SM-7021
IUNION SWITCH & SIGNALl(m]
A member of the ANSALOO Group
5800 Corporate Drive, Pittsburgh, PA 15237
SERVICE MANUAL 7021
Delivery/Acceptance, Operation and Field Maintenance
MODEL 6629 BATTERY CHARGER
Formerly Dynamic Sciences Limited Document
Reference 176-0004-00
November, 1990
A-2/93-2993-1
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
176-0004-00 Issue 1
2 of 52
90-November-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, 22.1
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. 1,293,996; 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
176-0004-00 Issue 1
3 of 52
90-November-12
PREFACE
INTENT OF MANUAL:
The intent of this document is to assist in repair and service.
Service
should be attempted 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
U.S.A. 17033
Telephone:
From u.s:
Fax:
(717) 533-4618
(800) 544-8879
(717) 533-4468
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
4 of 52
90-November-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 Buye~ 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
176-0004-00 Issue 1
5 of 52
90-November-12
CAUTION
o The Model 6629 Charger is intended for DSL
DIGITAIR batteries only. Attempts to charge
other batteries may cause damage to the
batteries or to the Charger.
o Recharge batteries only when the temperature
of the batteries is between l0°C a~~ 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. CHARGING BATTERIES THAT ARE TOO
HOT OR TOO COLD MAY BE HAZARDOUS.
o Do not cover or restrict air circulation
around the Charger.
o To ensure good electrical connections, clean
the battery contacts before servicing.
o Only qualified technicians who thoroughly
understand this manual should open the
Charger or attempt to service it. Always
disconnect power before opening Charger case.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
6
of 52
90-November-12
TABLE OF CONTENTS
Page
1.
1.1
1.2
1.3
1.4
1.5
1.6
GENERAL INFORMATION
Introduction
Functional Description
Charge Time
Termination of Fast Charge
Temperature sensors
Specifications
9
9
9
11
11
13
13
2.
2.1
2.2
2.3
DELIVERY/ACCEPTANCE PROCEDURE
Receiving Procedure
General Test
Operational Test
15
15
15
15
3.
3.1
3.2
3.3
3.4
3.5
OPERATING INSTRUCTIONS
Introduction
Starting the Unit
Charging
Battery Temperature Sensing
Summary of Lamp and Sound Indicators
17
17
17
17
18
18
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
FAILED BATTERY INDICATIONS
Introduction
Shorted Battery
FAIL 1 (Partial Short)
FAIL 2 (Low Battery Voltage)
FAIL 3 (Depressed Battery Voltage)
Dry Cell
Faulty Battery Connection
Open Battery
Venting Battery
21
21
21
21
21
22
22
22
22
22
5.
5.1
5.2
5.3
5.4
5.5
5.6
THEORY OF OPERATION
General
Auxiliary Circuit
Control Circuit
Charging Drivers
Display Indicators
Interface Jack
25
25
25
26
27
29
29
6.
6.1
6.2
6.3
6.4
6.5
AUDIO/VISUAL INDICATORS
Good Battery Indications
Faulty Battery Indications
Temperature-Related Indications
System Indications
Failures of the Charger
31
31
32
33
34
35
7.
PARTS LIST
41
8.
DRAWINGS
47
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
7 of 52
90-November-12
This page left blank intentionally.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
8 of 52
90-November-12
1.0
GENERAL INFORMATION
1.1
Introduction
The DSL Model 6629 Charger, illustrated in Figure 1, is a
fully automatic advanced microprocessor-controlled fast
charger for DIGITAIR nickel-cadmium batteries. Each unit
can accommodate up to 4 batteries at once.
To improve charging efficiency, the DSL 6629 Charger uses
the Reverse Load charge method. Reverse Load is a pulse
charge method that intersperses discharge current cycles
throughout the charging process. Increased charge efficiency, cooler batteries, and reduced "memory" phenomenon
are the result of this new method.
The DSL 6629 Charger assists the user with audible and
visible signals to indicate the battery status. Faulty
batteries are diagnosed and the cparge.cycle is terminated in time to protect the batteries and the Charger.
Nickel-cadmium batteries which have been stored in the
uncharged state for an extended period of time may
exhibit less than their rated capacity. This condition
cannot be rectified by a single charge on the Model 6629
Charger although it will be improved over time.
It is recommended that DIGITAIR batteries that are new,
or which have been stored unused for twelve (12) months
or longer, be exercised by discharging to approximately
10 Volts (i.e. 1 Volt per cell) and then recharging, two
or three times, in order to develop their full capacity.
This can be done by discharging the batteries in the
DIGITAIR Highly Visible Marker (HVM) light and then
recharging on the Model 6629 Charger, or by using the DSL
Model 6632 Battery Analyzer.
The DSL 6629 Charger is equipped with four "stations".
Each station accepts one battery and works independently
of the others. Charging defective batteries will not harm
the
unit.
Overloading
of the system is virtually
impossible.
1.2
Functional Description
To install the Charger, connect the power cord to line
voltage and turn the power on. A short tone signal is
heard and all lamps come on momentarily. With no battery
in place, all CHARGING and READY lamps will then remain
off.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
9 of 52
90-November-12
Figure 1
Model 6629 Battery Charger
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
10 of 52
90-November-12
When attaching a battery, a
CHARGING lamp comes on. The
charge.
beep is heard and the red
battery is now on fast
When fully charged, the unit switches to trickle charge
and the green READY lamp comes on. The battery may remain
on trickle charge for an extended period of time without
causing damage.
NOTE: The Charger may be turned·off and on with or without batteries connected. The unit will reset with a
short tone signal and then connect each of the
batteries sequentially. Batteries that were READY
before the power was disconnected will fast charge
again for a short time.
1.3
Charge Time
.
.
The charge time is controlled by the charge rate setting
and the choice of components. All DSL Model 6629 Chargers are set to a charge rate of 0.33, at which rate the
charge time for a fully discharged battery is approximately 5 hours; the charge time for a partially discharged
battery is typically about 4 hours.
If observed charge times are shorter than 5 hours, this
is either because the battery was partially charged
beforehand or because its capacity is low. If observed
charge times are longer, this is either because the
battery has a capacity which exceeds the nominal 100%
rating or because the line voltage is low. Batteries may
be diagnosed with the DSL Model 6632 Battery Analyzer.
1.4
Termination of Fast Charge
The DSL 6629 Charger uses several methods of terminating
the fast charge. How and when this occurs is governed by
the battery condition. The methods are:
a) Termination
voltage
of
fast
charge through incorrect battery
If a battery is unable to reach the Window Voltage
(see Note below) in the allotted time, the fast charge
is inhibited by one of the conditions: "Short", "Fail
1 11 ,
"Fail 2 11 , or "Fail 3 11 • Termination also occurs if,
due to a "soft cell", the charging battery exceeds the
Window Voltage; this condition is called "Dry Cell".
