately Battery Voltage: 12.5V cell) Battery Type: DIGITAIR Nickel Cadmium (NiCad) Battery capacity: 4 Ampere-hour (Ah) nominal Target Selector: Adjustable to 60%, 70%, 80%, 90%, or 100% of manufacturer's rated capacity (100% corresponds to 4 Ah) Program Selector: Selects 1 of 3 programs independently for each station: Audible Signals: Visible Signals (lamps): Nominal (10 cells at 1.25 V per o PRIME: Applies successive discharge/charge cycles until peak capacity is reached. o CHARGE: Charges battery; then maintains capacity with trickle charge. o AUTO: Exercises battery at least once. If selected Target Capacity is not met, Recondition is applied automatically. Acknowledge battery connected, service complete, battery short, and reverse polarity. o o All lamps consist of Light Emitting Diodes (LEDs), and are located on the front panel. "RUN" lamp on steady: Battery being serviced. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 11 of 95 90-Nov-12 o o o "READY" lamp on steady: Program completed, battery meets or exceeds target capacity. "FAIL" lamp on steady: Program completed, battery failed to meet target capacity. "FAIL" lamp flashing: Battery voltage incorrect. Thermal Protection: Thermal sensor for each station to protect battery from temperature extremes. Suspends operation when battery case temperature exceeds safe limit. Resumes automatically when temperature returns to normal. Fuses and Circuit Breakers: > Primary breaker: o located on right side of unit o 2 Ampere > Control fuse: o one fuse on main circuit board o GMA by BUSS 1.6A; 5 x 20 mm Logic Voltage Levels: > Logic control o > Analog control o Charging & Discharging > Fast Charge o Rate > Fast Charge o current > > > > Trickle Charge Current Discharge Current Reverse Load Current Recondition Current +5.12V 5V) +8.00V 8V) (hereinafter referred to as (hereinafter referred to as Currents (per station): 0.33 (A/Ah) 1.33A Nominal, unregulated (i.e., Fast Charge Rate x Nominal Battery Capacity per hour) 235mA Nominal, unregulated 1.33A Regulated Pulsed, DC Average is 160mA nominal Pulsed, DC Average is 200mA nominal Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 12 of 95 90-Nov-12 2.2 Model 6633 Display Unit (optional) Display (LCD): BO-character alphanumeric with multiple display formats: o Global Display Mode indicates status and average cell voltage of all batteries simultaneously. o Detailed Display Mode shows individual battery capacities, average cell voltage (digital form), and Fault Codes. Codes are explained by brief help messages on user command. Display Keys: Four, one per Station. Selects display format and requests help messages. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 13 of 95 90-Nov-12 This page left blank intentionally. Copyright 1990 OSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 14 of 95 90-Nov-12 3• DESCRIPTION OF THE EQUIPMENT 3.1 Overview The Model 6632 Analyzer is a self-contained unit and contains enough indicators, both visual and audible, to accommodate the needs of many users. Optionally, the Model 6633 Display Unit may be added. This consists of an SO-character alphanumeric liquid crystal display (LCD) unit which provides more detailed information. 3.2 Model 6632 Analyzer This main unit can handle up to four (4) batteries at once, each of which may be serviced independently of the others. Apart from the On/Off switch, located on the right side of the unit, all controls and displays are on the front panel (illustrated in Figure 3-1). = O6632 BATTERY ANALYZERO RUN--COlD8ATl£RYFFUS19m--RUN O . . -M..NOO READY-CHARGEONLYff'FLA911NG-READY O TARGET SELECTOR (1) READY-CHARGEONLYFFUS19m-READY G (}) RUN--COLDIIATTERYlf'FLASHINO--RUN P<))'(_l§R o FAIL--VOLTAGEFAULTIFFLASIUHG--fAIL o' CHARGE PRIME AUTO L_ __J o o· CHARGE PRIME AUTO L_ __J (%) O fAIL--VOLTAGEFAULTFFLA911NG--fAtl O 600100 PR~o~O 70 80 90 CHARGE PRIMc_o~O CHARGE Figure 3-1 Analyzer Front Panel At the extreme left of the front panel is the POWER ON lamp (amber) and in the centre of the panel is the rotary Target Selector switch used to select the minimum target capacity for batteries being serviced (60, 70, 80, 90, or 100% of the nominal 4 Ampere-hour capacity). All other switches and lamps are duplicated for each of the four battery stations. For each station there are: o o o o RUN lamp (yellow); READY lamp (green); FAIL lamp (red); and Three-position Program Selection Switch (PRIME/CHARGE/AUTO). Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 15 of 95 90-Nov-12 3.3 Model 6633 Display Unit The Model 6633 Display Unit is a small case with a cable. This cable plugs into a socket on the side of the Analyzer. The case contains a Liquid Crystal Display (LCD) and four Display Keys, one corresponding to each of the four battery stations. 3.4 Options Both the Unit are lows: Model 6632 Analyzer and the Model 6633 Display offered by DSL without options except as fol- o The standard Analyzer is intended to use 115 VAC, 60 Hz power. Alternate configurations are available on request for international use. o The Display Unit itself is an option. The Analyzer will work with or without the Display Unit. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 16 of 95 90-Nov-12 4. ON RECEIVING AN ANALYZER 4.1 General This chapter covers inspection, receiving, and check out of an Analyzer. 4.2 Packaging The box should contain: o o o 4.3 Analyzer with integral power cable; User Guide; and If ordered, Display Unit with integral cable. Receiving Procedure Before opening the box, check for, and record, any damage to the outside of the box. Remove contents of box; check for, and record, any damage. If the unit is damaged, the shipper should be notified immediately. Both packing material and contents must be kept available for inspection by the shipper's claim agent. Failure to do so may result in denial of liability for damage by the shipper. 4.4 General Test If you have the Display Unit option, plug the Display Unit cable into the Analyzer before turning power on. Plug the Analyzer power cable into an appropriate outlet, and turn on the power using the switch on the right side. The Analyzer should beep once and all of the indicator panel lights should flash. The amber POWER ON lamp should stay illuminated. If the lamps were missed, turn the power off and on again. 4.5 Operational Tests To verify that the Analyzer performs as specified and recognizes battery conditions, the following procedures should be followed: 4.5.1 Functional Test No. 1 Refer to Figure 4-1. Set the program selector switch for each station to PRIME. This setting is used to prepare new or stored batteries and uses all sections of the Analyzer circuitry. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 17 of 95 90-Nov-12 Set the TARGET SELECTOR Switch to 90%. This establishes a target of 3.6 Ah, 90% of the DIGITAIR battery's rated capacity. Install a new battery, or one known to be in good condition, in each of the stations. The yellow RUN lamp for each station will come on. If installed, the Display Unit will indicate either Discharge or Charge for each station. 1 ''6632 BATIERY ANALYZER ·OI /RUN--COLOBATIERYFFLA---RUN....G)"DBL ..................... 'I,, G) RUN--COl.OBATIERYIFFLASHING--RUN (])PO~R"•' ,,._ HOTl:~..NG READY-CHARGE ONLY IF FLASHING-READY Gl (]) FAIL--VOLTAGE FAULT IF FLASHING-- FAIL CHARGE PRIME AUTO ,C\ L.'e.} _J TARGET SELECTOR Q) (%) CHARGE PRIME AUTO €)• _J L.. Program Selection SW 'J...' O ~a·· 't\ o, o FAIL--VOLTAGEFAULTFFLASHING--fAIL O U> READY-CHARGEONI.YFFLASHl«;-READY CHARGE P R ~ AUTO CHARGE PRIME AUTO _"eJ_J L.D_J A Battery Target Capacity Selection SW Figure 4-1 Test No. 1 Settings The Analyzer will discharge and charge the batteries until the difference in capacity between successive discharges drops below 5%. At this point the process is terminated and a pass/fail decision is made. Each station functions independently and they will therefore not all terminate at the same time. Having started with four good batteries, each station should terminate with a steady green READY lamp, and with the Display Unit showing that each battery has "passed". Remove the four good batteries. