Motorola HTN9005 Series User manual

i1000
Professional Radio
Multi-Unit Chargers

CONTENTS
Important Safety Instructions ..............................................1
Introduction ...........................................................................3
General Description ..............................................................7
Circuit Description ................................................................9
Troubleshooting ....................................................................13
Exploded View.......................................................................19
Component location/Schematics/Parts List .......................20

1
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This document contains important safety and operating instructions. Please read these
instructions carefully and save them for future reference.
Before using the battery charger, read all the instructions and cautionary markings on (1) the
charger, (2) the battery, and (3) on the radio using the battery.
OPERATIONAL SAFETY GUIDELINES
• Turn radio off when charging 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 voltage (as
specified on the product).
• Disconnect from line voltage by removing mains plug.
• The socket outlet to which this equipment is connected should be close by and easily accessible.
• In equipment using fuses, replacements must comply with the type and rating specified in the
equipment instructions.
• Maximum ambient temperature around the power supply equipment must not exceed 40°C
(104°F).
• Output power from the power supply unit must not exceed the ratings stated on the product label
located on the bottom of the charger.
• Make sure the cord is located where it will not be stepped on, tripped over, or subjected to water,
damage, or stress.
!
WARNING
1. To reduce risk of injury, charge only the rechargeable Motorola authorised
batteries listed in Table 1. Other batteries may explode, causing personal injury
and damage.
2. Use of accessories not recommended by Motorola may result in risk of fire,
electric shock, or injury.
3. To reduce risk of damage to the electric plug and cord, pull by the plug rather
than the cord when disconnecting the charger.
4. An extension cord should not be used unless absolutely necessary. Use of an
improper extension cord could result in risk of fire and electric shock. If an
extension cord must be used, make sure that the cord size is 18AWG for lengths
up to 100 feet (30.48 m), and 16AWG for lengths up to 150 feet (45.72 m).
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. To reduce risk of electric shock, unplug the charger from the ac outlet before
attempting any repair, maintenance or cleaning.

2
RECHARGEABLE BATTERY DISPOSAL OR RECYCLING
Motorola is concerned about the environment and fully endorses and encourages the recycling or safe
disposal of rechargeable batteries. Legislation exists in many countries regarding the collection,
transportation and classification of spent batteries. Contact should be made with the relevant Government
departments such as Environment or Waste Management Agencies for specific local requirements. Motorola
participate in many battery collection schemes sometimes in partnership with Distributors and Industry.
Please contact your nearest Motorola operation for details or assistance.
Legislation now clearly identify ALL rechargeable chemistries as potentially harmful to the environment.
NiCd batteries must be recycled or disposed of properly and cannot be incinerated or disposed of in landfill
sites.
Currently recycling of Lithium Ion is being developed, therefore at this time incineration by registered
operators is the safest practice.

3
INTRODUCTION
Scope of Manual
This manual is intended for use by service technicians familiar with similar types of equipment. It contains
service information required for the equipment described and is current as of the printing date. Changes which
occur after the printing date may be incorporated by a complete manual revision or alternatively as additions.
NOTE: Before operating or testing these units, please read the IMPORTANT SAFETY INSTRUCTIONS
Section in the front of this manual.
Warranty and Service Support
Motorola offers long term support for its products. This support includes full exchange and/or repair of the
product during the warranty period, and service/ repair or spare parts support out of warranty. Any "return for
exchange" or "return for repair" by an authorised Motorola Dealer must be accompanied by a Warranty Claim
Form. Warranty Claim Forms are obtained by contacting an Authorised Motorola Dealer.
Warranty Period and Return Instructions
The terms and conditions of warranty are defined fully in the Motorola Dealer or Distributor or Reseller
contract. These conditions may change from time to time and the following notes are for guidance purposes
only.
In instances where the product is covered under a "return for replacement" or "return for repair" warranty, a
check of the product should be performed prior to shipping the unit back to Motorola. This is to ensure that the
product has been correctly programmed or has not been subjected to damage outside the terms of the
warranty.
Prior to shipping any radio back to the appropriate Motorola warranty depot, please contact Customer
Resources (please refer to pages 4 and 5 in this Chapter). All returns must be accompanied by a Warranty
Claim Form, available from your Customer Services representative. Products should be shipped back in the
original packaging, or correctly packaged to ensure no damage occurs in transit.
After Warranty Period
After the Warranty period, Motorola continues to support its products in two ways.
1. Motorola’s Radio Aftermarket and Accessory Division (AAD) offers a repair service to both end users and
dealers at competitive prices.
2. AAD supplies individual parts and modules that can be purchased by dealers who are
technically capable of performing fault analysis and repair.