Note: Window Voltage is the battery voltage range
that must be reached in a given time to successfully complete the Charge cycle.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
11 of 52
90-November-12
b) Full charge detection through Negative Slope
Most batteries respond to the Negative Slope Detector
for termination. In the carefully selected Window Voltage, the computer monitors the-voltage pattern of the
charging battery. Upon approaching full charge, the
battery voltage rises sharply, peaks, and starts to
fall off. This decrease in voltage (i.e., the Negative
Slope) is detected, a triple beep is heard and the
green READY lamp comes on.
c) Fast charge inhibit through Peak Timeout Timer
on certain batteries, no sufficient decrease in voltage is detected upon full charge. When this occurs,
the Peak Timeout Timer will terminate the fast charge
instead.
Typical reasons
slope are:
for
failing
to produce the n~gative
- Battery has poorly matched cells;
- Battery has leaky cell(s);
- Battery is new and is being charged for the first
time; or
- Battery had been in discharged condition for a long
time.
Similar to the Negative Slope Detector, the Peak
Timeout Timer produces a triple beep and the green
READY lamp comes on.
NOTE:
The
careful observer may notice different
pitches of the triple beep tones. If the fullcharge detection occurs through the Negative
Slope Detector, a high pitched triple beep is
heard (2400 Hz); if it is caused by the Peak
Timeout
Timer, a low pitched triple beep
occurs (674 Hz).
d) Fast charge disabled through "Dry Cell" condition
A battery normally fails due to low capacity before it
dries out.
However, if a Dry Cell condition exists,
the Charger will disable the fast charge. The Dry Cell
condition may show up after only a few minutes or
after hours of charging.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
12 of 52
90-November-12
1.5
Temperature Sensors
Temperature sensors are installed at each battery station. Should the battery case temperature exceed 44°C
(111°F), the sensor terminates al'l charge current. A hot
battery
is indicated by rapid flashing of the red
CHARGING lamp. After the battery has cooled down to 40°C
(104°F), trickle charge commences. The CHARGING lamp
alternates with the READY lamp.
To reset, remove and
replace the battery.
·
If the temperature is less than 15°C (59°F), trickle
charge is applied and the CHARGING lamp flashes once per
second. After the temperature rises above 15°C (59°F),
the battery is fast charged and the cycle proceeds as
usual.
It should be noted that there is no beep signal when
inserting a battery that is out of temperature range.
1.6
Specifications
Power source:
115 VAC +/- 15%, 60 Hz (unless
otherwise stated on the label on
the Charger itself)
Current:
1.4A
Primary fuse:
2A circuit breaker
Control circuit fuse:
1.6A, 5x20mm, time lag
Maximum charge current: SA
Dimensions:
36cm wide, 22cm high, 24cm deep
(14.25"
wide, 8.5" high, 9.5"
deep)
Weight:
6.6 kg (14.6 lb)
Number of stations:
4
Charge method:
Reverse Load. Fast charges battery; then switches to trickle
charge when fully charged.
Full charge detection:
Negative Slope with Peak Timeout
Timer as override (Software controlled).
Indicators.:
Visible (lamps). These lamps are
actually
LEDs
(Light Emitting
Diodes).
Audible (sounder).
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
13 of 52
90-November-12
Meanings of Indicators:
CHARGING lamps
(red LEDs)
READY lamps
(green LEDs)
On steady: Battery on fast charge
Flashing: but
of
temperature
range
On steady: Battery
· charge
Flashing: Battery
rect
ready, trickle
voltage incor-
POWER ON lamp
(amber LED)
On steady: Power on
Single beep tone:
Battery contact established
Triple beep tone:
Battery
charge
Wailing sound:
Reverse polarity
Continuous sound:
Battery shorted
Beeping sound:
Dry Cell condition
switches
to
trickle
Charge & Discharge Currents (per station):
Fast Charge Rate:
Fast Charge Current:
Trickle Charge
Current:
Discharge Current:
0.33 A/Ah
1.33 A Nominal, unregulated
(i.e., Fast Charge Rate x Nominal
Battery Capacity)
235 mA Nominal, unregulated
1. 33 A Regulated
Charge Time:
5 hours nominal
(for
discharged battery).
Reset:
By removing of battery.
Temperature protection: Fast charge is
tween 15°C and
lll°F)
a typical
enabled only be440C (59°F and
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
14 of 52
90-November-12
2.0
DELIVERY/ACCEPTANCE PROCEDURE
2.1
Receiving Procedure
The box should contain the Charger
power cable and the User Guide.
with its integral
Before opening the box, check for, and record, any damage
to the outside of the box. Remove Charger from the box;
check for, and record, any damages.
If the unit is damaged, the shipper should be notified
immediately. All packing material and contents must be
kept available for inspection by the shipper's claim
agent. Failure to do this may result in denial of liability for damage by the shipper.
2.2
General Test
Follow the power up procedure given in Section 3.2 below.
2.3
Operationa1 Test
Charge a battery as described in Section 3.3 below.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
15 of 52
90-November-12
This page left blank intentionally.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
16 of 52
90-November-12
3.0
OPERATING INSTRUCTIONS
3.1
Introduction
The Charger has four battery positions or "stations".
Each
position
has locating pins to ensure correct
placement of the battery and to prevent reverse polarity
connection. Each battery station functions independently.
Charging of a battery is automatic and starts when the
battery is placed on the Charger. Full charge is detected
automatically, after which the battery receives a trickle
charge to keep it at full capacity. Audible and visible
signals indicate battery status. Faulty batteries are
diagnosed and charging stopped in time to protect the
battery and the Charger.
3.2
starting the Unit
Connect the Charger to an appropriate power
normally 115V AC. See label on back of Charger.
~upply,
on power up, a single tone is heard and all lamps come on
momentarily. With no batteries in place, the red and
green lamps remain off and the yellow POWER ON lamp
remains on.
3.3
Charging
When a battery is placed in charging position, a beep
tone is heard indicating proper contact. The red CHARGING
lamp comes on showing that the battery is on fast charge.
Typical charge time for a battery in good condition is
approximately 5 hours. This will be less if the battery
capacity is low or if the battery was partially charged
initially. If the charge time is longer than 5 hours,
either the line voltage is low or the battery capacity
exceeds the nominal rating.
When a battery is fully charged, a triple beep tone is
heard, the green READY lamp comes on, the red CHARGING
lamp goes off, and the Charger switches to trickle
charge.
Batteries may be left on trickle charge for extended
periods without harming the batteries.
NOTE: The Charger may be turned off and on with or without batteries connected. The Charger will reset
with the power on tone and then connect each battery sequentially. Batteries that were READY before
the power was disconnected will charge again for a
short period of time.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
17 of 52
90-November-12
3.4
Battery Temperature Sensing
The DSL 6629 Charger is equipped
sensor at each battery station •
with
a temperature
.
Should the battery case temperature exceed 44°C (lll°F),
the red CHARGING lamp will flash. After the battery has
cooled down, trickle charge will commence indicated by
alternate flashing of the red and green lamps. To reset,
remove battery.
·
If the temperature sensor measures less than 15°C (59°F),
only trickle charge is applied, indicated by a slow
flashing of the red CHARGING lamp. When the temperature
rises to 15°C (59°F), the normal fast charge cycle will
commence.
