Motorola WPLN4108 Service Manual
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Motorola WPLN4108 Service Manual

Adaptive multi-unit charger
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IMPRES
AdaptiveMulti-Unit Charger
Disassembly& Board/T op Housing
Service Procedure
Accessories
Service Manual

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Summary of Contents for Motorola WPLN4108

  • Page 1 ™ IMPRES AdaptiveMulti-Unit Charger Disassembly& Board/T op Housing Service Procedure Accessories Service Manual...

  • Page 3: Table Of Contents

    Table of Contents IMPORTANT SAFETY INSTRUCTIONS.............. 1 REQUIRED TOOLS....................5 REPLACEMENT PARTS..................6 INSTRUCTIONS TO REPLACE A DEFECTIVE PC BOARD....... 8 INSTRUCTIONS TO REPLACE A DEFECTIVE RUBBER FOOT, TOP HOUSING AND/OR FAN ..............17 CHARGER DISPLAY MODULE (CDM).............. 21 Charger Compatibility ................21 Charger Display Module Installation ............
  • Page 4 IMPRES Battery Display Sequence............38 Before Calibration ..................38 After Calibration for NiCD & NiMH ............39 SEQUENCING DIAGRAMS FOR IMPRES Li-Ion BATTERIES ......39 IMPRES Battery Display Sequence............39 Before Calibration ..................40 After Calibration for Li-Ion ................ 40 DISPLAY TEXT ORIENTATION.................

  • Page 5: Important Safety Instructions

    This tri-chemistry unit is universal and charges all Motorola high tier radios’ smart or standard batteries. As a result of this advanced technology, battery operation time and cycle life can be maximized (when used in conjunction with IMPRES Smart Batteries).
  • Page 6 5. To reduce risk of fire, electric shock, or injury, do not operate the charger if it has been broken or damaged in any way. Take it to a qualified Motorola service representative. 6. This unit is repairable. Each pocket is powered by a unique printed circuit board & power supply.
  • Page 7 WARNINGS (continued) UK/British Power Cord 3087791G07 Australian/New Zealand Power Cord 3087791G10 Argentina Power Cord 3087791G13 Korea Power Cord 3087791G16 Americas User Guide 6880309L67 EMEA User Guide 6866537D22 Main Board Replacement Kit RLN5325 Top Housing Replacement Kit RLN5330 Astro/Saber Battery Adapter 4385922B01 Eric Battery Adapter Kit (6-adapters per kit) RLN5212...
  • Page 8 OPERATIONAL SAFETY GUIDELINES • Turn the radio off when charging the battery. • This equipment is not suitable for outdoor use. Use only in dry locations/conditions. • Connect equipment only to an appropriately fused and wired supply of the correct volt- age (as specified on the product).

  • Page 9: Required Tools

    REQUIRED TOOLS • Torque Driver Capable of delivering 8 and 10 in-lbs. • #10 Torx Bit. • #20 Torx Bit.

  • Page 10: Replacement Parts

    REPLACEMENT PARTS • Top Housing Assembly, RLN5330 which includes all parts except the Fan (5987634G01).
  • Page 11 REPLACEMENT PARTS, continued • Main PC Board, RLN5325. • Fan (5987634G01). • Miscellaneous Hardware: Screws – (left to right: 0371239S01, 0387775G01, and 0387775G02) Rubber Feet (7587636G01)

  • Page 12: Instructions To Replace A Defective Pc Board

    INSTRUCTIONS TO REPLACE A DEFECTIVE PC BOARD 1. Separate the Housing From the Base • From the bottom of the Base, remove the six screws (0371239S01) that secure the Top Housing to the Base using a Torx Bit #20.
  • Page 13 Separate the Housing from the Base, continued • Turn the unit over (Base down) – holding the Top Housing and Base together. • Lift the back of the Top Housing a few inches away from the Base, exposing the Fan Harness. Discon- nect the Fan Harness from the PC Board.
  • Page 14 2. Access the “Effected” Board • Disconnect the Power Harness from the effected board by pushing the receptacle snap away from the header. • Remove the Pocket Harness by pulling straight up on the connec- tor. • Remove the Communication Harness by pulling straight up on the connector.
  • Page 15 Access the “Effected” Board, continued • Remove the three Board Screws (0387775G01) using the #10 Torx Bit – two screws reside in the back of the unit (power-side) while the third is located in front.
  • Page 16 Access the “Effected” Board, continued • Lift the effected board at a 45-degree angle and slide it out from under the Pocket Assembly/ Shield.
  • Page 17 3. Replace with a New Board • Replace the new board by holding it at a 45-degree angle and slide it underneath the Pocket Assembly/ Shield. • Make sure the board is seated flush with the Base.
  • Page 18 Replace with a New Board, continued • Affix the three Board screws (0387775G01) using the #10 Torx Bit and torquing to approximately 8 in-lbs.
  • Page 19 Replace with a New Board, continued • Reinstall all Harnesses and Connectors – Power, Pocket, and Communication.
  • Page 20 4. Re-Assemble the Unit – Housing to Base • Replace the Top Housing. • With the Top Housing a few inches away from the Base, connect the Fan Harness into the PC Board (second from the right). • Turn the unit over (Base up) – hold- ing the Top Housing and Base together.