4
European Radio Support Centre (ERSC)
The ERSC Customer Information Desk is available through the following service numbers:
Austria: 06 60 75 41 Italy: 16 78 77 387
Belgium: 08 00 72 471 Luxemburg: 08 00 23 27
Denmark: 80 01 55 72 Netherlands: 60 22 45 13
Finland: 08 00 11 49 10 Norway: 80 01 11 15
France: 05 90 30 90 Portugal: 05 05 49 35 70
Germany: 01 30 18 75 24 Spain: 90 09 84 902
Greece: 00 80 04 91 29 020 Sweden: 02 07 94 307
UK : 08 00 96 90 95 Switzerland: 1 55 30 82
Ireland: 18 00 55 50 21 Iceland: 80 08 147
Or dial Customer Care Centre:
Tel: [phone]
Please use these numbers for repair enquiries only.
Piece Parts
Some replacement parts, spare parts, and/or product information can be ordered directly. If a complete
Motorola part number is assigned to the part, it is available from Motorola Radio Aftermarket and Accessory
Division (AAD). If no part number is assigned, the part is not normally available from Motorola. If the part
number is appended with an asterisk, the part is serviceable by Motorola Depot only. If a parts list is not
included, this generally means that no user-serviceable parts are available for that kit or assembly.
All part orders should be directed to:
Motorola GmbH
European Parts Department
65232 Taunusstein
Germany.

5
Technical Support
Motorola Product Services is available to assist the dealer/distributors in resolving any malfunctions
which may be encountered.
UK/Ireland - Richard Russell
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Central/East Europe - Siggy Punzenberger
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Northern Europe - Bjorn Rambert
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Germany
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
France - Lionel Lhermitte
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Italy - Ugo Gentile
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Africa & Middle East - Ralph Schubert
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

6

7
GENERAL DESCRIPTION
The MDHTN3004/ MDHTN3005 Multi-Unit Battery Chargers are accessory items for Motorola Professional
Radios using rechargeable nickel cadmium (Ni-Cd), nickel-metal-hydride (NiMH), and/or lithium-ion (Li-Ion)
batteries.
The MDHTN3004/ MDHTN3005 Multi-Unit Battery Charger kit comprise the following items listed in Table 1
The battery chargers are constant-current devices which can charge up to six batteries simultaneously. Each
charging pocket provides three different charge rates: a rapid-charge rate, trickle-charge rate, and a
maintenance-charge rate. Any of the batteries listed in Table 2 is charged initially at the rapid-charge rate (until
90% charged), reduced to the trickle-charge rate (until fully charged), and finally reduced to a maintenance-
charge rate to keep the battery at full charge. The battery may be left in the battery charger indefinitely without
any resultant harm.
The multi-unit rapid chargers are powered by an auto-ranging, switching power supply. The power supply will
operate on input source voltages between 90 and 265Vac. The appropriate ac power cable is provided with
the charger as detailed in Table 1. Table 2 provides a list of batteries that are approved for use with the
MDHTN3004/ MDHTN3005 Multi-Unit Battery Chargers. It is important to know that rechargeable batteries
other than those listed in Table 2, may not charge. Additional multi-unit battery charger information, such as
operating instructions, and troubleshooting (by understanding the light emitting diode (LED) indications), can
be found in the applicable Professional Radio Multi-Unit Charger Accessories User Guide (Part Number
6864110B33).
Table 1. MDHTN3004/MDHTN3005 Kits
Item Description
HTN9005 series Charger base
NTN7374 220/230Vac (Euro. plug) part of MDHTN3004
NTN7375 230/240Vac (UK plug) part of MDHTN3005
68P64110B33 User Guide
Table 2. Motorola Authorised Batteries
Battery Battery Description/Chemistry
HNN9008 High Capacity/NiMH
HNN9009 Ultra-High Capacity/NiMH
HNN9010 Ultra-High Capacity/Factory Mutual/NiMH
HNN9011 Ultra-High Capacity/Factory Mutual/NiCd
HNN9012 High Capacity/NiCd
HNN9013 High Capacity/Lithium-Ion
*HNN4023 High Capacity/Lithium-Ion
*HNN4024 High Capacity/Lithium-Ion
*Used with HTN9005C(and later) Series Chargers: not
compatible with HTN9005 Aand BSeries Chargers.