NOTE:
(a) There
is
no beep tone when a battery
temperature range is placed on the Charger.
'
out
of
(b) The temperature sensor at each station measures the
temperature of the battery case; for cold batteries
this
may
not
accurately
reflect the internal
temperature.
The
following warm-up times are
recommended when batteries have been exposed to low
temperatures for several hours.
Temperature: 0°C (32°F)
Warm-up time
(at room
temperature): 4 hours
***
3.5
-20°C (-4°F)
-40°C (-40°F)
8 hours
12 hours
DO NOT CHARGE COLD BATTERIES
***
Summary of Lamp and Sound Indicators
Table 3-1 provides
indicators.
a
summary
of
the
lamp
and sound
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
18 of 52
90-November-12
SOUND
LAMP
INDICATES
Yellow(POWER ON) None
Power On
Red (CHARGING)
Single Beep
Battery on Fast Charge
Green (READY)
Triple Beep
Battery Fully Charged Ready for Use
Green
(1 flash/sec)
Continuous
Fault - "SHORT"
Green
(1 flash/sec)
None
Fault - "FAIL l"
Green
(2 flashes/sec)
None
Fault - "FAIL 2"
Green
(4 flashes/sec)
None
Fault - "FAIL 3"
Green
(4 flashes/sec)
Continuous
Fault - "DRY CELL"
Red
(random flash)
Random
Faulty Battery Connection
Red
(1 flash/sec)
None
Cold Battery
Red
(4 flashes/sec)
None
Hot Battery
Red & Green
(4 flashes/sec)
None
Hot Battery has Cooled Remove & Replace to Reset
Red or Green
Any
If no battery in place System Fault
TABLE 3-1
SUMMARY OF INDICATORS
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
19 of 52
90-November-12
This page left blank intentionally.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
20 of 52
90-November-12
4.0
FAILED BATTERY INDICATIONS
4.1
Introduction
Full charge detection and analysis of battery deficiencies are functions of the software. The status of each
battery is indicated with the CHARGING and READY lamps
located near each battery station. For quick reference,
see the front label of the Charger or turn to the
Indicator tables given in Section 6 below.·
NOTE: If unconcerned with the nature of a battery defect,
simply
observe whether the lamp is steady or
flashing.
> Steady CHARGING Lamp:
> Slow flashing
CHARGING lamp:
> Fast flashing
CHARGING lamp:
> Steady READY Lamp:
> Flashing READY Lamp:
4.2
Temperature
normal, fast
charging
Temperature too low,
trickle charging
,
Temperature· too high, not
charging
Battery
voltage correct,
battery ready
Battery voltage incorrect,
battery faulty
Shorted Battery
When connecting a shorted battery, charging is terminated
after six (6) seconds.
The READY lamp flashes and a
continuous
sound
is heard. Remove and discard the
battery.
4.3
FAIL 1 (Partial Short)
This battery is basically shorted, but may have a few
functioning cells remaining. The charge time is limited
to three (3) minutes. The READY lamp flashes at a rate of
once per second to indicate the condition. The battery is
not usable.
4.4
FAIL 2 (Low Battery Voltage)
The low voltage battery has a number of faulty cells. The
charge is terminated after thirty (30) minutes. The READY
lamp flashes at a rate of twice per second. Discard the
battery.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
21 of 52
90-November-12
4.5
FAIL 3 {Depressed Battery Voltage)
Due to one or more faulty cells, the battery is unable to
reach the Window Voltage. The charge is terminated after
three (3) hours.
The READY lamp· flashes four (4) times
per second to inform the user of this deficiency.
and "Fail 2 11 , the
Note:
Unlike "Short", "Fail 1 11 ,
occurrence of "Fail 3" does not terminate the charge
completely but switches to trickle charge. The battery
may have limited use, but should ~e marked as faulty.
4.6
Dry Cell
A "Dry Cell" condition occurs when one or more cells lack
electrolyte. This condition makes the battery "soft" in
which state it can no longer clamp the terminal voltage
down when charging. A four-flash-per-second READY lamp
and continuous tone indicate this condition. Charging is
terminated. The battery can no longer be used and should
be discarded.
If a cold battery is fast charged, an apparent "Dry Cell 11
condition may also occur. Allow the battery to warm up
for several hours before charging.
4.7
Faulty Battery Connection
A faulty battery connection raises the terminal voltage
when in Charge mode. This condition switches the Charger
between Reset (no battery) and Charge (battery inserted).
Random flashing of the CHARGING lamp occurs and beep
tones are heard.
To correct this problem, clean all connections on both
the Charger and the battery. If no improvement is apparent,
the battery is probably faulty and should be
discarded.
4.8
Open Battery
The battery cannot accept a charge current, and the
Charger remains on Reset. No lamps or tone signals are
activated. Check and clean all contacts.
4.9
Venting Battery
Older batteries often develop a problem whereby, due to
aging, the cells become increasingly mismatched. This is
aggravated by the fact that the weak cells reach full
charge before the good ones do, thus causing elevated
temperature and excessive pressure in these cells. A
further deterioration of the weak cells is therefore
inevitable.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
22 of 52
90-November-12
When a cell reaches excessive pressure, venting occurs. A
popping or hissing sound may be heard. There is no danger
to battery or equipment; however, repeated venting can
lead to the "Dry-Cell" condition described above.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
23 of 52
90-November-12
This page left blank intentionally.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
24 of 52
90-November-12
5.0
THEORY OF OPERATION
5.1
General
The circuitry of the DSL 6629 Charger is divided into
four
sections:
Auxiliary
Circuit, Control Circuit,
Charging
Drivers,
and
Display Indicators (the LED
indicator lamps). A block diagram and schematic of the
complete Charger are provided in Section~ below.
5.2
Auxiliary Circuit
The Auxiliary circuit consists of: Power Supply, Overload
Detector, Reset Circuit, Sounder driver, POWER ON lamp
driver, Clock Oscillator, and Code Selector.
(a) Power Supply
The power supply consists of rectifiers CRl
and a three-terminal regulator Ul which has
protection for both overcurrent and excessive
ture.
output voltage is set to the required
using potentiometer Rl.
and CR2,
internal
tempera5.12 voe
(b) overload Detector
The overload detector senses the transformer temperature via a thermistor and shuts the Charger down
should the transformer exceed a certain temperature.
Since the charge rate on all DSL Model 6629 Chargers
is fixed, the current demand on Tl is fixed. As such,
the thermistor is not required and is therefore not
installed on any DSL Model 6629 Charger. The following description is included for completeness only.
The detector circuit consists of capacitor and comparator U2B.
If a thermistor (RTl) were installed,
it would be connected to P2. On sensing high temperature, RTl would allow Cl to charge, switching comparator U2B output Low then High.
The rising positive edge applied to processor U3 (INT
1 input) would place the processor in "sleep mode",
shutting down the Charger.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
25 of 52
90-November-12
(c) Reset Circuit
The Reset circuit provides a Power On reset to the
microprocessor when power is first applied. C4 charging at U2A pin 5, causes comparator U2A output pin 2 to
switch Low for a few milliseconds and then to switch
High.
