ISAT-100 Battery Replacement Manual

DOC0945

Applies to: ISAT-100 Mod None, Mod A, Mod AB

Document Revision: 01-000

June 2, 2011

SkyTrac Systems Ltd.

#200-170 Rutland Rd North
Kelowna, BC Canada
Tel. (250) 765-2393
Fax (250) 765-3767
Web: www.skytrac.ca
Email: techsupport@skytrac.ca

Copyright © 2011 SkyTrac Systems Ltd.

All rights reserved.
 SkyTrac Systems Ltd.

Document Revision History

Rev ECO Page Description Date Author
S. Thornber,
000.01 Initial Release 10 June2009
K. Lengert
Removed ambiguous instructions and
01.000 433 All added clarification. Added power up 2 June 2011 K. Lengert
check and battery checks.

Proprietary Notice: The Information contained in this document is proprietary and

confidential to SkyTrac Systems Ltd.

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Table Of Contents
1 Introduction ..................................................................................................................... 4
2 Parts List ......................................................................................................................... 4
3 Battery Precautions & Handling Instructions ................................................................... 5
4 Pre-Installation Battery Verification ................................................................................. 5
5 ISAT-100 Disassembly.................................................................................................... 6
6 Battery Replacement..................................................................................................... 12
7 ISAT-100 Assembly ...................................................................................................... 13
8 Post-Installation Battery Verification.............................................................................. 20

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1 INTRODUCTION

This manual contains information necessary to perform battery replacement of a SkyTrac

ISAT-100 Position/Data Communicator. Maintenance and repair procedures specified in this
manual that require disassembly of components are to be completed by an approved repair
facility.

The manual has been prepared to assist the approved facility to restore the equipment to
the original performance by the use of recommended maintenance, repairs and upgrades.

2 PARTS LIST

SkyTrac Systems Quantity Description Manufacturer & Part

Ltd. Part Number Number
BATTERY 12VDC 1.2AH, SkyTrac Systems Ltd.
ISAT-100-BAT 1
Sealed Lead-Acid ISAT-100-BAT
Threadlocker 243 Oil
Loctite® 243 As Required Loctite® 243
Resistant/Medium Strength
Panduit
TIE-CABL-PLT1.51 1 PANDUIT PLT1.5I CABLE TIE
PLT1.51

Screws and fasteners shall be reused as long as they are not damaged. Screw and fastener
sizes and descriptions are listed throughout this document.

CAUTION: Screws/fasteners are of a specific length/size and for design

purposes. Do not use any screws/fasteners that are not identical to original
parts.

Example: The #4 flat washers (WSH-FLT4-020) used in SkyTrac Systems Ltd products are
of a special outer diameter. Using too large of a flat #4 washer could result in electrical
shortages on the PCB’s.

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3 BATTERY PRECAUTIONS & HANDLING INSTRUCTIONS

• To avoid risk of explosion, do not place batteries near any source of sparks, heat or
fire.
• Avoid charging them in an upside-down position. If these batteries are charged
excessively, leakage of electrolyte from safety vents might occur.
• Avoid exposing or locating the batteries near a heat generating device.
• Do not press, bend or heat the terminals (such as solder).
• Charge battery immediately after deep-discharge and charge them before use.
• Never use a cracked, deformed or leaking battery
• Store the batteries under fully charged state and keep in a dry and low temperature
place. Also recharge them at least every 3 months during storage.
• Do not short-circuit or disassemble the battery.
• Never dispose the batteries into fire or garbage bin, especially in countries where
there are legal or voluntary regulations on recycling of batteries.
• The battery housing is made of ABS plastic and should be cleaned with a soft cloth
only. Do not use organic solvents or adhesives.
• In the event that acid (electrolyte) makes contact with eyes, wash eyes with clean,
cold water and consult a physician immediately.

4 PRE-INSTALLATION BATTERY VERIFICATION

Applies to: ISAT-100-BAT

Equipment:

• Voltmeter
• 0-30VDC 3A Power Supply

Instructions:

1. Measure the voltage across the terminals of the new battery. Expected voltage is a
minimum of 11.0VDC
2. If the battery voltage is between 11.0VDC and 12.2VDC, use a power supply set to
13.6VDC and current limited to 1.2A to charge the battery for about 1 hour. (Longer
charge time will not hurt the battery). Then disconnect the power supply and verify
the battery voltage is above 12.2VDC.

CAUTION: Do not reverse the polarity of the battery when charging!

3. If the battery fails to meet the voltage requirements contact SkyTrac Systems. Proper
maintenance must be maintained for batteries in storage. Charge every 3 months.

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5 ISAT-100 DISASSEMBLY

CAUTION: Before any work is performed ensure you are in a static safe
environment and wearing an antistatic wrist strap or equivalent
Note: All screws and fasteners will be reused unless damage has occurred. No stripped or
otherwise damaged screw or fastener shall be used. All screws use either a #1 or #2 Phillips
head screwdriver.

• Remove warranty stickers if present.

Note: Removing the warranty stickers voids the warranty of the ISAT-100. The battery
should not require replacement before the warranty period is over.

• Remove the two mounting rails on the sides of the ISAT using a #2 Phillips screwdriver.

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• Remove the bottom panel using #1 Phillips screw driver.

• Cut the zip tie holding the power cable to the modem very carefully so as to not nick the
wires.

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• Remove 2 screws, using #2 Phillips screw driver from the right side of the enclosure at
the front of the enclosure.

• Remove 2 screws, using #2 Phillips screw driver from the left side of the enclosure at the
rear of the enclosure.

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• Remove the 4 screws holding the top panel down using #1 Phillips screwdriver.

• Remove the nut and washer from the GPS SMA connector at the rear of the ISAT using
a 5/14 wrench or nut driver. Push the SMA connector into the ISAT. The SMA connector
is keyed to the hole so you may need to adjust the connector until it can be passed into
the ISAT. The rear label will also cause obstruction for the connector to pass into the
ISAT. This cable is delicate, proceed with caution.

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• Disconnect the programming cable from the GPS PCB.

• Place something soft and antistatic to the top panel like a piece of anti-static bubble wrap
that can be held in place with tape to prevent the top panel from scratching or causing
electrical shorts to other areas of the ISAT while the unit is apart.

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• Gently pull apart the ISAT, rotate the left and right sides so they are sitting on their
chassis. Ensure the top panel does not short any other exposed areas.

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6 BATTERY REPLACEMENT

• Disconnect the battery cable (ISAT-100-CAB-001) from the front panel.

• Remove battery as shown in the figure below.

• Disconnect battery cable (ISAT-100-CAB-001) and reattach to the new battery. Ensure
the connections to the battery are snug, they should not slide off without resistance.
Install new battery.

CAUTION: Connect the battery cable to the battery with red to red and
black to black. Do not reverse the polarity.

Reference STS Part Number Description QTY

# 14 SCW-FLT6-375 SCREW FLAT HEAD PHILIPS 6/32 4
3/8” SS
# 40 Part of: ISAT-100-MEC-ENCL ENCLOSURE LEFT 1
# 29 ISAT-100-CAB-001 Battery Cable 1
# 28 ISAT-100-MEC-BH BATTERY HOLDER, ALUM. 1
# 21 NUT-LOCK-NO6 NUT LOCKNUT #6 4

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7 ISAT-100 ASSEMBLY

Note: LocTite® 243 must be used on all metal penetrating screws/fasteners.

• Now with the new battery installed and the battery cable connected to the front panel,
confirm the PCB’s are in the locations show below. Carefully feed the GPS SMA
connector through the rear panel and connect the lock washer and nut.

Reference STS Part Number Description QTY

# 27 CAB-ASSY-007 GPS Antenna Cable 1
# 56 Part of: GPS/SMA STAR WASHER (PART OF 1
ISAT-100-CAB-007 GPS CABLE REF # 27)
# 57 Part of: GPS/SMA THREADING NUT (PART OF 1
ISAT-100-CAB-007 GPS CABLEREF #27)

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• Fold the modem over top of the battery and PCB assembly; lay the GPS PCB flat
on the table. Make sure there are no pinched cables and the screw holes line up
easily.

View before side screws are installed

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• Insert the 2 screws on each side that were removed in the disassembly taking
care the GPS cable does not suffer any strain.

Reference STS Part Number Description QTY

# 14 SCW-FLT6-375 SCREW FLAT HEAD PHILIPS 6/32 3/8” SS 4

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• The programming cable should fold neatly (not pinched) along the back of the battery
so the connector comes out at the top of the unit.

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• Screw down top panel ensuring no cables are being pinched.

Reference STS Part Number Description QTY

# 36 SCW-FLT4-187 SCREW FLAT HEAD PHILIPS 4-40 4
3/16” SS

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Reference STS Part Number Description QTY

# 59 TIE-CABLE-PLT1.5I PANDUIT PLT1.5I CABLE TIE 1

• Before sealing the unit, check that all cables are free flowing and that none are
pinched. Install bottom cover,

Reference STS Part Number Description QTY

# 36 SCW-FLT4-187 SCREW FLAT HEAD PHILIPS 4-40 3/16” 4
# 18 Part of: ENCLOSURE BOTTOM 1
ISAT-100-MEC-ENCL

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Reference STS Part Number Description QTY

# 13 SCW-FL10-250 SCREW FLAT HEAD PHILIPS 10-32 ¼” SS 4
# 30 ISAT-100-MEC-MR MOUNTING RAIL 2

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8 POST-INSTALLATION BATTERY VERIFICATION

Note: Always have the Iridium TNC connector connected to either an Iridium antenna or
50ohm dummy load when power is to be applied.

Equipment:

• 0-30VDC 3A Power Supply (set for +28VDC)

• STS-ISAT-ANT Combo GPS/Iridium Antenna or

STS0040/48 Iridium puck antenna or

50 ohm dummy load with 1.6 GHz and 10W minimum

(example Amphenol Connex part # 202117)

Instructions:

1. Connect an antenna or dummy load to Iridium TNC connector at the rear of ISAT. (If
using the STS-ISAT-ANT dual antenna, connect the GPS as well).

2. With a power supply set for +28VDC current limited to about 1.2A, apply +28VDC to
pin A on J1 System Connector and ground to pins B &C on J1 System Connector.

3. Verify initial current (first 30 seconds of power up) is less than 300mA. If the current is
higher there could be an electrical short and steps taken to prevent damage to the
ISAT.

4. After the first 30 seconds, the battery charging circuit will initialize and you can expect
the power supply current to jump up to about a maximum of 1.5A. This current should
then drop steadily as the battery charges and will settle to about 400mA or lower.

5. Ensure “PWR” and “CHG” LED’s are on solid. The “BAT” LED should blink for
approximately 30 seconds before becoming solid.

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6. Turn off the power supply, keep pins B & C on J1 System Connector connected to
ground, ensure the ISAT remains on. The LED’s should follow the below description:

LED Status
PWR Off
CHG Off
MDM Blinking or solid
GPS Blinking or solid
BAT Solid for about 30 seconds
then blinking

If the ISAT does not remain on, check that pin C on J1 System Connector is
connected to ground to enable the battery circuit. Open the bottom panel and confirm
battery cable is connected to the front panel and the cable terminals are connected
properly to the battery.

7. The ISAT should remain on with the above LED statuses. Expect complete shutoff of
the ISAT between 30 seconds and 5min17seconds. (Time is dependent on the
firmware version installed and whether an antenna or dummy load is connected to
the TNC connector).

If the ISAT shuts off immediately then there is no battery power. Check that the
battery is connected to the front panel of the ISAT and if needed perform step 4
again. Contact SkyTrac Client Services for any difficulties.

8. When an ISAT is not installed into an aircraft, the ISAT needs to be charged every 3
months. Refer to the ISAT-100 Specifications, Operating Instructions and Install
Manual (ISAT-100-OPD-SOI) for charging instructions.

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