8
SPECIFICATIONS
Table 3 lists multi-unit battery charger specifications.
Table 3. Specifications
Multi-Unit Charger Specification
Input Voltage between 90 and 265Vac; 50/60Hz
Size 44.7cm x 30.5cm x 13.5cm (17.6in. x 12in. x 5.3in.)
Weight 3.93 Kg (8.65lbs.)
Rapid Charge Rate 1200 mA Hours ±15% per pocket
Operating Temperature Range 0°C - 50°C
Rapid-Charge Temperature Window above 0°C (32°F) and below 50°C (122°F)

9
CIRCUIT DESCRIPTION
(Refer to the Block Diagram (Figure 1) and the Schematic Diagram.)
General
The MDHTN3004/ MDHTN3005 Series Multi-Unit Battery Charger is comprised of six battery charger circuits
(charger pockets) that operate independent of each other. The electronic circuitry of each pocket is identical.
Although the circuit description that follows applies to the circuitry of any one of the six battery charger
pockets, the component reference symbols used in the block diagram, in the schematic diagram, and in the
component location diagram, apply only to pocket one. Component reference symbols, silk-screened on the
physical circuit board, in pockets 2 through 6 are unique for their particular pockets. Refer to the parts list on
the back of the schematic diagram for the corresponding reference symbols used in the circuitry of pockets
two through six.
DC Power Supply
Input line voltage (between 90 and 265Vac) is applied to the multi-unit charger dc power supply. The dc power
supply converts the ac voltage to dc voltage. The output of the dc power supply is a regulated 12.5Vdc that is
routed through a jack/plug connector and applied to each of the six charger circuits. The 12.5Vdc is received
directly on the printed circuit board at E1/E2, red and black wires, 12.5Vdc and ground respectively. The
12.5Vdc is routed through fuse F1, and applied to the circuitry as V_IN. The dc power supply is a non-
repairable unit. Refer to the electrical parts list for the replacement Motorola part number.
Other dc power in the circuitry is produced by:
•a 5-volt regulator within module U3 supplies a regulated 5 volts (+5V) at U3 pin 13, which is distributed
throughout the multi-unit charger circuitry.
•a Zener diode (U1) supplies a regulated 2.5 volts (+2.5V) to the micro controller (uC) at U4 pin 13.
Buck Regulator
The input voltage from the dc power supply (V_IN) is converted to a current source by the Buck-regulator,
consisting of transistor Q6, coil L1, and capacitor C16. The Buck-regulator is driven by a pulse width
modulated (PWM) switch-mode voltage/current regulator controller module U3 at approximately 76 kHz. The
Buck regulator output is connected through a diode (D5) directly to the VBATT line (load). Blocking diode D5
prevents excess leakage current from the battery when the input power source is disconnected or OFF.
Pulse Width Modulator
The pulse width modulated (PWM) switch-mode controller (U3) is an integrated circuit operating at
approximately 76 kHz. Module U3 provides an appropriate pulse width signal to the Buck-regulator (Q6/L1/
C16), such that the value of the analog feedback signal across the current-sensing resistor (R58) equals the
value of current set by the D/A integrator, comprised of operational amplifier (Op Amp) U5D, capacitor C40,
and resistor R23. When these two signals are exactly equal, the correct charging current is being delivered to
the battery, as determined by the µC (U2). The output drive signal is sent to the Buck regulator driver
transistors Q11 and Q12. Integral to the PWM circuit is a hardware over-voltage safety cut-off circuit,
comprised of resistors R14 and R55, which feeds battery voltage back to one of the PWM error amplifiers.
The PWM will turn off the charger when the battery voltage exceeds a nominal 12.4 Vdc.