The Low applied to U3 pin 23 resets the
microprocessor U3.
A Watchdog timer circuit consisting of U2C and U2D
monitors microprocessor U3 for continuous activity and
enables the Reset circuit should normal operations
cease.
Pulses superimposed on the POWER ON lamp output
line (U3 pin 24) are monitored by pulse shaper U2D.
Should pulse activity cease for more
second, the output of U2D will go High.
output, normally High, now switches Low.
fed
to
comparator
U2A
via
C7
microprocessor Reset.
then about one
Comparator U2C
This signal is
initi&ting
a
The Watchdog timer circuit also triggers a reset if the
input
AC
power
rises
slowly.
(e.g., after a
brown-out).
(d) Code Selector
The Code Selector is unused in the DSL 6629 Charger.
The charge rate was at one time set by jumpers placed
on the Code Selector header, but now the rate is fixed
at 0.33 in firmware. The Code Selector header should
have no jumpers placed on it.
5.3
Control Circuit
Refer to both the block diagram and the schematic for the
following
descriptions; both drawings are provided in
Section 8 below.
The following items
processor U3, EPROM
Addressable latch U6.
comprise the Control Circuit: Micro(or PROM) U4, latch U5, and 8-bit
EPROM U4 contains the program for the Charger's microprocessor.
The microprocessor U3 uses a multiplexed address/data
bus DB 0-7 to obtain its instructions from U4.
To read an instruction from the EPROM, the microprocessor
first outputs 13 address bits.
The lower order address
bits 0-7 are latched in D latch U5. The higher order bits
remain on. the direct address bus throughout the read cycle.
The EPROM output is then enabled allowing the reading of
data, by the microprocessor, on DB lines Oto 7.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
26 of 52
90-November-12
Latch U6
stations.
acts
as
an
addressable LED driver for all four
The Control Circuit provides control signals for the four
charging stations via the Charging 'Drivers. Microprocessor
U3 provides Control and Supervisory information to the
drivers as follows:
(a) Control Signals
- three
lines
provide
each Charging Driver with
individual digital control signals for Fast Charge,
Trickle Charge, and Reverse Load.
> Fast Charge:
Active when high; low no charge
> Trickle Charge: Active when high; low no charge
> Reverse Load:
Active when high; low no activity
(b) Supervisory Signals
- three lines from each Charging Driver provide analog,
supervisory input signals to the microprocessor for
Battery
Voltage
(V-sense),
Battery
Temperature
(V-temp), and Reverse Polarity.
> v-sense:
Analog,
battery
below).
O to 5.12V , indicates
voltage (see Section 5.6
> v-temp:
Analog,
o to 5.12V, indicates
battery temperature
(see Sectin
5.6 below).
> Reverse Polarity: Normally high, low
reverse polarized.
5.4
when battery
Charging Drivers
The function of the Charging Drivers is to provide Fast
Charge, Trickle Charge, and Reverse Load cycling.
The DSL 6629 Charger contains four Charging Drivers, one
for each battery station.
The charge current and hence
charge time is determined by the choice of components and
by the control signals from microprocessor U3.
As all drivers are identical, only one circuit will be
described.
Refer to the block diagram and the schematic
for the following descriptions.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
27 of 52
90-November-12
(a) Driver Component Designation
All components in the Charging Drivers are identified
by a three-digit number.
The first digit designates
the Charging Driver (Driver 1, 2, 3 or 4). The second
and third digits position the components, and are repeated on each Charging Driver as their allocations are
the same for all positions. In the following description, the first digit is replaced by an "x", In this
way, the description is of Charging'Driver "x", where
"x" may be 1, 2, 3, or 4.
(b) Input/Output
Each Charging Driver responds to the three control signals described in Section 5.3(a) above and provides the
supervisory signals described in 5.3(b).
(c) Fast Charge
Voltage is applied on the Fast Charge line, via Rx03 to
pin 1 of UxOl.
Pin 2 of UxOl is connected to the
unregulated DC line from CR3; this has a high 60 cycle
ripple content.
The output of UxOl at pin 1 applies a ground potential
at a rate of 60 times per second, synchronous with the
line voltage.
Capacitor Cx02, also connected to pin 1
of UxOl, acts as an integrator to produce a sawtooth
waveform.
This sawtooth wave is compared with the reference voltage on pin 5 of UxOl. The resulting output pulse on
pin 2 of UxOl coincides with the positive half of the
AC and turns on driver QxOl-1, allowing charge current
to flow through the series pass transistor Qx02.
(d) Trickle Charge
Unlike fast charge, trickle charge uses only a fraction
of the positive AC pulse. A different timing ratio of
Rx04 and Cx02 produces a lower saw-tooth voltage. The
pulse width, and hence the trickle charge current, are
determined by the value of Rx04. (A higher resistance
will produce less current). The trickle charge current
is set to 235 mA nominal on the 6629 Charger; this value is approximate and varies both with battery terminal
voltage and with line voltage.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
28 of 52
90-November-12
(e) Reverse Load
A special feature of the DSL 6629 Charger is Reverse
Load cycling by which a brief discharge is applied between each charge pulse. This feature stimulates the
battery and reduces the "memory" phenomenon associated
with nickel-cadmium batteries.
On both fast charge and trickle charge, Rx12 and Rx13
produce a reference voltage (pin 10 of UxOl) that compares with the AC ripple which is superimposed on DC
(pin 11 of UxOl). The resulting output (pin 13) is a
zero going pulse, turning Qx03 on during that period.
The Reverse Load is active between charge pulses. The
average Reverse Load discharge is approximately 10% of
the battery's Ampere-hour (Ah) rating.
(f) Reverse Polarity Detector
If a negative voltage potential is read on the voltage
divider of Rxl8 and Rxl9, pin 14 of UxOl switches from
High to Low, informing the microprocessor of a reverse
polarity condition. CRx03 acts as buffer. If a battery
is
connected
backwards,
the
charge
current is
immediately stopped.
(g) Temperature Sensor
The voltage reading produced on the divider consisting
of Rx25 and the thermistor is fed to the A/D converter
of the microprocessor. The thermistor (NTC) has a nominal resistance of lOOK ohms at 25°C (77°F).
If the thermistor becomes disconnected, the software
will simply ignore the temperature sensing.
5.5
Display Indicators
The LEDs are driven
the Control Circuit.
refer to Tables 6-1
manual.
5.6
by the 8-Bit Addressable Latch U6 of
For definition of the LED signals,
through 6-4 in Section 6 of this
Interface Jack
The DSL 6629 Charger is equipped with an internal Interface
Jack, P4, a 2x5 header on the main PCB. It provides access
to the serial lines to the microprocessor and has the analog reference voltages (V-sense) of all four batteries.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
29 of 52
90-November-12
NOTES:
0
Since no function is presently implemented
for the serial lines, the Interface Jack P4
is useful only for monitoring the sensed
battery voltages.