  • Page 21: Instructions To Replace A Defective Rubber Foot, Top Housing And/Or Fan

    INSTRUCTIONS TO REPLACE A DEFECTIVE RUBBER FOOT, TOP HOUSING AND/OR FAN 1. Separate the Housing from the Base • From the bottom of the Base, remove the six screws (0371239S01) that secure the Top Housing to the Base using a Torx Bit #20.
  • Page 22 Separate the Housing from the Base, continued • Turn the unit over (Base down) – holding the Top Housing and Base together. • Lift the back of the Top Housing a few inches away from the Base, exposing the Fan Harness. Discon- nect the Fan Harness from the PC Board.
  • Page 23 2. Replace the Fan • Remove the two Fan Screws (0387775G02). • Remove the Fan from the Defec- tive Top Housing and insert into the New Top Housing. Insert the new Fan into the existing Top Housing. • Insert the two Fan Screws using a Torx Bit #10 and torque to approxi- mately 8 in-lbs.
  • Page 24 3. Re-Assemble the Unit – Housing to Base • Replace the Top Housing. • With the Top Housing a few inches away from the Base, connect the Fan Harness into the PC Board (second from the right). • Turn the unit over (Base up) – hold- ing the Top Housing and Base together.

  • Page 25: Charger Display Module (Cdm)

    CHARGER DISPLAY MODULE (CDM) Charger Compatibility The Charger Display Module (CDM), P/N RLN5382, can be installed in any of the following existing IMPRES Adaptive Multi-Unit Chargers: WPLN4108 WPLN4119 WPLN4109 WPLN4120 WPLN4110 WPLN4121 WPLN4118 WPLN4123 In addition, the CDM can be installed as a replacement for any of the following IMPRES Adaptive...

  • Page 26: Charger Display Module Installation

    Charger Display Module Installation It is recommended that qualified self-maintained users, independent service shops, or the Motorola Service Depot complete installation of the CDM. Note: For charger software versions 1.2 or earlier, the IMPRES multi-unit charger should be returned to the Rockford Support Center at the follow address for re-flashing:...
  • Page 27 Step 1. With the IMPRES Adaptive Multi-Unit Charger face down, remove the six screws, P/N 0371239S01, with #20 Torx bit. Torque Driver...
  • Page 28 Step 2. Turn the unit over (base down) while holding the top housing and base together. Lift the back of the top housing a few inches away from the base, exposing the fan harness. Disconnect the fan harness from the PC board. The top housing can then be fully removed from the base and set aside.
  • Page 29 Step 3. Remove the 12 screws, P/N 0387775G01, and take out the existing cover bezels, P/N 1587630G01, using a #10 Torx bit. Keep the screws for reassembly. Note: Check that the LCD is not broken. If the LCD breaks and you get liquid on your hands, wash hands with soap and water.
  • Page 30 Step 4. Replace the previously removed bezels with the LCD modules, using the 12 screws (removed in Step 3) with the #10 Torx bit. Torque down to approximately 8 in-lbs. Wire LCD Module Wire Harnesses...
  • Page 31 Step 5. Turn the unit around and plug each LCD module/ wire connector into its corresponding PC board. The connector and header are keyed (grooved to properly align during insertion.) Communication Harness (to DB15 Connector) LCD Module/Wire Connector...
  • Page 32 Step 6. Fold the front housing over the base assembly and plug the fan harness into the nearest PC board. The fan connector and header are keyed to properly align during insertion. Ensure all LCD wire harnesses are encased in the housing. Plug Fan Harness into 3rd PC board from the right.
  • Page 33 Step 7. Close the unit carefully to avoid pinching any wires. Replace all six screws (previously removed in Step 1) with #20 Torx bit, and torque to approximately 10 in-lbs.

  • Page 34: Charger Display Module (Cdm) Test Mode

    CHARGER DISPLAY MODULE (CDM) TEST MODE Once the installation of the CDM is complete, the display can be tested to ensure proper installation and functionality. To initiate the test mode: 1. Plug the charger into an AC power outlet. 2. Insert the end of a large paper clip into the pinhole below the display on the front of the charger. The paper clip should be inserted perpendicular to the desktop.
  • Page 35 Start Line 1 Line 2 Every 10.0 seconds Line 1 Line 2 Line 1 Line 2 Line 1 TEST MODE Line 2 TEST MODE Line 1 Line 2 5. Press the toggle button again to exit the test mode. Note: Each CDM operates independently. If more than one CDM is installed in a charger, the test mode sequence can be run for each individual CDM.

