Skytrac DSAT-300 Series Use and care manual

DSAT-300 Battery Replacement Instructions
DOC0595
Applies to: 108-300-01, 108-300-02
Document Revision: 01.000
Dec 15, 2009
SkyTrac Systems Ltd.
200-170 Rutland Road
Kelowna, BC Canada
Tel. [phone]
Fax [phone]
Web: www.skytrac.ca
Email: s[email protected]
Copyright © 2009 SkyTrac Systems Ltd.
All rights reserved.

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Proprietary Notice: The Information contained in this document is
proprietary and confidential to SkyTrac Systems Ltd.
Document Revision History
Rev Page Description Date Author Approval
01.000 237 Initial Release Dec 15, 2009 CB T. Ratch

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Table Of Contents
1 Battery Replacement Procedures..............................................................................4
2 DSAT-300E...................................................................................................................4
3 DSAT-300I ..................................................................................................................14

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1 B ATTERY R EPLACEMENT P ROCEDURES
The battery replacement procedure is given as a number of steps below. The actual
appearance of parts may differ from those shown. Pictures are for reference only.
2 DSAT-300E
Note: To avoid damage to the unit due to Electro Static Discharge (ESD) the battery
replacement should be performed in an ESD controlled environment, i.e. on an electrically
conductive mat with the person performing the replacement using an ESD strap connected
to the mat/ground at all times. Avoid touching the circuit board and its’ components.
1. Unfasten and remove the screws from the DSAT-300 at 6 locations using a #1
Phillips head screw driver (screw: Phillips #4-40). Retain the screws for later use.
Figure 1–Screw Locations
2. Turn the DSAT-300 over and lift the top enclosure from the right side as shown in
Figure2 , creating a hinge on the left end of the enclosure.
Figure2–Unhinging theEnclosures

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3. Hold the top enclosure perpendicular to the bottom enclosure as shown in Figure3 .
Figure3–PerpendicularPosition
Note: It is recommended to ensure that the Top Enclosure is held (or rested against a
wall) on top of the bottom enclosure similar to the Figure below in order to avoid the
connectors otherwise the connectors can short components on the microprocessor.
Figure4–RecommendedEnclosure“Resting”Position

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4. Disconnect the Batteries from the PCB.
Figure5–Disconnecting theBatteries
5. Release the batteries from between the battery cross bar and battery mounting
foam.
Figure6–BatteryRelease

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6. Slip the battery connectors under the battery cross bar where there is no heat shrink
(mid region) and remove the batteries as shown in Figure7 .
Figure7–BatteryRemoval
7. Take one of the replacement batteries and bend the cable around the front face to
the right as shown in Figure8 .
Figure8–BatteryCable Bend

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8. Bend the cables to the side with a loop as shown in Figure9 .
Figure9–BottomBatteryCable Bends
9. Repeat steps 7 and 0 for the second battery but to the left this time to get a battery
with cables bent to the left as shown in Figure10 .
Figure10–Top BatteryCable Bends

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10. Take the battery with its cables bent to the right and slide its connector underneath
the battery cross bar as shown in Figure11 .
Figure11–BatteryConnectorTuck
11. Position the battery between the battery mounting foam and the battery cross bar
ensuring that the body is tangent to the mounting standoffs of the enclosure as
shown in the Figure below.
Figure12–BatteryPosition

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12. Orient the battery so that the battery cable and its circuit are upwards as shown in
Figure13 . This will eliminate assembly collisions.
Figure13–BatteryOrientation
13. Connect the battery connectors to their nearest receptacle. Ensure that the Bottom
battery cable is over top the GPS cable as shown in Figure14 .
Figure14–BatteryConnection

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14. Repeat the above steps for the second battery, the battery installation should now
look like Figure15 .
Figure15–BatteryInstallation Complete
15. Lower the top enclosure onto the bottom enclosure creating a pivot at the right end
as shown in the Figure17 .
Figure16–LoweringtheEnclosures
Note: The IRIDIUM® modem is to be sandwiched between the batteries.

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Figure17–EnclosurePivotingat RightSide
16. Before mating the top and bottom enclosure together ensure that the Iridium Cable
is tucked beneath the battery cross bar. Refer to Figure18 .
Figure18–IridiumCable Tuck

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17. Slowly clamp the top and bottom enclosures together until they are slightly ajar or
fully shut, similar to similar to Figure19 .
Figure 19 –Enclosure AssemblyGap
18. Turn the assembly over and fasten the top and bottom enclosures together at 6
places using #4-40 screws from step one.
Warning: Do not exceed a torque of 3.2 in-lbs when fastening the enclosure together.

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3 DSAT-300I
1. Unfasten and remove the screws from the DSAT-300 at 6 locations using a #1
Phillips head screw driver (screw: Phillips #4-40). Retain the screws for later use.
Figure 20 – Screw Locations
2. Turn the DSAT over and lift the top enclosure from the right side as shown in Figure
21 , creating a hinge on the left end of the enclosure.
Figure21–UnhingingtheEnclosures

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3. Hold the top enclosure perpendicular to the bottom enclosure as shown in
4. Figure22
Figure22–PerpendicularPosition
5. Disconnect the Batteries from the PCB and remove the top enclosure assembly.
Figure23–DisconnectingtheBatteries

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6. Release the batteries from between the battery cross bar and battery mounting
foam.
Figure24–BatteryRelease
Slip the battery connectors under the battery cross bar where there is no heat shrink
(mid region) and remove the batteries as shown in
7. Figure25 .
Figure25–BatteryRemoval

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8. Take the new battery and tuck its connector underneath the Battery Cross Bar.
Figure26–BatteryConnectorTuck
9. Bend the Battery Cable around the front face of the Battery as shown in Figure 27.
Figure27–BatteryCable Position
10. Position the Battery between the cross bar and mounting foam and ensure that the
battery is tangent to the mounting standoffs of the enclosure.

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Figure28–BatteryTangenttoMountingBosses
11. Orient the battery cable and battery’s circuit board upwards in order to avoid
collisions with the modem during assembly.
Figure29– BatteryCable Orientation
12. Bend the battery cable roughly 180 degrees and push the cable down towards the
enclosure as shown in Figure30 . This will ensure that the cable will not collide with the
PCB during installation.
Figure30– BatteryCableDeformation

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Warning: It is extremely important that the positions of the battery cables are clear of
collisions with the push button connector, battery connectors, and any contact with the
PCB.
13. Repeat steps 9 to 12 for the second battery.
Figure31– BatteryInstallationComplete
14. Connect the battery connectors to their nearest receptacle as shown in Figure32 .
During battery connections, ensure that the Iridium cable is looped around the
battery connectors as highlighted in the circled area of the Figure below.
Figure32– BatteryConnectionswith Iridium Cable Detour

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15. Lower the top enclosure assembly onto the bottom enclosure assembly. Ensure the
power connector and USB receptacle are aligned properly.
16. Pivot the two enclosures at the power connector end as shown in Figure33 .
Figure33– ImaginaryEnclosureHinge
Warning: Forcing the enclosures together at this point would induce stresses in the PCB
resulting in undesirable deflection.
17. Slowly clamp the top and bottom enclosures together until they are slightly ajar or
fully shut, similar to Figure34 .
Figure 34 –Enclosure AssemblyGap
18. Turn the assembly over and fasten the top and bottom enclosures together at 6
places using #4-40 screws from step one.
Warning: Do not exceed a torque of 3.2 in-lbs when fastening the enclosure together.