0
V-sense is the
Rx18
and Rx19
CRx01.
o
The
v-sense outpu~s cannot be loaded;
high-impedance voltmeter may be used.
battery voltage dropped by
and dropped through diode
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
30 of 52
90-November-12
a
6.0
AUDIO AND VISUAL INDICATORS
6.1
Good Battery Indications
GOOD BATTERY
CONDITION
No
Battery
Open
Terminal
Battery
Inserted
Battery
Ready
Fully
charged
CHARGING
LED
READY SOUNDER
LED
Off
Off
Silent
Reset
On
Off
Single
Beep
(high
pityh)
Fast
charge
Off
MODE
COMMENTS
.
On
'
Triple Trickle
beep
charge
(low or
high
pitch
sound)
Low or
high pitch
depending
on termination
method (1)
TABLE 6-1
N.B. Notes to Tables 6-1 through 6-4 follow Table 6-4.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
31 of 52
90-November-12
6.2
Faulty Battery Indications
FAULTY BATTERY
Reverse
Polarity
CONDITION
CHARGING READY
LED
LED
Negative
Battery
Voltage
Flashing Flash- Wailing
4 per
ing 1 sound
.
sec.
per
sec.
Short
SOUNDER
MODE
COMMENTS
No
charge
Inhibits
charge
immediately
Flash- Continu- No
ous
charge
ing
1 per sound
sec.
Off
Inhibits
charge in
9 seconds
(2)
'
Fail 1
Partial
short
Off
Flash- Silent
ing
1 per
sec.
No
charge
Inhibits
charge
after 3
minutes
(2)
Fail 2
Low
battery
voltage
Off
Flash- Silent
ing
2 per
sec.
No
charge
Inhibits
charge
after 30
minutes
(2)
Fail 3
Depressed
battery
voltage
Off
Flash- Silent
ing
4 per
sec.
Trickle Inhibits
charge fast
charge
after 3
hours (2)
Dry Cell
(3)
Battery
voltage
rises too
high
Off
Flash- Continu- No
ing
ous
charge
4 per beeping
sec.
Inhibits
all charge
after 6
seconds
(2)
Faulty
Battery
Connection (4)
Unable to
clamp
battery
voltage
Random
intervals
Off
Alternates
between
reset and
charge
Beeping Starts
(random) to
charge
then
resets
TABLE 6-2
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
32 of 52
90-November-12
6.3
Temperature-Related Indications
TEMPERATURE
CONDITION
CHARGING
LED
READY
LED
SOUNDER
Cold
Battery
Battery
temp is
less than
l5°C
(59°F)
Flashing
1 per
second
Off
Off
Trickle No fast
charge charge
when temp
is below
l5°C
(59°F)
Hot
Battery
Battery
temp is
more than
44°C
(lll°F)
Flashing
4 per
second
Off
Off
No
charge
Hot
Battery
Terrninated,
Normal
Voltage
Battery
cooled to
35°C
(95°F)
Flashing
4 per
second
Flash- Low
triple
ing
4 per beep
sec.
Trickle "BATTERY
charge HOT" is
only
indicated
on battery
with
normal
voltage
Hot
Battery
Terminated, Low
Voltage
Battery
cooled to
35°C
(95°F)
No
flashing
Flash- Off
ing
according
to
Fail
No
charge
.
MODE
COMMENTS
'
Low
voltage
battery
shows Fail
1, 2, or 3
1, 2,
or 3
TABLE 6-3
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
33 of 52
90-November-12
6.4
System Indications
SYSTEM CHECK
CONDITION POWER
LED
System System
Error fault
Overload
(NOT
imp lemented)
Internal
temp 60°C
(140°F)
or more
On or
off
CHARGING READY SOUNDER
LED
LED
MODE
COMMENTS
On or
off
On or Silent
off
or continuous
sound
Any
mode
CAUTION:
Do not
use in
this
state
Off
No
charge
c;m any
batt
Charge
will resume .when
temperature
normal(S)
Flash- Off
ing 4
per
second
Continuous
beeping
TABLE 6-4
(1) The high pitched (2400 Hz) triple beep is used when the full
charge is terminated by the Negative Slope Detector (normal
battery). On batteries with poorly matched cells, the Peak
Timeout Timer terminates the fast charge, indicated by a low
pitched triple beep (674 Hz).
(2) Above indicated time
supplied by DSL).
is
for charge rate of 0.33 (i.e., as
(3) The
"DRY CELL" condition is activated when battery voltage
rises too high while on Charge.
(4) "FAULTY BATTERY CONNECTION" occurs when the terminal voltage
cannot be sufficiently clamped.
(5)
As explained in Section 5.2(b) above, this feature is not
implemented on the Model 6629 Charger.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
34 of 52
90-November-12
CAUTION:
6.5
Troubleshooting and repairing of this instrument must
only be performed by a qualified technician. Disconnect power before opening instrument.
Failures of the Charger
SYMPTOM
POSSIBLE CAUSE
FAULT DiiGNOSTIC
1. No reset tone,
no LED when
power turned
on
• No AC voltage
. No control voltage
a. Check for open breaker
or control fuse in
power supply.
b. Check for 5.12V on pin
7 of Interface Jack or
on any IC.
c. If no control voltage,
cpeck fpr heating up
of Ul (LM317 on heatsink).
2. No reset tone,
some LED(s) on
• No clock
• Microprocessor
not reset
. Faulty reset
circuit
a. Check clock activity
(11.0592 MHz). NOTE:
Oscillator is
integrated in U3 .
b. Reactivate power
switch. Check for
low-to-high voltage on
pin 2 of U2.
c. Manually activate reset by momentarily
shorting pin 2 of U2
to ground. NOTE: If
microprocessor resets
with step 2a, problem
is in reset circuit.
3. CHARGING LED
[email protected] 1Hz
and continuous
tone (same as
short but with
no battery)
• Dead driver
• 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
Interface Jack.
V-sense for Station 2
is pin 3 of Interface
Jack. v-sense for
Station 3 is pin 6 of
Interface Jack.
V-sense for Station 4
is pin 4 of Interface
Jack.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
35 of 52
90-November-12
POSSIBLE CAUSE
SYMPTOM
FAULT DIAGNOSTIC
b. Check for short in
battery leads or
receptacle.
c. Check V-sense circuit.
d. If V-sense is low,
raise V by applying +V
.(5.12 V) and observe.
e. If no charge current,
initiate charge by
turning on Qx02
(momentarily connect
lK resistor from base
to ground and observe
charge current).
f. Examine pulse activity
of Charge Regulator on
pin 1 of UxOl.
If
dead:
g. Check voltage on input
side of Rx03 and Rx04
(leading to U3). NOTE:
Fast charge: Rx03
high. Trickle charge:
Rx04 high. No battery:
Rx03 & Rx04 low (no
charge). Short: Rx03 &
Rx04 low (no charge).
Hot battery: Rx03 &
Rx04 low (no charge).