  • Page 36: Charger Display Module (Cdm) General Display Information

    CHARGER DISPLAY MODULE (CDM) GENERAL DISPLAY INFORMATION The CDM is designed to provide the user with valuable information while performing battery maintenance and care. Below details the information the CDM will display along with the corresponding LED indicator. Start Up Upon Charger Power-up SINGLE FLASH GREEN Line 1...
  • Page 37 IMPRES Battery in the Pocket IMPRES and Software Versions are Displayed Defined by Charge State Line 1 IMPRES Line 2 SW xx.yy; aa.bb Note: xx.yy denotes charger SW version, and aa.bb denotes CDM SW version. Note: For charger software versions 1.2 or earlier, the IMPRES multi-unit charger should be returned to the Rockford Support Center (see the address on page 22) for re-flashing.
  • Page 38 Forecasted # of Cycles prior to Automatic Recondition Defined by Charge State Line 1 - - - -CYCLES Line 2 TO RECONDITION * Displayed only when the number of cycles to recondition is less than 6 Charger Waiting to Charge, Battery is Hot Flashing YELLOW Line 1 WAITING TO CHG...
  • Page 39 Charger is in Rapid Charge Mode Steady RED Line 1 RAPID CHARGE Line 2 Charger is in Trickle Charge Mode Flashing GREEN Line 1 TRICKLE CHARGE Line 2 Charge is Complete Steady GREEN Line 1 CHARGE COMPLETE Line 2 Charger is in Discharge/Reconditioning Mode Steady YELLOW Line 1 DISCHARGE...
  • Page 40 Charger is Calibrating an IMPRES Battery Steady YELLOW, RED, Flashing YELLOW or GREEN Line 1 Calibrating Line 2 Battery Steady GREEN Line 1 Battery Line 2 Calibrated * An IMPRES batteries should be cali- brated before initial use. An IMPRES charger will automatically initiate calibra- tion for all new batteries.
  • Page 41 Note: Not all screens shown will be displayed. For example, Waiting to Charge displays (battery hot, cold, low voltage) will only be shown if the situation warrants. Note: Fully charged IMPRES batteries immediately inserted into a different pocket will show a slightly lower initial capacity due to stand loss estimation, but the charger will correct this deviation when the battery reaches full charge in the new pocket, typically in a few minutes.

  • Page 42: Sequencing Diagrams For Impres Nicd & Nimh Batteries

    SEQUENCING DIAGRAMS FOR Before Calibration IMPRES NiCD & NiMH BATTERIES Start Every Defined by Charge State 71.0 sec IMPRES Battery Display Sequence Line 1 KIT# xxxxxxxx (4.0 sec) Line 2 SN: yyyyyyyyyyyy Every Start Defined by Charge State 73.0 sec Line 1 KIT# xxxxxxxx Defined by Charge State (4.0 sec)

  • Page 43: After Calibration For Nicd & Nimh

    After Calibration for NiCD & NiMH SEQUENCING DIAGRAMS FOR IMPRES Li-Ion BATTERIES Every Start Defined by Charge State 61.0 sec IMPRES Battery Display Sequence Line 1 KIT# xxxxxxxx (4.0 sec) Line 2 SN: yyyyyyyyyyyy Start Defined by Charge State Line 1 KIT# xxxxxxxx Defined by Charge State Every (4.0 sec)

  • Page 44: Before Calibration

    Before Calibration After Calibration for Li-Ion Every Start Every Start 51.0 sec Defined by Charge State Defined by Charge State 61.0 sec Line 1 KIT# xxxxxxxx Line 1 KIT# xxxxxxxx (4.0 sec) (4.0 sec) Line 2 SN: yyyyyyyyyyyy Line 2 SN: yyyyyyyyyyyy Defined by Charge State Defined by Charge State Line 1 KIT# xxxxxxxx...

  • Page 45: Display Text Orientation

    DISPLAY TEXT ORIENTATION In order to allow for desk or wall mounting of the IMPRES Adaptive Multi-Unit Charger, the CDM is equipped with the ability to “flip” the display text 180 degrees. To do this, insert a large paper clip into the pinhole below the display perpendicular to the desktop. A “click”...
  • Page 46 Motorola and The Stylized M logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2001, 2002, 2003, 2006 by Motorola. Inc. Printed in U.S.A. All Rights Reserved.

This manual is also suitable for:

Wpln4119Wpln4109Wpln4120Wpln4110Wpln4121Wpln4118 ... Show all

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