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 18 of 95 90-Nov-12 4.5.2 Functional Test No. 2 This procedure will take a considerable amount of time (as much as 12 hours) depending on the condition of the batteries used. Refer to Figure 4-2. Set the Program Selection Switches to PRIME. Set the 5-position TARGET SELECTOR Switch located on the front panel to 100% capacity. Place four batteries of known low capacity on the Analyzer. The yellow RUN lamp for each position will come on. If a Display Unit is installed, it will display the status of each station. All four stations should be reporting DISCHARGE. Leave the unit to charge and discharge the four batteries until all terminate. For this test with batteries known to be below rated capacity, each position should terminate on "FAIL" indicated by a steady red FAIL lamp. The Display Unit, if present, will indicate the capacity of each battery and one or more error codes. (}) RUN--COlOBATTERYIFFUSlftNG--RUN PO"'l§R IIOT~~NG READV-CHARGEONLYIFFUSlftNG-READY (i) 0 6632 BATTERY ANALYZERO G> FAIL--VOLTAGEFAULTIFFLASHING--FAIL~O~· L- o' __. CHARGE PRIME AUTO · L- o· __. CHARG~ PRIME AUTO TARGET SELECTOR (%) 70 80 90 60~100 iv RUN--COlDBATTERYIFR.ASNNG--RUN G> • • (}) READV-CHARGEOIILYIFFUSlftNG-READY (}) Q> FAIL--VOt.TAGEFAULTIFFLASHING--fAIL O CHARGE PRIME ' AUTO L-o__. CHARGE PRIME ' AUTO L-o__. Battery Target Capacity Selection SW Program Selection SW (one per station) Indication After Test (one per station) Figure 4-2 Test No. 2 Settings Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 19 of 95 90-Nov-12 This page left blank intentionally. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 20 of 95 90-Nov-12 5. FUNCTIONAL DESCRIPTION 5.1 Programs The selector switch for each station selects one of three programs (PRIME, CHARGE, or AUTO). These programs are described in the following sections. At the conclusion of any of the three programs, the STANDBY feature is invoked; it is described in section 5.5. The four stations may be programmed independently. 5.2 PRIME The PRIME program provides the important step of preparing a new battery for field use. The Analyzer repeatedly exercises the battery until peak performance is reached. New or stored batteries often take several cycles to reach maximum capacity. The battery first discharges to 10 volts (1 volt per cell) and then recharges. An additional discharge-charge cycle is applied, giving a second capacity measurement. If a 5 percent improvement over the previous capacity reading is detected, a further charge-discharge is applied; on a difference of less than 5%, a final charge is applied and the program is completed. If the final capacity meets or exceeds the target, the READY lamp comes on, otherwise FAIL is shown. When ready, the battery switches to trickle charge. Repeating the program after the battery has been on trickle charge for several hours can further improve the capacity. Note: A battery with no charge completes the discharge immediately and proceeds to charge. first Typical Applications: o Prepare new batteries for field use; o Condition batteries that have been in storage; and o Verify battery condition to support warranty claim. 5.3 CHARGE The CHARGE program fast charges the battery to full capacity, then switches to trickle charge. In this mode, the Model 6632 Analyzer behaves identically to the Model 6629 Charger. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 21 of 95 90-Nov-12 A fully charged condition is detected by the Negative Slope method. Poorly matched cells that do not produce an adequate Negative Slope are timed out by the Peak Voltage Timer. The combination of these two methods provides an accurate and safe means by which to terminate the fast charge. Thermal sensing to override the system on battery temperature extremes (cold or hot) is included for each battery position. The Analyzer recognizes a partially or fully charged battery and shortens the charge time accordingly. A shorter than average charging time will also occur on batteries that have low capacity due to "memory", age, or other deficiencies. To improve the charge characteristics, the Model 6632 Analyzer employs the Reverse Load charge method. This method achieves a cooler and more effective charge than with conventional chargers. In addition, the "memory" phenomenon is reduced since the battery is stimulated while charging. This method is used in all three programs. CAUTION Do not charge batteries below 10°c (500F) or above 44°c (111°F). The built-in thermal sensors should inhibit charging outside this range. The CHARGE program produces satisfactory results when used for 2 to 3 months. Within that time, the performance degradation due to "memory" (dendrite formation) can be reversed easily. If maintenance is omitted for longer periods, the dendrite inside the cells becomes difficult to dissolve and the charge/discharge cycle (the "Exercise" cycle) of the CHARGE program has little effect. Usually, the AUTO program can restore batteries that have been incurring "memory" for up to a year. Typical Applications: o Doubles as convenient fast charger; o Performs quick diagnostic tests on batteries with voltage problems; and o Stimulates battery while on fast charge or trickle charge. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 22 of 95 90-Nov-12 5.4 AUTO The AUTO program is recommended for routine battery maintenance. Good batteries are exercised to retain optimum performance, while those unable to reach the target capacity are rejuvenated automatically. This program is effective in restoring batteries that have been weakened by "memory". The battery is first discharged to 1 Volt per cell (10 Volts per battery) to measure the residual capacity. If this capacity meets or exceeds the target, a final charge is applied and the READY lamp comes on when the program is completed. For instance, if the target capacity is set to 90% and the residual capacity is 92%, the Analyzer simply applies the final charge. Typical program time is 2 to 3 hours. If the residual capacity is below target, the battery is fully recharged and a second discharge is applied. The resulting "true" capacity is compared with the target setting. If this capacity meets or exceeds the target, the program concludes with a final charge, otherwise "Recondition" is applied. "Recondition" is a controlled deep discharge that effectively removes "memory". At the end of a "Recondition" cycle, the battery goes into a brief (approximately 15 minutes) neutralizing period. A full recharge follows and the battery is discharged once more to measure the improved capacity. Depending on the condition of the battery, the AUTO program may take several hours to complete. This can be done conveniently overnight. The Recondition cycle of the AUTO program often restores the battery to full rated capacity. Typical results of Recondition versus Exercise cycles of the AUTO program are illustrated in Figure 5-1 below. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 23 of 95 90-Nov-12 TYPICAL TEST RESULTS 'lb of bollery copacily 120 Battery A improved adequately with Exercise; batteries B, c & D required Recondition. 110 100 90 80 70 60 so 40 30 20 10 ., " NOTE: ~-~- * 0 - -......~ - - ~ . . - - , . ~.......--i..--.---..,.... 4 S 6 7 8 2 3 Number ol cycles - Exercise discharges the battery to 1V/cel l * Recondition consists of a deep discharge below 1V/cell. - - - -· Exercise -.Recondiliomng Figure 5-1 Batteries A, B, and C in Figure 5-1 had incurred "memory". Only Battery A responded well to Exercise. This response is typical of a battery that had been in service for only a few months or was exercised periodically. Batteries B and C required "Recondition" to recover full performance. After the reconditioning, and six months of field use, the batteries still had excellent capacity. Typical Applications: o Restores batteries affected by "memory"; o Eliminates poorly performing batteries; and o Verifies adequate capacity reserve for typical field use. NOTES: 5.5 o Batteries with voltage errors (shorted cells) or high leakage cannot be corrected with "Recondition". o High leakage batteries will have very short shelf life. See section 6.4 below, "Analyzing Batteries", for shelf life test. STANDBY Feature The STANDBY feature is automatically implemented at the end of all three programs. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 24 of 95 90-Nov-12 A NiCad battery should not be left on trickle charge for prolonged periods, as degradation due to "memory" occurs. On the other hand, a fully charged battery placed on the shelf is subject to significant self-discharge. Approximately 10% of the battery's charge is lost in the initial 24 hours after charge, after which the rate of selfdischarge tapers to about 10% per month. At higher storage temperatures, and in the case of older batteries, this rate is considerably higher. These two characteristics make it difficult to provide fully charged NiCad batteries on demand. The STANDBY feature solves this problem. A battery left on trickle charge receives an automatic discharge-charge cycle every 30 days. This regular exercise keeps the battery in peak working condition. To maximize operational readiness, only one battery per Analyzer is placed on the scheduled discharge/charge cycle at any one time. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 25 of 95 90-Nov-12 This page left blank intentionally. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 26 of 95 90-Nov-12 6. OPERATION 6.1 General The Model 6632 Analyzer is user-friendly and can be operated with confidence by non-technical staff. Defective batteries can be safely analyzed without the battery or the Analyzer being damaged. To fully utilize the many features of the Model 6632 Analyzer, it is advised that the following instructions be read carefully. NOTE: In the following material it is assumed that the Display Unit is fitted to the Analyzer. If no Display Unit is fitted, ignore the comments about displayed information. 6.2 Power-Up Connect the Analyzer to the correct line voltage as indicated on the instrument label. If the Model 6633 Display Unit is used, ensure that it is connected before power is applied. Turn on the on/off switch located on the right side of the unit. After a short start-up routine, the display message reads: DIAGNOSTIC OK. The TARGET SELECTOR switch setting is shown briefly, and then the display reverts to the Global Display. Figure 6-1 demonstrates this sequence. The Analyzer will beep once and all of the indicator lamps will flash. The amber POWER ON lamp on the front panel will stay illuminated. To review the display sequence again, turn the power off and on again. If the Analyzer is powered up with at least one battery connected, the Analyzer commences service after the initial start-up sequence. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 27 of 95 90-Nov-12 BATTERY STATION NUMBER 2 STATUS © C2000 3 4 1988 CADEX ELECTRONICS DIAGNOSTICS OK Irr.= VESION 4.XX E:1L.,....~~~,...,-~~~~~--:-~~-;---,-~~--~ll-::::T' VOLTAGE t SHORT t ZONE 1 END Of RECONDlllON t ZONE 2 SOFT END OF NOMINAL DISCHARGE VOLTAGE BATTERY STATION NUMBER 2 STATUS L-...J 4 CAPACITY 80% Irr.= 1234 VOLTAGE 3 t TARGET SELECTOR Setting t I ..,_~~~,...,....~~~~~~~~~--.-~~~~....---- SHORT ZONE 1 END OF RECONDlllON ZONE 2 SOFT END OF NOMINAL DISCHARGE VOLTAGE BATTERY STATION NUMBER STATUS 1 2 3 4 EMPTY EMPTY EMPTY EMPTY Irr.= 1234 L-...J VOLTAGE SHORT t ZONE 1 END OF RECONDlllON t ZONE 2 I Global Display with no batteries installed SOFT END OF NOMINAL DISCHARGE VOLTAGE Figure 6-1 Power Up Display Sequence 6.3 TARGET SELECTOR Switch The TARGET SELECTOR switch enables the user to set a minimum acceptable battery capacity. This capacity is indicated as a percentage of the rated capacity for DIGITAIR batteries, where 100% rated capacity is 4.0 Ah. When in AUTO mode, this feature assures that all batteries have at least the selected minimum capacity. Batteries that cannot obtain the target after a full charge are reconditioned automatically. Note that many batteries will have been charged to a level greater than the (minimum) target. A common Target Capacity is 80%. Higher settings should be used where reliability and adequate reserve are critical. For less stringent applications, a lower target may be used. A suitable target can be established by measuring the residual capacity of several random batteries returned from the field. When in PRIME or AUTO mode, the battery Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 28 of 95 90-Nov-12 is first discharged and its residual capacity measured. This can only be indicated if the Model 6633 Display Unit is used. A recharge and second discharge follow, resulting in a "true" capacity reading. The residual capacity is displayed first, then the true capacity as shown in Figure 6-2. If, for example, the residual capacity is 20% and the true capacity 80%, the capacity consumed is 60%. To assure reliable battery service, the residual capacity of all batteries should be at least 20%. If this cannot be obtained consistently, the TARGET SELECTOR setting should be increased. Note that a higher target will yield fewer acceptable batteries. Battery Status Position Residual Capacity BATTERY STATION NUMBER 2 (CAPACITY OK) r;:: 1234 VO~E 1.43 I ~HORT V CELL I~ END OF RECONDITION Voltage per cell Battery Voltage: ·,ox CAP: CODE: ZONE 1 True Capacity 3 ~ ~ 16, 78, NONE ZONE 2 105% Final Capacity ---t-Battery Status soFT Message I l END OF NOMINAL DISCHARGE VOLTAGE 1.43 V = 14.3 Volts Figure 6-2 Detailed Display at Completion of PRIME or AUTO Program Changing the program selector during service does NOT affect the program in process. To initiate a new program, remove and replace the battery. The TARGET SELECTOR setting can be altered at any time during service. 6.4 Analyzing Batteries Three programs are available: CHARGE, PRIME, and AUTO. See Chapter 5 above for a detailed description of the programs. After a program has been selected, the Analyzer is ready for service. Battery connection is acknowledged with a beep. Program time on PRIME or AUTO varies according to battery condition. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 29 of 95 90-Nov-12 IMPORTANT: It is not possible to obtain an immediate capacity reading simply by inserting a battery. The capacity is determined by discharging the battery at a calibrated current to a voltage equivalent to lV per cell. The elapsed time is measured and displayed as the usable battery capacity. SHELF LIFE: The Analyzer cannot determine the shelf life of a battery unassisted. To measure shelf life, a battery should be PRIMED, the capacity noted, the battery stored for 48 hours, then its remaining capacity remeasured using the PRIME program a second time. The difference at the start of the second priming cycle compared to the end of the earlier priming cycle is the lost capacity. It should not exceed 30%. 6.5 Evaluating Batteries Each battery station is equipped with RUN, READY, and FAIL lamps. on completion of a program, a battery which meets the Target Capacity on PRIME or AUTO is identified by the green READY lamp; one which cannot reach the target shows the red FAIL lamp. A flashing FAIL lamp indicates incorrect battery voltage. A battery meeting the target capacity in CHARGE mode shows a blinking READY. For a convenient summary of the lamp indications and their meanings refer to the tables in section 8.5 below. In addition to the indicator lamps, the Model 6633 Display Unit allows the status of all batteries in service to be observed simultaneously; average cell voltages are also displayed continuously in analog form. Pressing a Display Key gives more details on an individual battery. Several capacity figures may be shown on multi-cycle programs. Average cell voltage and battery Fault Codes (if present) are also displayed. For more information on Fault Codes, refer to Chapter 9 below. 