Cold battery: Rx04
high (trickle charge) •
4. CHARGING LED
on, no
continuous
tone, (same as
fast charge
but with no
battery)
• Low line
voltage
. Faulty Driver
. Faulty Rev.Load
. Faulty V-sense
a. Check line voltage,
must be 100 VAC or
more.
b. Examine Charge Driver
and Reverse Load
Driver for leaky
component, ie, QxOl,
Qx03, CRx03.
c. Check V-sense circuit.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
36 of 52
90-November-12
SYMPTOM
POSSIBLE CAUSE
FAULT DIAGNOSTIC
5. CHARGING LED
flashing,
sounder
beeping,
(switching between reset
and charge
with no battery)
• Faulty battery
reset
a. Examine Rx21 (pull-up
resistor).
b. See also 4 a, b, & c.
NOTE: With no battery
in, all V-sense lines
· should be 5. 24V (reset
mode). Leakage in
v-sense circuit will
lower V-sense voltage,
stimulating a battery
and hence initiating
charge. V-sense rises
to reset mode, the
cnarge.is turned.off,
and the cycle is
repeated.
6. CHARGING LED
off, sounder
silent with
battery in
. Faulty battery
leads
. Faulty V-sense
a. Check for open battery
terminals, cables and
plug •
b. Examine drop in
V-sense when battery
inserted (clamping
action); if none:
c. Check for fault in
v-sense line (short to
+V).
d. Simulate v-sense drop
by placing lOOK from
Rxll to ground and
observe.
7. Good battery
fails:
. Charge current
too low
. No charge current
. Wrong charge
rate setting
(too high)
a. Analyze whether
problem is common to
all Stations. If yes:
check reference
voltage on pin 5 of
UxlOl; it should read
0.9V. If incorrect,
examine R105, R106,
C105, UlOl.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
37 of 52
90-November-12
POSSIBLE CAUSE
SYMPTOM
FAULT DIAGNOSTIC
b. Check charge rate setting. On DSL 6629,
setting is 0.33 (Code
0100). If problem is
isolated to one
station·:
c.·Examine charge current
by placing ammeter in
line with affected
battery. on the DSL
6629, charge current
should be between
0.8A and l.2A on good
battery.
d. If charge current.low,
examine· .Rxl O. NOTE :
All parallel power
resistors (set of 4)
should heat up
equally.
e. Examine charge pulse
on battery terminal.
Check for full positive wave. If only
partial wave present,
check pulse width in
Charge Regulator.
f. Check voltage on Rx03
(input side), must
read 5.12V; check CxOl
and UxOl.
g. If no charge, refer
also to 3 e, f, & g.
8. Battery gets
hot when in
charge mode
(see "Note" at
end of table)
. Old battery
. Wrong charge
rate setting
(too low)
. Faulty microprocessor
a. Old and leaky batteries heat up more
towards end of charge
cycle than do newer
batteries. No excessive heat build up
should occur with any
battery.
b. If charge rate setting
is too low, time-out
will be delayed. NOTE:
Timers are used on
Short, Fail modes, and
Peak Timeout Timer.
c. Observe microprocessor
for proper operation.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
38 of 52
90-November-12
POSSIBLE CAUSE
SYMPTOM
9. Battery gets
hot when in
READY mode
(see "Note" at
end of table)
. Trickle charge
current too
high
FAULT DIAGNOSTIC
a. Analyze whether
problem is common to
all Stations. If yes,
check reference
voltag~ on pin 5 of
UxlOl. It should read
· 0.9V. If incorrect,
examine R105, R106,
C105, 0101. If problem
is isolated to one
Station:
b. Examine charge current
by placing Ammeter in
line with affected
b~ttery. On DSL 6629,
charge current should
be between 0.2A and
0.3A on a good
battery.
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 Reverse Load.
Between charge pulses,
observe brief discharge. If missing,
check Reverse Load
Driver/Modulator,
check Qx03-1, Rx20;
also check voltage on
input of Rx12. Reference voltage on pin 10
of 0101 should read
3.25V when in charge
mode. NOTE: Fast
charge: Rx12 high (on
input side). Trickle
charge: Rx12 high (on
input side). No battery: Rx12 low (on
input side) .
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
39 of 52
90-November-12
POSSIBLE CAUSE
SYMPTOM
FAULT DIAGNOSTIC
10. CHARGING LED
[email protected]
lHz
. Ambient too
cold
. Faulty thermistor
11. CHARGING LED
[email protected]
4Hz
a. Check battery tempera. Thermistor hot
. Faulty thermisture. If thermistor
tor
reads more than 44°C
. Housing hot
{lll°F), Charger
switches to "Battery
Hot" mode.
b. See also 10 a, b, & c.
Note:
a. Check room temperature. If less than
15°C (59°F), fast
charge is disabled.
b. Check thermistor {lOOK
@ 25°C'or 77°F). NOTE:
· A temperature range of
15°C-44°C {59°F-lll°F)
produces v-temp of
3.4-l.7V.
c. Disconnect thermistor
and observe. v-temp
should reach 5.12V.
NOTE: If no thermistor
is used, temperature
s'ensing is ignored .
The temperature of a good battery will increase to
about 10 Celsius degrees above ambient at end of fast
charge.
On
older batteries, a 15 Celsius degree
increase is common. A nickel-cadmium cell should never
exceed 55°C.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
40 of 52
90-November-12
7.0
PARTS LIST
The following
which follows.
Rl
RxOl
RxOl-1
R2A"'D
Pl-1)\5
R3AA
R3ABA
R3AC
J9xl
J91x
R4 (Raised)
R5,7,9,x03 >
R12,15,18 >
lA -> 3A
SIDE??
conventions
are
used
in
the Parts List
- 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
- AAD: 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
DCH
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
PAN
HD
PH
SLOT, SL
-
Round (Head)
Binding (Head)
Pan (Head)
Head
Phillips Drive
Slot Drive
PCB, PC Board
-
Printed Circuit Board
Cl.ear
Board
Transformer
90*
u
CLR
BRD
TRAFO
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
41 of 52
90-November-12
on
Parts List, sheet 1 of 5
Item 15-010-2020
DSL6629 Charger 115V/60Hz. complete
Item No:
Description
Reference
17-721-0050
17-721-0040
17-650-0010
80-915-0010
16-150-0010
70-111-0003
75-108-2201
68-223-1801
69-132-0003
59-314-1001
50-121-0200
69-132-0004
62-726-0020
75-606-3201
66-504-5001
25-237-0001
69-121-0002
75-406-0202
75-206-0101
66-333-6601
68-723-1802
70-132-0002
57-111-0005
66-263-4301
75-408-0203
75-208-0101
75-606-1101
75-106-2203
75-106-2202
88-820-0001
AY, DSL6629 CHARGER BOARD
AY, DSL6629 LED BOARD
AY, CONTACT PLATE DSL66 •• FLOT
LOWER HOUSING, DSL6629 COMPLETE
UPPER HOUSING, DSL6629 COMPLETE
BUMPER, RUBBER .5xl"DIA BLACK
SCREW, 8-32xl/2 11 SS PH PAN
HOOK-UP WIRE, BLK 18AWG(l6x30)
TUBING, HEAT-SHRINK 3/16 11 BLACK
SWITCH, ROCKER lOA 250V I/0
CIRCUIT BREAKER, THERMAL 2A
TUBING, HEAT-SHRINK 1/4 11 BLACK
CONNECTOR, BLOCK 2-TERMINAL
SCREW, #6x5/8" TAPPING SS PH
FERRULE, 7mm NON-INSUL 16AWG
VARISTOR, RADIAL 4500A 130Vrms
TUBING, PVC 20AWG CLEAR
WASHER, LOCK #6 SS INTERNAL
NUT, 6-32 x 1/4" FLATS SP or SS
TERMINAL, #6 RING 22-18AWG
CORD, POWER GRY 8'SJT 3x18 115
STRAIN RELIEF, .300 11 WIRE DIA
TRANSF'R 150VA 115V 60Hz 42VCT
DISCONNECT, FEMALE 16-14AWG
WASHER, LOCK #8 SS EXT TOOTH
NUT 8-32x 11/32" FLATS SP or SS
SCREW, 6-32xl/4 11 SELF-CUT PH
SCREW, 6-32x3/8 11 SS PH PAN
SCREW, 6-32x3/8" SS PH FLAT
NAME PLATE, DSL6629
Sheet 2 of 5
Sheet 4 of 5
Sheet 5 of 5
1
1
4
1
1
4
8
1
0.1
1
1
0.,13
1
1
2
1
0.1
11
1
LOWER HOUSING
Tl, BUMPER
Sl, CBl
Sl
Sl
CBl
CBl
CONNECTOR BLOCK
RVl & PWR CORD
RVl
RVl
1
GND STUD
GND
1
1
1
3
8
4
3
PWR CORD
Tl
Tl SEC.
