Skytrac DSAT-300 Series Battery Replacement Instructions

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DSAT-300 Battery Replacement Instructions

DOC0595

Applies to: 108-300-01, 108-300-02

Document Revision: 01.000

Dec 15, 2009

SkyTrac Systems Ltd.

200-170 Rutland Road

Kelowna, BC Canada

Tel. +1 250 765-2393

Fax +1 250 765-3767

Web: www.skytrac.ca

Email: support@skytrac.ca

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Summary of Contents for Skytrac DSAT-300 Series

Page 1 Applies to: 108-300-01, 108-300-02 Document Revision: 01.000 Dec 15, 2009 SkyTrac Systems Ltd. 200-170 Rutland Road Kelowna, BC Canada Tel. +1 250 765-2393 Fax +1 250 765-3767 Web: www.skytrac.ca Email: support@skytrac.ca Copyright © 2009 SkyTrac Systems Ltd. All rights reserved.
Page 2 Date Author Approval 01.000 Initial Release Dec 15, 2009 T. Ratch Proprietary Notice: The Information contained in this document is proprietary and confidential to SkyTrac Systems Ltd. Document Revision 01.000 DOC0595 Page 2 of 21 Restricted Proprietary and Confidential Information...
Page 3 SkyTrac Systems Ltd. Table Of Contents Battery Replacement Procedures ................4 DSAT-300E ........................4 DSAT-300I ........................14 Document Revision 01.000 DOC0595 Page 3 of 21 Restricted Proprietary and Confidential Information...
Page 4: Battery Replacement
SkyTrac Systems Ltd. ATTERY EPLACEMENT ROCEDURES The battery replacement procedure is given as a number of steps below. The actual appearance of parts may differ from those shown. Pictures are for reference only. 2 DSAT-300E Note: To avoid damage to the unit due to Electro Static Discharge (ESD) the battery replacement should be performed in an ESD controlled environment, i.e.
Page 5 SkyTrac Systems Ltd. Hold the top enclosure perpendicular to the bottom enclosure as shown in Figure 3 Figure 3 – Perpendicular Position Note: It is recommended to ensure that the Top Enclosure is held (or rested against a wall) on top of the bottom enclosure similar to the Figure below in order to avoid the connectors otherwise the connectors can short components on the microprocessor.
Page 6 SkyTrac Systems Ltd. Disconnect the Batteries from the PCB. Figure 5 – Disconnecting the Batteries Release the batteries from between the battery cross bar and battery mounting foam. Figure 6 – Battery Release Document Revision 01.000 DOC0595 Page 6 of 21...
Page 7 SkyTrac Systems Ltd. Slip the battery connectors under the battery cross bar where there is no heat shrink (mid region) and remove the batteries as shown in Figure 7 Figure 7 – Battery Removal Take one of the replacement batteries and bend the cable around the front face to...
Page 8 SkyTrac Systems Ltd. Bend the cables to the side with a loop as shown in Figure 9 Figure 9 – Bottom Battery Cable Bends Repeat steps 7 and 0 for the second battery but to the left this time to get a battery...
Page 9 SkyTrac Systems Ltd. Take the battery with its cables bent to the right and slide its connector underneath the battery cross bar as shown in Figure 11 Figure 11 – Battery Connector Tuck Position the battery between the battery mounting foam and the battery cross bar ensuring that the body is tangent to the mounting standoffs of the enclosure as shown in the Figure below.
Page 10 SkyTrac Systems Ltd. Orient the battery so that the battery cable and its circuit are upwards as shown in . This will eliminate assembly collisions. Figure 13 Figure 13 – Battery Orientation Connect the battery connectors to their nearest receptacle. Ensure that the Bottom...
Page 11 SkyTrac Systems Ltd. Repeat the above steps for the second battery, the battery installation should now look like Figure 15 Figure 15 – Battery Installation Complete Lower the top enclosure onto the bottom enclosure creating a pivot at the right end...
Page 12 SkyTrac Systems Ltd. Figure 17 – Enclosure Pivoting at Right Side Before mating the top and bottom enclosure together ensure that the Iridium Cable is tucked beneath the battery cross bar. Refer to Figure 18 Figure 18 – Iridium Cable Tuck Document Revision 01.000...
Page 13 SkyTrac Systems Ltd. Slowly clamp the top and bottom enclosures together until they are slightly ajar or fully shut, similar to similar to Figure 19 Figure 19 – Enclosure Assembly Gap Turn the assembly over and fasten the top and bottom enclosures together at 6 places using #4-40 screws from step one.
Page 14 SkyTrac Systems Ltd. DSAT-300I Unfasten and remove the screws from the DSAT-300 at 6 locations using a #1 Phillips head screw driver (screw: Phillips #4-40). Retain the screws for later use. Figure 20 – Screw Locations Turn the DSAT over and lift the top enclosure from the right side as shown in Figure , creating a hinge on the left end of the enclosure.
Page 15 SkyTrac Systems Ltd. Hold the top enclosure perpendicular to the bottom enclosure as shown in Figure 22 Figure 22 – Perpendicular Position Disconnect the Batteries from the PCB and remove the top enclosure assembly. Figure 23 – Disconnecting the Batteries Document Revision 01.000...
Page 16 SkyTrac Systems Ltd. Release the batteries from between the battery cross bar and battery mounting foam. Figure 24 – Battery Release Slip the battery connectors under the battery cross bar where there is no heat shrink (mid region) and remove the batteries as shown in Figure 25 Figure 25 –...
Page 17 SkyTrac Systems Ltd. Take the new battery and tuck its connector underneath the Battery Cross Bar. Figure 26 – Battery Connector Tuck Bend the Battery Cable around the front face of the Battery as shown in Figure Figure 27 – Battery Cable Position Position the Battery between the cross bar and mounting foam and ensure that the battery is tangent to the mounting standoffs of the enclosure.
Page 18 SkyTrac Systems Ltd. Figure 28 – Battery Tangent to Mounting Bosses Orient the battery cable and battery’s circuit board upwards in order to avoid collisions with the modem during assembly. Figure 29– Battery Cable Orientation Bend the battery cable roughly 180 degrees and push the cable down towards the enclosure as shown in .
Page 19 SkyTrac Systems Ltd. Warning: It is extremely important that the positions of the battery cables are clear of collisions with the push button connector, battery connectors, and any contact with the PCB. Repeat steps 9 to 12 for the second battery.
Page 20 SkyTrac Systems Ltd. Lower the top enclosure assembly onto the bottom enclosure assembly. Ensure the power connector and USB receptacle are aligned properly. Pivot the two enclosures at the power connector end as shown in Figure 33 Figure 33 – Imaginary Enclosure Hinge Warning: Forcing the enclosures together at this point would induce stresses in the PCB resulting in undesirable deflection.
Page 21 SkyTrac Systems Ltd. Document Revision 01.000 DOC0595 Page 21 of 21 Restricted Proprietary and Confidential Information...

This manual is also suitable for:

Dsat-300e Dsat-300i 108-300-01 108-300-02