6.6 Fault Codes The optional Display Unit also displays the ''Fault Code" numbers. These numbers are assigned to identify certain battery faults such as mismatched cells, incorrect voltages, soft cells, or wrong battery type. For brief on-line explanations of any codes, press the appropriate Display Key. If several codes are present, each key-press will step through the messages and revert to the Global Display after the last code. See examples in Figures 6-3 and 6-4. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 30 of 95 90-Nov-12 BATTERY STATION NUMBER 2 #l STAiUS I f"""rr: 3 CHARGE Program Selected 4 FAST-CHARGE IN PROGRESS CODE: NONE 1. 34 V/CELL, 1234 L..---1 VOLTAGE t SHORT t ZONE 1 END OF RECONDITION t I ZONE 2 SOFT I END OF NOMINAL .PISCHARGE VOLTAGE BATTERY STATION NUMBER 2 1 4 3 AUTO Program Selected DISCHARGE CYCLE 0% V/CELL, CODE: 1. 21 NONE I f"""rr: 1234 STAiUS L---J VOLTAGE t SHORT t ZONE 1 t I ZONE 2 SOFT NOMINAL END OF DISCHARGE VOLTAGE END OF RECONDITION BATTERY STATION NUMBER 2 4 3 DISCHARGE CYCLE 0% V/CELL, 1. 21 CODE: NONE I f"""rr: 1234 STAiUS L__J VOLTAGE t SHORT ZONE 1 t t I ZONE 2 SOFT PRIME Program Selected NOMINAL END OF DISCHARGE VOLTAGE ENO OF RECONDITION Figure 6-3 Detailed Display Examples BATTERY STATION NUMBER 2 3 4 CHARGING CHARGING CHARGING CHARGING STAiUS I rr=;E 1234 Global Display CHARGE Program Selected for all positions ----- ...,...~~~--,-,~-,-~~~~~~~~-.-~~~~---,~-,-1 VOLTAGE SHORT Z9NE 1 ZONE 2 SOFT L__J . t END OF RECONDITION t t I END OF NOMINAL DISCHARGE VOLTAGE Figure 6-4 Global Display Example Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 31 of 95 90-Nov-12 This page left blank intentionally. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 32 of 95 90-Nov-12 7. SELECTING THE APPROPRIATE PROGRAM 7.1 Preparing New Batteries New batteries should be prepared using the PRIME program. o o o Turn on Analyzer. Set Program Selector Switch to PRIME for each station. Set TARGET SELECTOR Switch to 100%. Install battery Analyzer. The yellow beep once. with DSL logo towards the top of the "RUN" lamp will come on and the Analyzer will A new battery should meet the 100% capacity requirement. If installed, the Model 6633 Display Unit will read "DISCHARGE" for the station used. The Detailed Display will read as shown in Figure 7-1. BATTERY STATION. N U V I 1 I STAl\JS I fr;= 123-4V~EI I DISCHARGE 1.21 V /CELL SHORT 1+ 2 CODE: ZONE 1 I ,,3 I 4 0% CYCLE NONE • • I ZONE 2 I SOFT I ENO Of NOMINAL DISCHARGE VOLTAGE END OF RECONDITION 1 I Percent of Capacity Discharged So Far 2 3 4 [gJ [gJ [gJ [gJ BATTERY STATION SELECT DSL 6633 DISPLAY UNIT Figure 7-1 PRIME Program Detailed Display At the end of the PRIME cycle, if the battery has met the selected target capacity, the green READY lamp will come on and the Model 6633 Display Unit will report the measured battery capacity as a percentage of nominal full capacity. See Figure 7-2 for an example after priming batteries in all four stations. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 33 of 95 90-Nov-12 BATTERY STATION NUMBER ,~ STATUS 2 1 CAP: 94% CAP: 1234 t - 4 3 110% CAP: t 105% t CAP: 92% L........J ........~ ~ ~ - - - . - - , - ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ - - , , ~ ~ ~ ~ ~ - - , - ~ - , - , VOLTAGE SHORT ZONE 1 END OF RECONDITION ZONE 2 I SOFT I END OF NOMINAL DISCHARGE VOLTAGE Figure 7-2 PRIME Program Global Display at Program Completion If any battery does not meet the target capacity, the red FAIL lamp will come on and the Display Unit will indicate one or more Fault Codes. By pressing the appropriate Display Key on the Model 6633 Display Unit, detailed information can be obtained for each station. See Figure 7-3. BATTERY STATION NUMBER I 'STA1US I Jr.= 1234 VOillGE I 1 2 I 3 , #3 READY (CAPACITY OK) 1.43 I SHORT ZONE 1 78, 16, t t I I 4 , 105% ' NONE\ I ZONE 2 SOFT True Capacity I END OF NOMINAL DISCHARGE VOLTAGE END OF RECONDITION 1 I Resi dual Capacity CODE: V/CELL, It Ii 2 4 3 [gJ [gJ [gJ [gJ Fina1 Capacity BATTERY STATION SELECT 6633 DISPLAY UNIT Figure 7-3 PRIME Program Detailed Display at Program Completion Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 34 of 95 90-Nov-12 7.2 Batteries in Regular Use During regular use, batteries should be charged for service using the CHARGE program. o Set Program Selector Switch to CHARGE for each station used. The TARGET SELECTOR Switch setting has no impact on the CHARGE program. o Install the battery with the DSL logo toward the top of the Analyzer. The yellow RUN lamp for that station will come on and the Analyzer will beep. The Model 6633 Display Unit will read "CHARGING" at each station used. If the appropriate Display Key will read as shown in Figure 7-4. is pushed, the display BATTERY STATION NUMBER I STATUS I ffr= 1234 ........., VOLTAGE I 1 2 I 3 I I 4 FAST-CHARGE IN PROGRESS CODE: NONE =11=1 1. 34 V/CELL, I SHORT It ZONE 1 END OF RECONDITION 1 t t I I ZONE 2 SOFT I END OF NOMINAL DISCHARGE VOLTAGE 2 3 4 [gJ [gJ [gJ [gJ BATTERY STATION SELECT DBL 6633 DISPLAY UNIT (The battery in position #1 is being fast charged.) Figure 7-4 CHARGE Program Detailed Display Upon successful completion of the charge, the Analyzer will beep three times and the green READY lamp will blink. If the battery cannot be charged, report this via the red FAIL lamp. the Analyzer will Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 35 of 95 90-Nov-12 7.3 Maintenance and Service of Batteries After approximately three months' use, the AUTO program should be used to confirm a battery's capacity and, if needed, to recondition it automatically. Any battery suspected of being of low capacity should also be put through an AUTO cycle. o Set Program Selector Switch to AUTO. o Set the TARGET SELECTOR Switch to the desired minimum capacity. o Install battery Analyzer. with DSL logo toward the top of the The yellow RUN lamp will come on and the Global Display will indicate that a "DISCHARGE" has started as shown in Figure 7-5. BATTERY STATION NUMBER 2 1 3 DISCHARGE DISCHARGE DISCHARGE DISCHARGE ~Arus Im 12~4 \/Of.l'Aqf L,------,,-,--------....-:---....-:---,------;--r' t SHORT t ZONE 1 END OF RECONDl110N t I ZONE 2 SOFT ENO OF NOMINAi. DISCHARGE VOLTAGE Figure 7-5 AUTO Program Global Display at Program Start If the station select button is pressed, the Detailed Display will read as shown in Figure 7-6. BATTERY STATION NUMBER_,, 2 3 4 DISCHARGE CYCLE 0% ifri= 1.21 V/CELL, CODE: NONE STAlUS ..-,.-------,----,--,------,--r 1234..,__ _ _ V~E SHORT t ENO OF RECONDlllON ZONE 1 t t ZONE 2 SOFT I ENO OF NOMINAL DISCHARGE VOLTAGE Figure 7-6 AUTO Program Detailed Display at Program Start Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 36 of 95 90-Nov-12 At the end of the AUTO program cycle, if the battery has met or exceeded the selected target capacity, the green READY lamp will come on. If not, the red FAIL lamp will come on. The Model 6633 Display Unit will indicate the capacity achieved for the station in use and, when the station's Display Key is pushed, the Detailed Display will read as shown in Figure 7-7. BATTERY STATION NUMBER 2 STATUS !Irr= #3 READY 1.43 r - ~~--~-Residual 4 3 (CAPClTY OK) CAP: 16, 78, 105% Final Capacity CODE: V/CELL, Capacity 1234 '--~~~~~~~~~~~~~~~~~--'.--~~---' V~E I SHORT It ZONE 1 END OF RECONDITION I • SOFT I END OF NOMINAL DISCHARGE VOLTAGE True Capacity Figure 7-7 AUTO Program Detailed Display at Completion If the minimum target capacity is not met, the display will report a "FAIL" as shown in Figure 7-8. BATTERY STATION NUMBER s~;I I . FAIL I. 2 3 I I 4 15 1234 ~-~~~~~~~~~~~~~~~~~~~~~~-vo'i:t;:t;E I SHORT J • END OF RECONDITION ZONE 1 • • ZONE 2 I soFT I END OF NOMINAL DISCHARGE VOLTAGE Figure 7-8 AUTO Program Display with FAIL Indication Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 37 of 95 90-Nov-12 This page left blank intentionally. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 38 of 95 90-Nov-12 8 STATUS INDICATORS 8.1 overview The status of the batteries is indicated by the RUN, READY, and FAIL lamps. These give the user a quick overview of whether a battery is being serviced, is ready, or has failed. If fitted, the optional Display Unit provides additional information. 8.2 Lamps on the Analyzer RUN steady: Battery service in progress READY steady: Battery ready; target capacity READY flashing: Battery ready on CHARGE program FAIL steady: Program not met FAIL flashing: Battery voltage corrected. POWER steady: Analyzer operational POWER flashing: Analyzer on hold due to high temperature condition; will resume automatically when temperature within range. meets 8.3 complete listing exceeds completed. Target capacity fault; READY & FAIL flashing: Battery hot; program (CHARGE mode only) For a more Appendix A. or of cannot be terminated lamp indications, see Liquid Crystal Display (LCD) The LCD is the display on the optional Model 6633 Display Unit. The LCD is arranged in multi-frame formats. In Global Display mode, the status of all batteries in service can be observed simultaneously. The first 1:-ine is divided into four fields, one for each battery station. On the second line, the average cell voltage of each battery is displayed in bar graph form. Pressing a Display Key allows the user to access Detailed Display mode for an individual battery. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 39 of 95 90-Nov-12 The following paragraphs explain the most common display messages and how they can be accessed. For additional LCD messages, refer to Appendix A. 8.3.1 Global Display Mode The Global Display is best recognized by the bar graphs on the lower half of the LCD. When inserting a battery, or if the Analyzer is left unattended for one minute or more, the LCD will revert to the Global Display. When battery service is complete, a message in the field may say, for example: CAP:117%. This indicates that the battery is ready and has a final capacity of 117%. Other messages include: DONE, when a battery was charged in CHARGE mode; FAIL 26, indicating that this battery has a voltage problem, or EMPTY, when no battery is present. For other messages, refer to Appendix A. Fault Codes are listed in Chapter 9. The bottom line of the Global Display indicates the average cell voltage of each battery in bar graph form. Four horizontal bars are present when all stations are occupied. The voltage range of the bars is divided into SHORT, ZONE 1, ZONE 2, and SOFT regions. SHORT: If a battery cannot clear the SHORT zone in 2 seconds, the message SHORTED appears and a continuous tone is heard. Remove battery and discard. ZONE 1: Three fault types may occur in this zone: "PARTIAL SHORT", "LOW VOLTAGE", and "DEPRESSED VOLTAGE". Each fault type has a different charge time-out. These faults are noncorrectable. For additional information refer to FAULT CODES ( Chapter 9) • ZONE 2: For a successful charge, a battery must enter and remain in ZONE 2. Full charge is detected by either the Negative Slope method or the Peak Voltage Timer (in the case of mismatched cells). SOFT: A "soft" battery is one that is unable to clamp the charge voltage. The program is terminated; the battery is unserviceable. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 40 of 95 90-Nov-12 8.3.2 Detailed Display An example Detailed Display is shown in Figure 8-1. To view the Detailed Display, press the Display Key for the appropriate battery. The battery status, capacity readings, and Fault Code (if applicable) can then be seen on the Detailed Display. During discharge, battery capacity is measured and the result displayed as a percentage of the rated capacity. When the battery begins to discharge, 11 0% 11 first appears in the center of the top line. This figure increases until the battery voltage has dropped to 1 volt per cell. At that point, the reading freezes and is transferred to the upper right adjacent to the previous capacity reading(s), if present. The Detailed Display provides up to three capacity readings. An example of typical readings is "CAP: 22, 84, 107% 11 • The residual capacity is 22% and is displayed after the initial discharge cycle of the AUTO or PRIME program. The true capacity (fully charged battery) is 84% and is displayed after the first charge cycle. The final capacity is 107% and is displayed at the end of the program after any number of recondition or exercise cycles. If only two capacities are displayed, this indicates that the battery obtained the target capacity on the first charge cycle. Voltage per cell is indicated at the bottom left, Fault Codes in the middle. The battery case temperature is shown in degrees Celsius at the lower right of the display. If a Fault Code is present, the top line of the Detailed Display provides a brief message explaining the nature of the battery deficiency. Pressing the same Display Key again will either revert to the Global Display or indicate additional Fault Codes if there are any. If unattended, the LCD will return to the Global Display after one minute. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 41 of 95 90-Nov-12 ,--~-Residual Capacity Battery Status Program State BATTERY STATION NUMBER 2 #3 STATUS ilrr= READY 1 .4-3 ~~~~~True Capacity 4 3 (CAPACITY OK) 16, V/CELL, 78, 1 05% NONE Final Capacity '--~~~~~~~~~~~~~~~~+-~~~--' 1234 vo'i:.,=;t;E I SHORT It ZONE 1 END OF RECONDITION I t SOFT I END OF NOMINAL DISCHARGE VOLTAGE ~~~- Battery Status Message Figure 8-1 Detailed Display at End of AUTO or PRIME Program 8.4 Audible Indicators The audible indicators are tone signals and will occur with or without the optional Display Unit. The following actions or conditions produce the indicated tones. Battery inserted: Key pressed: READY, successful service: Completion, Code 15: Intermittent Battery: Shorted battery: Wrong polarity: Note: 8.5 Single beep tone acknowledges battery connected. Single beep tone. High pitched triple beep (2400 Hz). Low pitched triple beep (674 Hz). Repetitive beeping sound until battery removed. Continuous tone. Charge is terminated. Wailing sound. Reverse leads and reinsert. Do not leave battery with wrong polarity in Analyzer. Summary Tables of Indicators The following three tables summarize visible indicators relating to: o o o the audible and Battery Capacity Evaluation; Battery Temperature Protection; and Analyzer System Protection. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 42 of 95 90-Nov-12 Table 8-1 Battery Capacity Evaluation CONDITION LEDs NO BATTERY:! Open terminal BATTERY INSERTED: * I I I I I I Battery in service RUN READY FAIL off off off RUN READY FAIL -------On Steady------off SOONDER MOOE COMMENTS silent reset Sta ti on resets when battery removed. single beep active service Beep tone when battery inserted. off BATT READY (CHARGE) Normal battery voltage RUN READY FAIL off -------Blinking-------off triple beep trickl,e charge Target setting not used in CHARGE mode. BATT READY (PRIME or AUTO) Battery meets Target Capacity RUN READY FAIL off -------On Steady------off triple beep trickle charge High pitch* triple beep if READY; low pitch* if FAIL. Battery fails to meet Target Capacity RUN READY FAIL off silent trickle charge If program was, PRIME, try AUTO. REVERSE POLARITY Negative terminal·voltage RUN READY FAIL off off ------on Flashing------ wailing no charge Reverse leads. Do not leave battery unattended. SHORT Zero or very low battery voltage RUN READY FAIL off off ------on Flashing------ continuous sollld no charge Charge terminated after 2 seconds. Discard battery. LO\.I Battery has shorted cell(s) RUN READY FAIL off off ------on Flashing------ silent VOLTAGE SOFT BATTERY Battery voltage rises too high RUN READY FAIL off off -On--Off--On--Off--On- silent INTERMITTENT Unable to clamp battery voltage RUN READY FAIL off off -On--Off--On--Off--On- repeated beeping High pitched is 674 Hz. off -------On Steady------- no charge Partial Short, Low ! c. Manually activate reset by momentarily shorting pin 2 of U2 to ground. If microprocessor resets, problem is in reset circuit. 