Tl - IN/OUTSIDE
Tl
LED BOARD
10
UPPER HOUSING
BACK OF UNIT
2
1
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
42 of 52
90-November-12
Parts List. sheet 2 of 5
Item 17-721-0050
AY. DSL6629 CHARGER BOARD
Item No:
Description
Reference
17-721-0010
90-101-0100
20-323-2613
20-323-5603
20-323-1183
20-323-4702
20-125-0471
20-323-1103
20-323-8252
20-323-5603
21-515-0820
21-515-0330
33-243-1001
68-110-2001
69-111-0002
64-121-2030
64-911-2020
21-535-0689
73-901-0010
75-306-1401
75-106-2201
72-102-1105
38-112-0001
36-222-4003
69-360-0003
69-220-0002
75-104-1201
68-110-2001
69-111-0002
AY, UNIV 4STN Cl CHARGER SUBBOARD 1
FIRMWARE, CCP VER CCll.0/.33
1
4
RESISTOR, 1/4W 1% 261k
4
RESISTOR, 1/4W 1% 560k
4
RESISTOR, 1/4W 1% 118k
4
RESISTOR, 1/4W 1% 47k
4
RESISTOR, 1/4W 5% 470R
RESISTOR, 1/4W 1% llOk
1
RESISTOR, 1/4W 1% 82k5
4
RESISTOR, 1/4W 1% 560k
1
4
RESISTOR, 5W 5% 82R
4
RESISTOR, 5W 5% 33R
DIODE, 1N5402 3A 200V
4
WIRE, BUS BAR 20AWG (SOLID)
0.25
TUBING, TEFLON 20AWG NATURAL
0.15
HEADER, 3-PIN .156" STRAIGHT
4
HEADER, lx2-PIN .455" STRAIGHT
1
RESISTOR, lOW 5% 6R8
16
HEAT RAIL, CBl ALU CLR CHROMAT
1
SPACER, • 250 11 ALU #6 HOLE
4
SCREW, 6-32xl/2" SS PH RD
4
1
PCB, BLANK ClOOO RESISTOR BRD
IC, LM317T POS V REG 1.5A
TRANSISTOR, PNP TIP42C -lOOV 6A
1
12
INSULATOR, T0-220 SILICON RUBB
WASHER, T0-220 .050 11 NYLON
9
9
SCREW, 4-40xl/4" SS PH RD
WIRE, BUS BAR 20AWG (SOLID)
1. 35
1.2
TUBING, TEFLON 20AWG NATURAL
Sheet 3 of 5
Rx04
Rx14
Rxl8
Rx19
Rx09
R105
Rx25
R327
Rx08
Rx20-1
CRx10,
J911"914,SIDE ??
J911"914,SIDE ??
PxOl
P5-3"4
RxlOA''D
Ul
Qx01-1,x02,x03-1
P110-1,P310-1
P110-l,P310-1
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
43 of 52
90-November-12
Parts List. sheet 3 of 5
Item 17-721-0010
AY, UNIV 4STN C1 CHARGER SUBBOARD
Item No:
Description
72-102-1103
20-125-0272
20-125-0102
20-125-0681
20-125-0105
20-323-1004
20-125-0473
20-125-0104
20-125-0474
20-125-0103
20-125-0273
20-125-0151
23-111-0501
22-110-2682
20-323-4702
20-125-0472
20-125-0682
20-323-5601
20-323-1002
28-247-1104
28-336-1105
28-276-1100
28-277-1102
28-952-2104
33-232-1001
33-131-1001
36-111-1001
40-104-1401
63-121-4280
41-203-2001
41-203-1603
51-112-0001
64-911-2101
43-201-6401
48-120-0001
69-111-0001
52-546-0160
66-161-0001
46-211-0001
28-627-1107
28-647-3477
PCB, BLANK ClOOO MAIN BOARD
RESISTOR, 1/4W 5% 2k7
RESISTOR, 1/4W 5% lk
RESISTOR, 1/4W 5% 680R
RESISTOR, 1/4W 5% lM
RESISTOR, 1/4W 1% lM
RESISTOR, 1/4W 5% 47k
RESISTOR, 1/4W 5% lOOk
RESISTOR, 1/4W 5% 470k
RESISTOR, 1/4W 5% lOk
RESISTOR, 1/4W 5% 27k
RESISTOR, 1/4W 5% 150R
TRIMMER, 1-TURN PCB 500R
RESISTOR, NW BUSSED lOSIP 6k8
RESISTOR, 1/4W 1% 47k
RESISTOR, 1/4W 5% 4k7
RESISTOR, 1/4W 5% 6k8
RESISTOR, 1/4W 1% 5k6
RESISTOR, 1/4W 1% lOk
CAPACITOR, MONO 20% 50V. luF
CAPACITOR, TANT 10% 35v luF
CAPACITOR, MONO 10% 200V lOpF
CAPACITOR, MONO 20% 200V. OOluF
CAPACITOR, MKT 2% 63V .luF
DIODE, 1N4002 lA lOOOV
DIODE, 1N4148 lOmA lOOV
TRANSISTOR, NPN 2N3904 40V
IC, 339 QUAD COMPARATER
IC SOCKET 28-PIN TIN DUAL LEAF
IC, 74HC373 OCTAL D-TYPE LATCH
IC, 74HC259 8-BIT ADDR LATCH
FUSE, CLIP 5mm PCB TYPE
HEADER, 2x5-PIN .455 11 STRAIGHT
IC, uPD78C10 MICRO-CONTROLLER
CRYSTAL, 2-LEAD 11.0592MHz
TUBING, TEFLON 22AWG NATURAL
FUSE, 5x20mm 1.6A 250V FST
QUICK CONNECT, MALE .250 11 PCB
TRANSDUCER, AUDIO QMB 70db 12V
CAPACITOR, ELEC RAD 25V lOOuF
CAPACITOR, ELEC RAD 50V 470uF
Reference
1
1
5
R2
R3,x02
Rx16
R7,11,13
Rxll
R9,10,12,x01,x03
R8,x22
R14
R15,17,x21
R4
R16
Rl
R20
R5,6,x15
Rx07,x17,x23
Rx24
Rx12
R206,xl3
C2,4,11"'13,x01
C6,7,105,x03
C8,9
4
3
4
11
5
1
6
1
1
1
1
6
12
4
4
5
9
7
2
1
4
2
cs
Cx02
CRl,2
CR3,x01,x02,x03
Ql,2
U2,x01
U4
13
2
5
1
us
1
1
2
1
1
1
0.04
1
3
1
1
1
U6
Fl
P4
U3
Yl (STICK TO U3)
Yl (.225 11 LONG)
Fl
Pl-1"'3
SIDE??