10
Precision Reference
A +2.5v reference is derived from a precision voltage regulator, Zener diode (U1). This reference provides the
accuracy required for Lithium battery charge control. It is measured by the microcontroller (U2), via the
multiplexer (MUX) X0 and X5 inputs at U4 pins 13 and 5 respectively.
Microcontroller (µC)
The microcontroller (µC), module U2 queries the battery EPROM to determine the type of battery to be
charged. All Professional Radio batteries use an EPROM to identify the battery type; none use a code
resistor. The microcontroller then evaluates battery parameters from the MUX (U4) via Current Control D/A
Integrator U5A and U5C, and sets an appropriate charge current. The battery parameters evaluated include
B+ voltage (battery state of charge) and thermistor voltage (battery temperature). The general operation is
described in the CHARGER OPERATION paragraphs (Nickel Batteries and Lithium Batteries). The
microcontroller controls the amount of charging current via the Current Control D/A Integrator circuitry of Op
Amp U5A. It analyses the Charge Current measurement from Op Amp U5B and makes appropriate
adjustments. Also, the microcontroller produces red, green, and yellow LED control signals for each charger.
In addition to the LED states described in the CHARGER OPERATION paragraphs, the charger also supports
flashing red and flashing yellow states. A flashing red LED indicates that a fault has been detected.
Detectable faults include open B+ and B- contacts, and invalid battery type (faulty battery EPROM data), and
a charger self-test (checksum) fault. A flashing yellow LED indicates standby mode. This can be initiated by
low battery voltage or out-of-range (high or low temperature) thermistor values.
Multiplexer
The multiplexer (MUX), U4, is used to increase the number of A/D inputs at the microcontroller (U2). The
autozero reference, +2.5V, VBATT, Thermistor, and Rcode (not used) values are available at the X0 through
X7 pins of the MUX. These parameters are sampled sequentially by the microcontroller via MUX channel
address inputs at U4 pins 9, 10, 11. The selected input value appears on the X output at U4 pin 3. This output
is passed through a differential amplifier (Op Amps U5A and U5C) to remove noise effects due to ripple
current passing through the current-sense resistor (R58). The values are then sent to the microcontroller A/D
input at U2 pin 1.
Current Control, Digital-to-Analog (D/A) Integrator
The D/A integrator is a resistor-capacitor, low pass filter comprised of resistors R38/R40 and capacitor C40.
The circuit receives a PWM signal from the microcontroller at U2 pin 4 (to decrease current) or from U2 pin 12
(to increase current), wherein the microcontroller PWM output signal is de-modulated by feeding it through the
low pass filter to recover the average value of the PWM signal. To improve the performance of the low pass
filter, an Op Amp (U5D) is used. The input of the Op-amp is biased at 2.5volts to allow single supply
operation. The output of the op-amp is divided by a resistor string to set the appropriate current level at the
Buck regulator controller (U3 pin 2). This signal is also fed back to the microcontroller (U2 pin 3) to improve
the accuracy and stability of the D/A via software control techniques.
Autozero Circuit
To improve the accuracy of the charging current, an Op-Amp (U5B) is used to amplify the signal. The input of
the Op-Amp, from the current sensing resistor (R58), is controlled by the auto-zeroing, field-effect transistor
(FET), Q5 switch. Under control of the microprocessor (U2 pin 13), the FET switch operates such that the
current feedback signal can be “short circuited”. When the auto-zeroing FET (Q5) is turned “off”by the
microcontroller logic, the amplified value of the regulated current feedback signal, including the effect of the
amplifier offset error, is brought into the software through the A/D input of the microcontroller (U2 pin 2). When
the auto-zeroing amplifier FET (Q5) is turned “on”by the uC logic, the current feedback signal is shorted out,

11
and the input to the op-amp is now equal to the value of only the amplifier offset error, Vos. The software
algorithm operates on the A/D values read and stored in the steps above and corrects the current feedback
signal. The microcomputer (U2 pins 4 and 12) now commands the Current Control D/A integrator (U5A) to
increase or decrease the current, thereby bringing it to the corrected value.
Light-Emitting Diode (LED) Drivers
Component D4 is a dual, light emitting diode. One side is red and the other side is green. Via transistor Q1, a
signal from the microprocessor (U2 pin 17) controls the green side of the LED. Via transistor Q9, a signal from
the microprocessor (U2 pin 16) controls the red side of the LED. When the microprocessor activates both
sides of the LED at the same time, a yellow glow is achieved.
BATTERY CHARGER OPERATION
Nickel Batteries
A battery or radio with battery (radio turned off) is placed in one of the six battery charger pockets. The
charger instantly detects the battery. If both battery temperature and battery voltage are in normal ranges, the
battery charger will begin the rapid charge process, and the LED of that pocket will light red. At the completion
of the rapid-charge mode, the charge current reduces to a trickle-charge rate, and the LED of that pocket will
flash green, indicating that the battery is charged to >90% of available capacity and that the battery is in the
trickle-charge mode. The battery will trickle charge for approximately two hours. At the end of the trickle-
charge cycle, the charge current reduces to a fully-charged rate, and the LED of that pocket will change to a
steady green, indicating that the battery is charged to approximately 100% of available capacity. While in the
fully-charged mode, if the measured battery voltage drops below the defined cut-off voltage minus a defined
delta voltage, the charger reverts to the rapid charge mode, the LED indicates red, and the process resumes.
If the battery current exceeds a predetermined value, a polyswitch in the battery will act as a fuse (self
resetting) to protect the battery from overheating. The polyswitch is also temperature sensitive, and will open
above a preset temperature.
If the:
•temperature rise of the battery exceeds a defined rate, or
•if the battery voltage reaches or exceeds the defined cut-off voltage, or
•if the battery temperature reaches or exceeds the defined cut-off temperature, or
•if the charger has been charging for longer than the defined time limit,
the charger will stop charging and the LED will flash yellow. The charger will wait until the parameter is within
specification to begin the normal charge cycles.
Lithium Batteries
A battery or radio with battery (radio turned off) is placed in one of the six battery charger pockets. The
charger instantly detects the battery. If both battery temperature and battery voltage are in normal ranges, the
battery charger will begin the rapid charge process, and the LED of that pocket will light red. At the completion
of the rapid-charge mode, the charge current reduces to a trickle-charge rate, and the LED of that pocket will
flash green, indicating that the battery is charged to >90% of available capacity and that the battery is in the
trickle-charge mode. The battery will trickle charge for approximately two hours. At the end of the trickle-
charge cycle, the charge current reduces to a fully-charged rate, and the LED of that pocket will change to a
steady green, indicating that the battery is charged to approximately 100% of available capacity. While in the
fully-charged mode, if the measured battery voltage drops below the defined cut-off voltage minus a defined
delta voltage, the charger reverts to the rapid charge mode, the LED indicates red, and the process resumes.
The battery itself has a safety circuit to protect the battery and the user. If the battery voltage exceeds

12
approximately 8.4 VDC, or if the battery current exceeds a predetermined value, two transistors will open the
charging circuit, preventing a potentially hazardous condition.
If the:
•temperature rise of the battery exceeds a defined rate, or
•if the battery voltage reaches or exceeds the defined cut-off voltage, or
•if the battery temperature reaches or exceeds the defined cut-off temperature, or
•if the charger has been charging for longer than the defined time limit,
the charger will stop charging and the LED will flash yellow. The charger will wait until the parameter is within
specification to begin the normal charge cycles.
Figure 1. Multi-Unit Charger Block Diagram
2
1
J4
3
U4
MUX
U2
µC
V BATT
BATT-1
EPROM
THERMISTOR
B
A
T
T
E
R
Y
4
Q1/Q9
D4
LED
U5A
U5C
U5D
CURRENT
CONTROL D/A
U3
PWM
V IN
+5V +2.5V
U5B
R58
CURRENT
SENSE
Q5
AUTOZERO
Q11/Q12 DRIVERS
Q6, L1, C16 BUCK REGULATOR
D5 BLOCKING DIODE
E1 E2
F1
U1
ZENER

13
TROUBLESHOOTING
When troubleshooting, always observe the colour of the LED:
No LED Indication?
1. Check that the radio with battery, or the battery alone, is inserted correctly.
2. Make sure that the power cord is plugged into an appropriate ac outlet.
Flashing Red LED Indicator?
1. Remove the battery from the charger, and:
a. make sure that it is a Motorola authorised battery listed in Table1. Other batteries may not charge.
b. remove power from the battery charger and, using a clean dry cloth, clean the gold metal, charging con-
tacts of the battery and charger.
2. Power up the charger and place the battery back into the charger pocket. If the LED indicator continues to
flash red, replace the battery.
Flashing Yellow LED Indicator?
—the battery temperature may be below 5°C (41°F) or above 40°C (104°F).
—the voltage may be lower than the predetermined threshold level for rapid charging.
Note: Rapid charging outside of the stated temperature and voltage limits can drastically reduce the life
expectancy of the battery.
Note: When the battery charger detects the proper battery conditions, rapid charging begins automatically
(steady red LED).
Table 4. LED Indications of Battery/Charger Status
LED Colour Battery/Charger Status
No LED indication Battery is inserted incorrectly.
Single flash green Successful charger power-up.
Flashing red Battery is unchargeable or not making proper contact.
Steady red Battery is in rapid-charge mode.
Flashing yellow Battery is in charger, not in rapid-charge mode, but waiting to be charged.
Flashing green Battery is charged (to 90% or greater capacity).
Steady green Battery is fully charged.

14
Test Procedures
All connections made for resistance and voltage measurements are referenced to Battery- (BATT-1).
Table 5. Test Procedures
Test Setup Procedure Pass
Requirements Record Data
VBATT Thermistor EPROM Power
1
Battery Drain
(Charger off) 9.8V 0.33V Connected Off Measure current through
VBATT and record as
I DRAIN.
I DRAIN:
0.5 mA. I DRAIN is:
2
Low Current
Accuracy 4.0V 0.87V Connected On
Measure current into VBATT
after sufficient delay; verify
status of the LED and
measure I LOW
(Battery Charger Current).
Green LED On; I
LOW =
50mA ± 20mA
I LOW is:
3
Low Voltage
Lower Limit
Detection
4.1V 0.98V Connected On Measure current into VBATT after sufficient delay, verify
status of the LED.
LED Off;
0.5 mA current
into VBATT
LED is:
4
Voltage
Upper limit
and High
Temp. Lower
Limit
Detection
4.7V 0.98V Connected On Measure current into VBATT after sufficient delay; verify
status of the LED.
Red LED On;
0.5 mA current
into VBATT
LED is:
5
High Temp.
Upper Limit
Detection
4.7V 0.98V Connected On
Reduce Vth until LED = Off.
Measure current into VBATT
after sufficient delay; verify
status of the LED.
LED Off;
0.5 mA current
into VBATT;
Vth = 0.94V
±.050V
Vth is:
6
Low Temp.
Upper Limit
Detection
8.3V 1.81V Connected On Measure current into VBATT after sufficient delay; verify
status of the LED.
Red LED On;
0.5 mA current
into VBATT
LED is:
7
Low Temp.
Lower Limit
Detection
8.3V 1.81V Connected On Increase Vth until LED = Off. Measure current into VBATT
after sufficient delay; verify
status of the LED.
LED Off; Vth =
1.86V ±50mV;
0.5 mA current
into VBATT
Vth is:
8
High Voltage
Lower Limit
Detection
8.3V 1.81V Connected On Measure current into VBATT after sufficient delay; verify
status of the LED.
Red LED On;
0.5 mA current
into Battery+
LED is:
9
High Voltage
Upper Limit
Detection
8.3V 1.81V Connected On Increase VBATT until LED =
OFF. Measure current into
VBATT after sufficient delay;
verify status of the LED.
LED Off;
0.5 mA current
into VBATT;
VBATT = 8.4V±
0.10V
VBATT is:

15
Battery Diagram
The partial view of the battery and the simplified schematic diagram in Figure 2, illustrate the charging
contacts and the contact’s associated name.
Figure 2. Battery Diagram
10
High Current
Accuracy 8.7V 1.98V Connected On
Measure current into VBATT
after sufficient delay; verify
status of the LED.
Green LED On; I
BAT=1250mA±
15%intoVBATT;
I Source =
850mA.
I BAT:
I Source:
11
Hardware
Cut-Off
Voltage
Accuracy
10.95V 1.98V Connected On
Increment battery voltage
(VBATT) in 0.10 Volt steps
until current falls. After
sufficient delay, measure
VBATT and current into
VBATT.
VBATT is
11.6V
13.3V
VBATT is:
12
A/D
Reference
Accuracy
None None None On Measure voltage between
Thermistor contact and
Battery- contact.
VTHERMISTOR
is  2.4830V, 
2.510 V
VTHERM.
is:
Table 5. Test Procedures
13
24
1
2
3
4
EPROM
Thermistor
+
VBATT
THERMISTOR
EPROM
BATT -1

16
Battery Charger Problems and Possible Cause
Table 6 lists several problems that could occur with the multi-unit battery charger. Each of the problems
corresponds with a corresponding test procedure described in Table 5.
Table 6. Problems/Possible Causes of Failure
Problem Related Test
Procedure Possible Cause of Failure
Battery Drain Current 1 D5 shorted
Low Current Accuracy Ibat 2 U2, U3, U4, U5, and other current amp, PWM, and Buck regulator
circuit components missing, cold solder, or component failure
Low Current Accuracy LED On
(Green) 2D4, Q1, R4, R29, U2-17 missing, cold solder, or component
failure
Low Voltage Lower Limit
Detection Ibat 3 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49 missing, cold solder, or component failure
Low Voltage Lower Limit
Detection LED Off 3 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49 missing, cold solder; Q1 or Q9 shorted
Low Voltage Upper Limit and
High Temp Lower Limit
Detection Ibat
4 U2, U4, U5, R3, R20, R21, R26, R46, R47, R48, R49 missing, cold
solder, or component failure; Q8 shorted
Low Voltage Upper Limit and
High Temp Lower Limit
Detection LED On (Red)
4 D4, Q9, R13, R30, U2-18 missing, cold solder, or component failure
High Temp Upper Limit
Detection Ibat 5 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49 missing, cold solder, or component failure; Q8 shorted
High Temp Upper Limit
Detection LED Off 5 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49, Q8 missing, cold solder, or component failure; Q1 or Q9 shorted
Low Temp Upper Limit
Detection Ibat 6 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49 missing, cold solder, or component failure; Q8 shorted
Low Temp Upper Limit
Detection LED On (Red) 6 D4, Q9, R13, R30, U2-18 missing, cold solder, or component failure
Low Temp Lower Limit
Detection Ibat 7 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49 missing, cold solder, or component failure; Q8 shorted
Low Temp Lower Limit
Detection LED Off 7 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49 missing, cold solder, or component failure; Q1 or Q9 shorted
High Voltage Lower Limit
Detection Ibat 8 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49 missing, cold solder, or component failure
High Voltage Lower Limit
Detection LED On (Red) 8 D4, Q9, R13, R30, U2-18 missing, cold solder, or component failure
High Voltage Upper Limit
Detection Ibat 9 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49 missing, cold solder, or component failure
High Voltage Upper Limit
Detection LED Off 9 U2, U4, U5, R20, R21, R26, R46, R47, R48, R49 missing, cold solder, or component failure; Q1 or Q9 shorted

17
MAINTENANCE
Introduction
This section of the manual describes preventive maintenance, safe handling of CMOS devices, and repair
procedures and techniques. Each of these topics provides information vital to the successful operation and
maintenance of your multi-unit battery charger.
Preventive Maintenance
The HTN9005 Series Multi-Unit Battery Chargers do not require a scheduled preventive maintenance
program; however, periodic visual inspection and cleaning is recommended.
Inspection
Check that the external surfaces of the multi-unit battery charger are clean, and that the power supply fan and
charger pocket LEDs are functional. A detailed inspection of the interior electronic circuitry is not needed or
desired.
Cleaning
The following procedures describe the recommended cleaning agents and the methods to be used when
cleaning the external and internal surfaces of the multi-unit battery charger. External surfaces should be
cleaned whenever a periodic visual inspection reveals the presence of smudges, grease, and/or grime.
Internal surfaces should be cleaned only when the multi-unit charger is disassembled for servicing or repair.
The only recommended agent for cleaning the external plastic surfaces is a 0.5% solution of a mild
dishwashing detergent, such as JOY®, in water. The only factory recommended liquid for cleaning the printed
circuit boards and their components is isopropyl alcohol (70% by volume).
High Current Accuracy Ibat 10 U2, U3, U4, U5, and other current amp, PWM, and Buck regulator
circuit components missing, cold solder, or component failure
High Current Accuracy LED On
(Green) 10 D7,Q2,R6,R20,U3-17 missing, cold solder, or component failure
Hardware Cut-Off Voltage
Accuracy 11 U3, R55 missing, cold solder, or component failure;
R14 shorted or wrong value
A/D Reference Accuracy 12 U1, R22 (2.5V regulator), R3 missing, cold solder, or component
failure
Table 6. Problems/Possible Causes of Failure
Problem Related Test
Procedure Possible Cause of Failure
The effects of certain chemicals and their vapors can have harmful results on certain
plastics. Aerosol sprays, tuner cleaners, and other chemicals should be avoided.
!
C a u t i o n

18
Cleaning External Plastic Surfaces
The detergent-water solution should be applied sparingly with a stiff, non-metallic, short-bristled brush to work
all loose dirt away from the battery charger. A soft, absorbent, lintless cloth or tissue should be used to
remove the solution and dry the battery charger. Make sure that no water remains entrapped near the
connectors, cracks, or crevices.
Cleaning Circuit Boards and Components
Isopropyl alcohol may be applied with a stiff, non-metallic, short-bristled brush to dislodge embedded or caked
materials located in hard-to-reach areas. The brush stroke should direct the dislodged material out and away
from the inside of the multi-unit battery charger.
Alcohol is a high-wetting liquid and can carry contamination into unwanted places if an excessive quantity is
used. Make sure that controls or tunable components are not soaked with the liquid. Do not use high-pressure
air to hasten the drying process, since this could cause the liquid to puddle and collect in unwanted places.
Upon completion of the cleaning process, use a soft, absorbent, lintless cloth to dry the area. Do not brush or
apply any isopropyl alcohol to the plastic parts of the multi-unit battery charger.
NOTE: Always use a fresh supply of alcohol and a clean container to prevent contamination by dissolved
material (from previous usage).
Safe Handling of CMOS Devices
Complementary metal-oxide semiconductor (CMOS) devices are used in this family of multi-unit battery
chargers. While the benefits of CMOS are many, their characteristics make them susceptible to damage by
electrostatic or high voltage charges. Damage can be latent, resulting in failures occurring weeks or months
later. Therefore, you must take special precautions to prevent device damage during disassembly,
troubleshooting, and repair. Handling precautions are mandatory for CMOS circuits, and are especially
important in low humidity conditions. DO NOT attempt to disassemble the multi-unit battery charger without
first referring to the CMOS CAUTION paragraph in the Disassembly and Reassembly section of the
applicable radio service manual.
Repair Procedures and Techniques
Parts Replacement and Substitution
Special care should be taken to be as certain as possible that a suspected component is actually the one at
fault. This special care will eliminate unnecessary unsoldering and removal of parts, which could damage or
weaken other components or the printed circuit board itself.
When damaged parts are replaced, identical parts should be used. If the identical replacement component is
not locally available, check the parts list for the proper Motorola part number and order the component from
the nearest Motorola Communications Parts office listed in the Piece Parts Availability section
(refer to Page 3).
Rigid Circuit Boards
This family of multi-unit battery chargers uses bonded, multi-layer, printed circuit boards. Since the inner
layers are not accessible, some special considerations are required when soldering and unsoldering
components. The printed-through holes may interconnect multiple layers of the printed circuit. Therefore, care
should be exercised to avoid pulling the plated circuit out of the hole.
When soldering near the module socket pins, use care to avoid accidentally getting solder in the socket. Also,
be careful not to form solder bridges between the module socket pins. Closely examine your work for shorts
due to solder bridges. When removing modules with metal enclosures, be sure to desolder the enclosure
ground tabs as well as the module pins.