3. Scrambled LCD Line voltage glitch a. Contact DSL for firmware 14J9rade 4. Short indication with no Battery Faulty Terminal Faulty V-Sense a. Determine which driver is faulty and find V-Sense pin on Interface Jack. NOTE: V-Sense for Station 1 is pin 5 of Auxiliary Jack v-sense for Station 2 is pin 3 of Auxiliary Jack V-Sense for Station 3 is pin 6 of Auxiliary Jack v-sense for Station 4 is pin 4 of Auxiliary Jack b. Check for short in battery leads or receptacle. c. \lith high iqiedance voltmeter, check voltage on battery terminals. Open terminal voltage should be 15V to 25V, depending on battery type. 5. No Charge May indicate Codes 22, 23, 24, 25, 44, Faulty Driver a. Check charge current. If not present, check for 5V on input side of Rx03; check for square wave on pin 1 of Ux01; check for bi as voltage on pin 4 of Ux01; check for pulse activity on pin 2 of Ux01; check pulse activity on Collector of Qx01. (See Table 10-1.) Check Check Check Check for open primary fuse or control fuse. for 5.12V on pin 7 of Auxiliary Jack or on any IC. input and output voltages on 5V and 8V regulators. for overheating of voltage regulators (LM317 on heat sink) and IC's. DRIVER PROBLEMS NOTE: Code 44 is shown if allotted charge time is exceeded due to oversized battery. 6. No Discharge May indicate Code 42 b. If pulse activity on Collector of Qx01, activate charge by momentarily connecting a 1K resistor from Base of Qx02 to Ground. c. Check current-limiting resistors Rx10. Fault Current Regulator NOTE: If capacity exceeds 160%, code 42 is also shown. a. Check discharge current. If not present, check for 5V on input side of Rx21; check bias voltage on pin 3 of Ux02; check reference voltage on pin 2 of Ux02 (should be similar to pin 3 in discharge mode); check voltage on pin 1 of Ux02. c. Check load resistor Rx30, regulator transistor Qx04, and reference resistor Qx29. Table 14-1 Troubleshooting (page 1 of 2) Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 66 of 95 90-Nov-12 SYMPTOM POSSIBLE CAUSE 7. Discharge remains on at all times Hay indicate code 42 Faulty Current Regulator a. Set u,it to calibration Mode. With all modes disabled, connect voltage to battery contacts and observe discharge current. There should be no +V on Rx12, Rx24, and pin 1 of Ux02. b. Pin 2 of Ux02 should indicate positive voltage when not in discharge mode. 8. No Recondition Hay indicate Code 46 Faulty Recondition circuit a. Check recondition current (u,regulated, should be arOll'ld 10X of nominal Ah rating). If not present, check SV on input side of Rx12; check signal on pin 11 of Ux01 (envelope of line voltage on +DC); check pulse activity on pin 13 of Ux01. NOTE: Recondition and Reverse Load Charge circuits are shared. Problems may be related 9. No Reset i.tlen battery removed NOTE: Unit may beep and RUN l ~ may fl ash at 1 sec. intervals DIRECTION b. Check load resistor Rx20 and switching transistor Qx03. Low line voltage C ~ n t leakage Faulty V·Sense circuit a. b. c. d. Check line voltage, IILISt be 90 Exanine leakage in Qx02, Qx03, Check V-Sense circuit. V-Sense Exanine Rx33 (pull-up resistor NOTE: VAC or more. Qx04, and related c ~ t s voltage should be arOU"ld +S.2V for reset) With no battery in, all V-Sense lines should be S .2V (reset mode) Leakage in V-Sense circuit will lower v-sense voltage, simulating a battery and hence initiating charge. V-Sense rises to reset mode, the charge is turned off, and the cycle is repeated. 10. No activity when Battery inserted Faulty battery leads· Faulty V-Sense 11. Battery too warm i.tlen in Ready mode Trickle charge a. Verify whether problem is conman to all Stations. If yes, check reference voltage on pin 4 of Ux01. Should read 0.9V. current too high battery has high If problem is isolated to one Station: self discharge b. Check trickle charge current by placing ammeter in line with battery. The trickle charge current should be about 10X of the nominal Ah rating. NOTE: The teo.,erature of a good battery will increase by about 10C at end of fast-charge. On older batteries, a 15C rise is conman. A Nied cell should never exceed SOC. a. b. c. d. Check for open battery terminals, cables and plug. Examine drop in V-Sense when battery inserted (clamping action); if none: Check for fault in v-sense line. Simulate V-Sense drop by placing 100K from V-Sense pin to ground and and observe. c. Examine charge pulse on battery terminal; should show only partial positive wave (approx. 1/3 towards end before going to zero). If charge pulse is too wide, check pulse shape in Charge Regulator. d. Examine presence of Reverse Load by connecting oscilloscope to battery terminals or Rx10. If missing, check Reverse Load circuit. Table 14-1 Troubleshooting (page 2 of 2) Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 67 of 95 90-Nov-12 This page left blank intentionally. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 68 of 95 90-Nov-12 APPENDIX A STATUS MESSAGES AND CODES · Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 69 of 95 90-Nov-12 Information Codes: Code Disolav Detail Messaae 12: (CELL MISMATCH) (FAST CHARGE TIME-OUT) 44: 46: RECONDITION TIMED OUT 55: (BATTERY HOT) 56: (TEMPERATURE INCREASE) 92: CELL MISMATCH CORRECTED 95: CAPACITY IMPROVED TO TARGET Fail Code 15: 21: 22: 23: 24: 25: 26: 27: 28: 42: 53: 54: Codes: Disolav Detail Messaae TARGET CAPACITY NOT MET REVERSE POLARITY! REMOVE BATTERY! BATTERY SHORTED BATTERY HAS A PARTIAL SHORT LOW BATTERY VOLTAGE BATTERY HAS WEAK CELLS BATTERY HAS SHORTED CELLS TIMEOUT IN ZONE 1 SOFT BATTERY DISCHARGE TIMEOUT - CHECK UNIT 1 TEMPERATURE INCREASE IN ZONE 1 BATTERY HOT IN ZONE 1 General Status Messaaes: Disnlav Detail Messaae CAPACITY FAILED CHARGE CYCLE FIRST CHARGE 2ND CHARGE FINAL CHARGE CHARGE AFTER RECOND. DISCHARGE CYCLE ###X. FIRST DISCHARGE ###X. 2ND DISCHARGE ###X. FINAL DISCHARGE ##If?. FAST-CHARGE DONE FAST-CHARGE IN PROGRESS HOLDING (BATTERY TOO COLD) HOLDING (FULL LOAD) NOT ACTIVE· INSERT A BATTERY READY (CAPACITY OK) READY (RESERVE OK) RECOND I Tl ON ING Global Disolav DONE (12) DONE (44) liaht Pattern XGGGGGGGXGGGGGGG XGGGGGGGXGGGGGGG DONE (55) DONE (56) RGGGGGGGRGGGGGGG XGGGGGGGXGGGGGGG s c H H T T H T - - Global Disnlav FAIL 15 REVERSED! SHORTED! FAIL 23 FAIL 24 FAIL 25 FAIL 26 FAIL 27 FAIL 28 FAIL 42 FAIL 53 FAIL 54 liaht Pattern RRRRRRRRRRRRRRRR RXRXRXRXRXRXRXRX RXRXRXRXRXRXRXRX RXRXRXRXRXRXRXRX RXRXRXRXRXRXRXRX RXRXRXRXRXRXRXRX RXRXRXRXRXRXRXRX RXRXRXRXRXRXRXRX RXRXRXRXRXRXRXRX YXYXYXYXYXYXYXYX RXRXRXRXRXRXRXRX RXRXRXRXRXRXRXRX s c l T c T - Global Disolav FAILED 15 CHARGE CHARGE CHARGE CHARGE CHARGE DISCHARGE DISCHARGE DISCHARGE DISCHARGE DONE CHARGING COLD## DEG C HOLDING EMPTY CAP: ##% CAP: ##% RECOND. Li aht Pattern RRRRRRRRRRRRRRRR yyyyyyyyyyyyyyyy yyyyyyyyyyyyyyyy yyyyyyyyyyyyyyyy yyyyyyyyyyyyyyyy yyyyyyyyyyyyyyyy yyyyyyyyyyyyyyyy yyyyyyyyyyyyyyyy yyyyyyyyyyyyyyyy yyyyyyyyyyyyyyyy XGGGGGGGXGGGGGGG s c w c T T T - H XYYYYYYYXYYYYYYY GGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGG yyyyyyyyyyyyyyyy - T F F F F T D D D D T F T - H H T T R Descriotion Battery OK, but no slope Battery OK, but total timeout Not able to discharge fully Battery OK, but over teq>erature Battery OK, but t~rature increasing Charge curve i nproved with eye ling Batterv caoacitv iRDroved after =clina Descriotion capacity did not meet target Battery polarity is reversed Battery i's shorted Low voltage, 1 C'*min low voltage, 10 C*min low voltage, 60 C*min Slope detect at low voltage No slope in Fail region Soft battery Not able to discharge battery fully T~rature rise at low voltage Batterv hot at low vol ta"" Descriotion capacity did not meet target Charge cycle of PRIME Charge of AUTO Charge of AUTO Charge of AUTO Battery recovering after RECONDITION Discharge cycle of PRIME Discharge of AUTO Discharge of AUTO Discharge of AUTO Done (after fast-charge-only) Fast-charge only Battery cold (waiting to warm 14)) Charger full-load limit active No battery installed in unit Capacity met selected target Reserve capacity exceeded target Recondition cvcle is in oroaress Legend on following page. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 70 of 95 90-Nov-12 Legend: X: G: R: Y: S: C: Lamp off Green lamp on Red lamp on Yellow lamp on {Sound) H = High-pitched triple beep, L = Low-pitched triple beep, c = Continuous, W = Warble. {Charge Mode) T=Trickle, F=Fast, D=Discharge, R=Recondition e.g.: RXRXRXRXRXRXRXRX XGGGGGGGXGGGGGGG means that red lamp is blinking means that green lamp is flashing Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 71 of 95 90-Nov-12 This page left blank intentionally. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 72 of 95 90-Nov-12 APPENDIX B GLOSSARY OF TERMS This glossary addresses terms relating to Nickel-Cadmium batteries and to the Analyzer. rechargeable Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 73 of 95 90-Nov-12 Residual Capacity: The amount of charge after field use. left Full Capacity: The amount battery. on a fully recharged Note: of charge in the battery The Capacity is derived by discharging the battery at the manufacturer's specified mAh rate to 1.00 volt per cell. The elapsed time is recorded and displayed as the usable battery capacity. Charging voltage of a sealed NiCad battery reaches a peak and then declines when the battery reaches full charge. This voltage is used to terminate the fast decline charge. Negative Slope: Peak Voltage Timer: On a battery with mismatched cells, each cell reaches full charge at different times, counteracting the typical voltage drop. The result is a flat voltage curve that does not indicate full charge reliably. The Peak Voltage Timer limits the duration of the voltage plateau to terminate the charge safely. (Code 12 is shown on Display Unit if fitted). Memory: Term commonly used to refer to Voltage Depression. "Memory" is a dendrite deposit on the cell plates that causes an increase of the internal resistance of the cell. If not corrected by periodic cycling, "memory" can destroy the battery prematurely. Exercise: Battery is first discharged to lV per cell, recharged and a second discharge-charge cycle applied. Fast Charge: Recharges typical battery Uses 800 ma charge current. Trickle Charge: Float charge to maintain battery in operational readiness. Typical trickle charge is 10% of fast charge current. Recondition: Battery is first deep discharged below 1 V per cell, re-charged, and a second discharge-charge cycle applied. in 100 minutes. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 74 of 95 90-Nov-12 APPENDIX C PARTS LIST This appendix contains: o Conventions for Numbering and Abbreviations Used o Parts List for Model 6632 Battery Analyzer and for Model 6633 Display Unit. This is in six parts as follows: > 1 > 2 > 3 > 4 of of of of 6 6 6 6 > 5 of 6 > 6 of 6 6632 6632 6632 6632 Analyzer Analyzer Analyzer Analyzer 6632 Analyzer 6633 Display Unit- Overall Main Board Universal Analyzer Board Charge/Discharge Power Resistor Board LED Board Complete Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 75 of 95 90-Nov-12 CONVENTIONS The following follows. Rl RxOl RxOl-1 R2A'"D Pl-1"'5 R3A"' R3"'B"' R3"'C J9xl J91x R4 (Raised) R5,7,9,x03 > R12,15,18 > lA -> 3A SIDE?? conventions are used in the Parts''List which - Capital letter(s) indicate component group - Numbers indicate location - Lower case x substitutes numbers 1,2,3,4 e.g. RxOl - R101,R201,R301,R401 - Dash 1 (-1) specifies alternate location for RxOl Note: Only one location is populated - A"'D: A through Din parallel (4 resistors on R2) - Plug 1, contacts 1 through 5 -}Resistors of different value in parallel }(3 resistors on R3) } - J9xl = J911,J921,J931,J941 J91x = J911,J912,J913,J914 Comment Same component entered on several lines AY, ASSY RES GND C-SEL S-SEL UNIV STN PWR EXT, P-EXT CH OCH COM - Connect lA to 3A - Mount to solder/component side depending finished product - 90 Degree - Lower case u is used for micro e.g. uF - Assembly - Resistor - Ground - Common Selectable - Station Selectable - Universal - Station - Power extension - Charge - Discharge - Common SP SS ALU - Steel, plated - Stainless Steel - Aluminum RD BD - Round (Head) Binding (Head) Pan (Head) Head Phillips Drive Slot Drive - Printed Circuit Board Clear Board Transformer 90* u PAN HD PH SLOT, SL PCB, PC Board CLR BRO TRAFO Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 76 of 95 90-Nov-12 on Parts List. part 1 of 6 Item 15-020-2020 DSL6632 Analyzer 115V/60Hz, complete Item No: Description 17-722-0060 17-210-0010 17-722-0050 17-650-0010 17-620-0010 16-150-0020 80-915-0020 87-915-0020 70-205-0001 70-111-0003 75-108-2201 57-111-0005 75-408-0203 75-208-0101 66-263-4301 62-726-0020 25-237-0001 66-504-5001 69-121-0002 75-606-1101 59-404-0002 59-224-1001 75-421-0101 59-314-1001 50-121-0200 69-132-0004 68-723-1802 70-132-0002 75-304-1101 68-223-1801 66-333-6601 75-406-0202 75-206-0101 69-250-0002 75-406-0203 75-106-1201 75-106-2204 75-106-2201 73-401-0001 86-602-0001 75-106-3204 75-606-3201 70-152-0004 70-152-0006 70-152-0005 75-106-2202 88-820-0002 70-152-0008 AY, DSL6632 ANALYZER BOARD AY, CH/OCH Pa.lER RESIS DSL6632 AY, DSL6632 LED BOARD AY, CONTACT PLATE DSL66 •• FLOT AY, CABLE HEADR/SUB-D 14/15 PIN UPPER HOUSING, DSL6632 CCJo1PLETE LOWER HOUSING, DSL6632 CCJo1PLETE PACKING KIT FOR CB2000 FOAM TAPE, 8x1Clllln BLACK ADHESI BUMPER, RUBBER .5x1" DIA BLACK SCREW, 8-32x1/2" SS PH PAN TRANSF'R 150VA 115V 60Hz 42VCT WASHER, LOCK fl8 SS EXT TOOTH NUT 8-32x 11/3211 FLATS SP or SS DISCONNECT, FEMALE 16-14AWG CONNECTOR, BLOCK 2-TERMINAL VARISTOR, RADIAL 4500A 130Vrms FERRULE, 7nm NON-INSUL 16AWG TUBING, PVC 20AWG CLEAR SCREW, 6-32x1/4" SELF-CUT PH SWITCH, ROTARY 10-Pos LUGS SWITCH, SPOT Pa.lER TOGGLE WASHER, FLAT 5/1611 MS SERIES ·SWITCH, ROCKER 10A 250V 1/0 CIRCUIT BREAKER, THERMAL 2A TUBING, HEAT-SHRINK 1/411 BLACK CORD, POWER GRY 8'SJT 3x18 115 STRAIN RELIEF, .30011 WIRE DIA JACK SCREW, 4-40 C/W NUT/WASHER HOOK-UP WIRE, BLK 18AWG (16x30) TERMINAL, #6 RING 22-18AWG WASHER, LOCK #6 SS INTERNAL NUT, 6-32 x 1/4" FLATS SP or SS WASHER, FLAT 5/3211 FIBRE 1/1611 WASHER, LOCK #6 SS SPLIT SCREW, 6-32x1/4" SS PH PAN SCREW, 6·32x1/211 SS OVAL PH SCREW, 6-32x1/2" SS PH RD HEATSINK, 30 FINS 9.875x2.25 11 THERMAL JOINT CCJo1POUND, WHITE CAP SCREW, 6-32x5/8" SS HEX DR SCREW, #6x5/811 TAPPING SS PH KNOB, 15nm GREY WLINE 1/4-SHA NUT COVER, 15nm GREY WLINE CAP, 15nm GREY WLINE SCREW, 6-32x3/8" SS PH FLAT NAME PLATE, DSL 6632 DUST COVER, SUB-D 15 Reference 4 C/W HARNESS & THERMISTOR P2 0.06 LOWER HOUSING LOWER HOUSING TRAFO, FEET 4 8 1 8 4 3 1 2 0.1 3 TRAFO TRAFO TRAFO LOWER HOUSING TERMINAL BLOCK TRAFO/VARISTOR VARISTOR LED BOARD (SWS) 4 1 (SW1"4) ROTARY SWITCH 0.25 1 SWITCH, BREAKER 2 POWER CORD SUB-0 CONNECTOR GROUND 11 9 16 13 POWER RES ASSY 6 8 4 HOUSING POWER RES ASSY 0.01 5 2 UPPER HOUSING HEAT RAIL HEAT RAIL/SINK TERMINAL BLOCK ROTARY SWITCH KNOB KNOB UPPER HOUSING BACK OF HOUSING SUB-D CONNECTOR Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 77 of 95 90-Nov-12 Parts List, part 2 of 6 Item 17-722-0060 AY, DSL6632 ANALYZER BOARD Item No: Description 17-722-0010 90-102-0100 20-323-5603 20-323-1003 20-323-2703 20-323-3902 20-323-2008 20-323-6802 20-323-2202 20-323-8252 20-125-0152 20-125-0471 20-125-0681 20-125-0472 24-115-0104 69-111-0001 69-111-0002 68-110-2001 21-515-0820 21-515-0330 33-243-1001 36-122-4001 36-222-4003 36-152-3001 38-112-0001 64-131-3020 64-131-3040 73-902-0020 69-360-0003 69-220-0002 75-104-1201 75-106-2201 75-306-1401 64-911-2140 68-321-2401 69-250-0001 64-121-2030 AY, UNIV CB24 ANALYZER BOARD FIRMWARE, ACP VER CA21.01B/.33 RESISTOR, 1/4W 1% 560k RESISTOR, 1/4W 1% 100k RESISTOR, 1/4W 1% 270k RESISTOR, 1/4W 1% 39k RESISTOR, 1/4W 1% 2RO RESISTOR, 1/4W 1% 68k RESISTOR, 1/4W 1% 22k RESISTOR, 1/4W 1% 82k5 RESISTOR, 1/4W 5% 1k5 RESISTOR, 1/4W 5% 470R RESISTOR, 1/4W 5% 680R RESISTOR, 1/4W 5% 4k7 THERMISTOR, NTC AXIAL 5% 100k TUBING, TEFLON 22AWG NATURAL TUBING, TEFLON 20AWG NATURAL WIRE, BUS BAR 20AWG (SOLID) RESISTOR, SW 5% 82R RESISTOR, SW 5% 33R DICX>E, 1N5402 3A 200V TRANSISTOR, NPN TIP41C 100V 6A TRANSISTOR, PNP TIP42C ·100V 6A TRANSISTOR, NPN TIP122 100V SA IC, LM317T POS V REG 1.SA HEADER, 2-PIN w/LOCK .15611 PC HEADER, 4-PIN w/LOCK .15611 PC HEAT RAIL, CB2 ALU CLR CHROMAT INSULATOR, T0-220 SILICON RUBB WASHER, T0-220 .05011 NYLON SCREW, 4-40x1/411 SS PH RD SCREW, 6-32x1/2" SS PH RD SPACER, .25011 ALU #6 HOLE HEADER, 2x7-PIN .455 11 STRAIGHT CABLE, JUMPER 8.625 11 3x24AWG WASHER, #6 SHOULDER FIBRE HEADER, 3-PIN .15611 STRAIGHT Qty. Reference 1 4 4 4 4 16 4 4 4 4 4 4 4 U4 0.15 0.5 1 4 4 4 4 8 4 2 4 Rx04 Rx05 Rx24 Rx26 Rx29al4 Rx34 Rx36 Rx45 Rx07 Rx09 Rx16 Rx17 HEAT RAIL THERMISTOR J9x1, Rx08 J9x1 (.400"PC) Rx08 Rx20 CRx10 Qx01 Qx02,x03 Qx04 U1,11 CH,DCH COM 14 15 15 3 3 4 P2 P3/P8 PCB CENTRE MTG Px01 Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 78 of 95 90-Nov-12 Parts List. part 3 of 6 page 1 of 2 Item 17-722-0010 AY, UNIV CB24 ANALYZER BOARD Qty. Item No: Description 72-202-1101 91-800-0010 20-323-2701 20-323-4991 20-323-4702 20-323-1103 20-323-1002 20-323-5601 20-323-3303 20-125-0105 20-125-0102 20-125-0183 20-125-0105 20-125-0104 20-125-0473 20-125-0473 20-125-0474 20-125-0103 20-125-0151 20-125-0472 20-125-0561 20-125-0682 23-111-0501 23-111-0103 22-110-2682 28-647-3477 28-627-1101 28-952-2104 28-247-1104 28-277-1102 28-276-1100 28-336-1105 28-336-1335 33-131-1001 33-131-1001 33-232-1001 32-121-0056 36-111-1002 36-211-1002 41-203-1603 41-203-1601 41-203-2001 40-101-0801 40-104-1401 43-201-6401 43-802-4001 46-211-0001 PCB, BLANK C2 •• /DSL MAIN BOARD CUT RES TONGUES .35011 FRCl4 END RESISTOR, 1/4W 1% 2k7 RESISTOR, 1/4W 1% 4k99 RESISTOR, 1/4W 1% 47k RESISTOR, 1/4W 1% 110k RESISTOR, 1/4W 1% 10k RESISTOR, 1/4W 1% Sk6 RESISTOR, 1/4W 1% 330k RESISTOR, 1/4W 5% 1M RESISTOR, 1/4W 5% 1k RESISTOR, 1/4W 5% 18k RESISTOR, 1/4W 5% 1M RESISTOR, 1/4W 5% 100k RESISTOR, 1/4W 5% 47k RESISTOR, 1/4W 5% 47k RESISTOR, 1/4 5% 470k RESISTOR, 1/4W 5% 10k RESISTOR, 1/4W 5% 150R RESISTOR, 1/4W 5% 4k7 RESISTOR, 1/4W 5% 560R RESISTOR, 1/4W 5% 6k8 TRIMMER, 1-TURN PCB SOOR 'TRIMMER, 1-TURN PCB 10k RESISTOR, NW BUSSED 10SIP 6k8 CAPACITOR, ELEC RAD SOV 470uF CAPACITOR, ELEC RAD 25V 100uF CAPACITOR, MKT 2% 63V. 1uF CAPACITOR, MONO 20% SOV .1uF CAPACITOR, MONO 20% 200V .001uF CAPACITOR, MONO 10% 200V 10pF CAPACITOR, TANT 10% 35V 1uF CAPACITOR, TANT 10% 35V 3.3uF DIOOE, 1N4148 10mA 100V DIOOE, 1N4148 10mA 100V DIOOE, 1N4002 1A 1000V DIOOE, ZENER 1N5232B 0.SW 5.6V TRANSISTOR, NPN 2N4401 40V TRANSISTOR, PNP 2N4403 -40V IC, 74HC259 8-BIT ADDR LATCH IC, 74HC139 QUAD 2/4 DECOOER IC, 74HC373 OCTAL D-TYPE LATCH IC, MOT.LM358N OP AMP, NO SUB. IC, 339 QUAD CCl4PARATER IC, uPD78C10 MICRO-CONTROLLER IC, uPD71055 PARALLEL INTERFACE TRANSDUCER, AUDIO QMB 70cb 12V 0.0 1 10 1 5 4 4 4 6 3 5 3 8 6 9 4 2 8 2 Reference C2000 STD BOARD R2 RS R8,9,x03,x15 R23 R24,x13 Rx12 Rx14 Rx37 R3,6,x02 R7 R10, 14, 16 R11,x41 R12, 13, 15 > Rx01,x21 > R17 R18,20,x33 R19 R21,x22,x42 R22 Rx43 R1 ,4 Rx25,x35 R25,26 C1 cs 4 17 1 2 10 17 12 2 4 2 4 Cx02 C3,4,6,12A21,x01 C7 C10,11 C8,9,x03,x04 C22 CR3A11,x01,x02,> CRx03,x04,xOS, > CR1,2 ZX01 Q1,2 QxOS U6 U7 us 4 5 Ux02 U2,x01 U3 U8 LS1 Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 79 of 95 90-Nov-12 Parts List, part 3 of 6 page 2 of 2 Item 17-722-0010 AY, UNIV CB24 ANALYZER BOARD Qty. Item No: Description 48-120-0001 51-112-0001 52-546-0160 64-911-2100 63-121-4280 66-161-0001 CRYSTAL, 2-LEAD 11.0592MHz FUSE, CLIP 5nm PCB TYPE FUSE, 5x20nm 1.6A 250v FST HEADER, 2x5-PIN .725" STRAIGHT IC SOCKET 28-PIN TIN DUAL LEAF QUICK CONNECT, MALE .250 11 PCB 2 1 2 3 Reference Y1 F1 F1 P4 U4,9 P1-1"3 Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 80 of 95 90-Nov-12 Parts List. part 4 of 6 AY, CH/OCH POWER RESIS DSL6632 Item 17-210-0010 Item No: Description Qty. Reference 21-535-0150 21-535-0689 64-533-5020 64-533-5040 65-203-6701 68-110-2001 68-223-1801 68-223-1802 68-223-1803 69-111-0003 72-202-1201 RESISTOR, 10W 5% 15R RESISTOR, 10W 5% 6R8 CONNECTOR, SHELL LOCK 2-CIRCUIT CONNECTOR, SHELL LOCK 4-CIRCUIT CONTACT, FEMALE 18-24AWG TIN WIRE, BUS BAR 20AWG (SOLID) HOOK-UP WIRE, BLK 18AWG(16x30) HOOK-UP WIRE, RED 18AWG(16x30) HOOK-UP WIRE, BLU 18AWG(16x30) TUBING, TEFLON 18AWG NATURAL PCB, BLANK CB2000 RES. STRIP 12 16 4 Rx30AAC (OCH) Rx10AAD (CH) CH, OCH 1 12 0.35 2.5 2.5 2.8 COM CH, OCH, COM JUMPER CH OCH COM RES NEAR SCREW 2 Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 81 of 95 90-Nov-12 Parts List. part 5 of 6 AY, DSL6632 LED BOARD Item 17-722-0050 Qty. Item No: Description 72-202-1103 20-125-0221 20-125-0223 28-247-1103 20-125-0471 41-203-1401 41-203-1602 46-131-0002 46-121-0002 46-111-0002 46-141-0004 68-525-0003 68-525-0004 68-525-0005 68-223-2404 72-202-1103 68-223-2401 PCB, BLANK LED BOARD DSL6632 RESISTOR, 1/4W 5% 220R RESISTOR, 1/4W 5% 22k CAPACITOR, MONO 20% 50V .01uF RESISTOR, 1/4W 5% 470R IC, 74HC02 QUAD 2-1 NOR GATE IC, 74HC147 10-4 ENCCDER LED, YELLOW/DIFF 3nm DIA LED, SUPER-GREEN 3nm DIA LED, ULTRA-RED/DIFF 3nm DIA LED, AMBER/DIFF 3nm DIA FLEX JUMPER, 811 11-CONDUCTOR FLEX JUMPER, 811 5-CONDUCTOR FLEX JUMPER, 811 6-CONDUCTOR HOOK-UP WIRE, GRN 24AWG C7x32) PCB, BLANK LED BOARD DSL6632 HOOK-UP WIRE, BLK 24AWG (7x32) Reference 1 8 1.25 R53"61 C51 R62 U21 U22 DSx1 DSx2 DSx3 DS1 P3-B P6-B P7-B SW5 2.5 SW1"4 9 1 1 4 4 4 1 Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 82 of 95 90-Nov-12 Parts List. part 6 of 6 Item 15-020-2030 AY, DISPLAY UNIT DSL6633 Qty. Item No: Description 17-780-0010 17-680-0030 69-132-0006 70-121-0003 47-211-0001 88-830-0001 59-111-2010 75-104-1201 70-132-0004 75-406-0201 75-606-2101 68-223-2404 68-223-2401 68-223-2402 70-111-0005 88-812-0010 AY, KEYB'R CASE w/CUT'S &MTG AY, 4' CABLE/SUB-D 15PIN MALE TUBING, HEAT-SHRINK 3/811 BLACK BUSHING, SIZE 6 RUBBER LCD, 5x8MAT 40x2LIN REFLE 6o'cl OVERLAY, DSL6633 DISPLAY UNIT SWITCH, SPST PUSHBUTTON BLACK SCREW, 4-40x1/411 SS PH RD CABLE CLAMP, 1/4x3/811 NYLON WASHER, FLAT #6 SS .031 11 THICK SCREW, #6x3/8" TAPPING PH PAN HOOK-UP WIRE, GRN 24AWG (7x32) HOOK-UP WIRE, BLK 24AWG (7x32) HOOK-UP WIRE, RED 24AWG (7x32) FEET, 10tmOIA BLK SELF ADHESIVE LABEL, DSL6633 NAME &S/N 0.05 Reference 1/211 LONG BEFORE HEAT SHRI 1 4 4 0.5 0.4 0.5 4 STN 1"4 LCD CABLE CLAMP CABLE CLAMP 1A ·> 38 18 -> 48 2A -> 3A -> 4A AFTER TESTING BACK LOWER LEFT Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 83 of 95 90-Nov-12 This page left blank intentionally. Copyright 1990 DSL Dynamic Sciences Limited Confidential Proprietary Information 176-0005-00 Issue 1 84 of 95 90-Nov-12 APPENDIX D DRAWINGS This appendix contains the following drawings for reference: 1. Overall System Block Diagram (6632 and 6633) 2. 6632 - Main Board (Schematic) 3. 6632 - Analog Section (One Station) 4. 6632 - Main Board (Layout) 5. 6632 - Power Supply 6. 6632 - Power Resistor Extension 7. 6632 - LED Board (Schematic) 8. 6632 - LED Board (Layout) 9. 6633 - Display Unit - overall Schematic (Schematic) Note: o Drawing No. 1 covers both the Model 6632 Analyzer and the Model 6633 Display Unit. o Drawings Analyzer. No. 2 through 8 covers the Model 6632 o Drawing No. 3 covers the Model 6633 Display Unit. Copyright 1990 DSL Dynamic Sciences Limited/Cadex Electronics Inc. Confidential Proprietary Information 176-0005-00 Issue 1 85 of 95 90-Nov-12 This page left blank intentionally. Copyright 1990 DSL Dynamic Sciences Limited/Cadex Electronics Inc. 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OJ/88 COt1i>01.>1ir,IT 90-Nov-12 Feh. 7.1989 #'PIIOYED 8Y: l LAVOOT t'Ol. L\;.0 2:,0P.lt) CADE)( ELECT~OIJIC.S INC, fDIIAWN av ~ lttEYlltO ("32) lc~ucqo/ --------------- ,... 8~-, 7 ' - '~,,,_ -- 13 611 ll :; r °'2 4 :: - O o, 8 0 07 10 II_ ;: os - '",.,- i " 2 - +- ,,,... 0/J ;: 63 g- 'V l ~<>, LCD I LM402J-S I + ~o 9 ~o 9 I 2 ii) ~C) r .,, .,, 4 3 -----------· BATT[ll.Y ANALYZ[Jl C2000 SCALE: - ----~ 6633 Display Unit - overall Schematic Copyright 1990 DSL Dynamic Sciences Limited/Cadex Electronics Inc. Confidential Proprietary Information DATE: - APPROVED BY: 95 of 95 DRAWN BY: ~ · REVISED: t.lout111b,r 5 1 198' DISPLAY BOX (f>f>33) DRAWING NUMBER CA~X "L£CTQONICS INC... ----- 176-0005-00 Issue 1 - 90-Nov-12 C2000A