LSl
SIDE??
C3
SIDE??
Cl
SIDE??
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
44 of 52
90-November-12
Parts List. sheet 4 of 5
Item 17-721-0040
AY, DSL6629 LED BOARD
Item No:
Description
20-125-0221
46-111-0002
46-121-0002
46-131-0002
72-102-1104
68-525-0001
RESISTOR, l/4W 5% 220R
LED, ULTRA-RED/DIFF 3mm DIA
LED, SUPER-GREEN 3mm DIA
LED, YELLOW/DIFF 3mm DIA
PCB, BLANK CBlOOO DISPLAY BRO.
JUMPER, 8 11 LONG IO-CONDUCTOR
QtL.
9
4
4
1
1
1
Reference
R21"29
DSl,3,5,7
DS2,4,6,8
DS9
P3
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
45 of 52
90-November-12
Parts List. sheet 5 of 5
Item 17-650-0010
AY, CONTACT PLATE DSL66 ••
Item No:
Description
Reference
16-650-0100
17-680-0010
82-612-0020
69-250-0007
69-250-0008
75-700-2102
86-602-0001
86-502-0001
68-223-2401
75-748-0102
75-106-3201
75-406-0203
69-250-0006
75-706-0402
75-706-0401
AY, CONTACT B-D-GRN PTO XD
AY, CABLE HARNESS & THERMISTOR
CONTACT PLATE, DSL FLOATING
WASHER, #6 FLAT FIBRE GREY
WASHER, #6 FLAT FIBRE BLACK
RIVET, TUB .142x.375" BRASS OV
THERMAL JOINT COMPOUND, WHITE
HOT GLUE, WHITE
HOOK-UP WIRE, BLK 24AWG (7x32)
RET. RING, SELF-SEAT 3/16 11 EXT
SCREW, 6-32x5/811 SS PHIL PAN
WASHER, LOCK #6 SS SPLIT
WASHER, #6 EXTRUDED FIBRE
GUIDE POST, .250 11 DIA ALU
GUIDE POST, .375 11 DIA ALU
POS/NEG,FLOATING
RED+,BLK-,BLUE
2
1
1
1
1
1
0.1
0.1
0.2
2
2
2
RIVET
RIVET
ADD WASHER
THERM
SEAL RIVET
THERM
.015 11 GAP
BOTTO~ GUIDE
BOTTOM
CENTER
1
1
1
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
46 of 52
90-November-12
8.0
DRAWINGS
The following pages contain the drawings listed below:
Block Diagram
- Model 6629 Charger
1 sheet
Schematic Diagram
- Model 6629 Charger
1 sheet
Assembly Drawing
- Main PCB
1 sheet
Assembly Drawing
- Resistor Board PCB
1 sheet
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
47 of 52
90-November-12
This page left blank intentionally.
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
48 of 52
90-November-12
BLOCK
DIAGRAM OF DSL 6629 BATTERY FAST-CHARGER
REF#
<-- 42-1
< - 44-1
<-- 48-1
62-1 - >
64-1 - >
68-1 - >
~oNE
VAC
)
REF#
20 - - - >
22
>
24-1
24-2
24-3
24-4
AUXILIARY
CIRCUIT
<- 78
-->
-->
->
->
C
20
22
24
c
78
Reset
Overload
Code Selector
Transducer
42
44
48
V Sense
Battery Temperature
Reverse Polarity
62
64
68
Fast Charge
Trickle Charge
Reverse Load
72
74
76
Charge LED
Ready LED
Power LED
< - 42-2
<-- 44-2
<-- 48-2
62-2 -->
64-2 - >
68-2 -->
DRIVER
2
< - 42-3
< - 44-3
<-- 48-3
62-3 - >
64-3 - >
68-3 - >
DRIVER
3
<-- 42-4
< - 44-4
< - 48-4
62-4 - >
64-4 - >
68-4 - >
DRIVER
4
t - -_ __
+
M
I
R
0
REFERENCE#
+
DRIVER
1
0
N
T
R
0
L
L
E
R
0
+
+
0
0
0
o
Charge Charge Charge Charge
Power
0
0
0
0
Ready
Ready
Ready
Ready
76
72-1
74-1
72-2
74-2
72-3 _ _ _ _ _ _ ____,
74-3
72-4
t----74-4
Copyright 1990 DSL Dynamic Sciences Limited
Confidential Proprietary Information
176-0004-00 Issue 1
49 of 52
90-November-12
THtS DRAWING IS THE EXCt.USWE PROPERTY OF DSL DYNAMIC SCIENCES LIMITED (DSt.) AHO SHALL
NO~ USED, COPIED NOft TRANSMm'l!D TO ANY OTHER PARTY WITHOUT THE PRtOR EXPRESS
WR
N CONSENT OF DSL UPON EVALUATION OR OTHER USUAGE AS AUTHORIZED IN WRmNG BY
DSL, THIS DRAWING MUST BE RETURNED TO DSL
OWNBY
UNLESS OTHERWISE
SPECIFIED DIMENSIONS
ARE IN INCHES
VANCOUVER O
APPD
±
.xxx ±
DECIMAL .XX
FRACTION
ANGULAR
DSL DYNAMIC SCIENCES LIMITED
CHECKER
MATERIAL
±
TITLE
MONTREAL
O
RESISTOR BOARD PCB ASSY DWG
MODEL 6629 CHARGER
±
2-' Ff'b §$
DO NOT SCALE DWG
DRAWING STATUS
$
~
FINISH
PILOT
x PROO
DRAWING NO.
A
0
0
0
PROTO
REV
(PART NO.)
(DWO NO.)
RELEASE DATE
I SCALE
ISH I OF I
-
?I:)
w
C)
I
• •
•
• •
•
~'
•
•
'
I
;II;)
f\~:~
",~
•
I
•
""
• •
"
•
• •
• • •
e~,
. ~~
o'' ~,~
J
0· ' : $
0
7~
"
:1
I
. ..
•
.
0
-------------- ··-·· .. -----...
fl
0
•
..
113
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement