Synthes Universal Battery Charger II User manual

USER‘S MANUAL
UNIVERSAL
BATTERY CHARGER II

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools
TABLE OF CONTENTS
INTRODUCTION
OPERATING INSTRUCTIONS
CARE AND MAINTENANCE
TROUBLESHOOTING 18
SYSTEM SPECIFICATIONS 21
ELECTROMAGNETIC COMPATIBILITY 25
ORDERING INFORMATION 33
General Information 2
• Intended use 2
• Compatibility 2
• Abbreviations 2
• Safety precautions 3
• Scope of delivery 3
• Storage and transport 3
• Warranty 3
Description of the Controls 4
Starting the System 5
Charging the Battery/Power Module 6
• Charging the battery 6
• Temperature monitoring 7
• Charging new batteries or batteries 7
not recently used
• Errors during charging 7
Checking and Refreshing Batteries/Power Module 8
• Battery Power Line and
Small Battery Drive batteries 8
• Battery Power Line II and
Small Battery Drive II batteries 10
• Trauma Recon System power module 12
Storing Batteries 13
Slot Covers Set 14
Cleaning 15
Repair and Technical Service 16
Disposal 17

2 DePuy Synthes Power Tools Universal Battery Charger II User’s Manual
Intended use
The Universal Battery Charger II (05.001.204), referred to
henceforth as the charger or device, allows the following
DePuy Synthes Power Tools batteries to be automatically
charged and manually checked:
INTRODUCTION
General Information
System Handpieces Battery/ Power Module
Battery Power Line 530.605 530.620 (14.4 V, NiMH)
530.610
530.615
Battery Power Line II 530.705 530.630 (14.8 V, Li-Ion)
530.710
530.715
Trauma Recon System 05.001.201 05.001.202 (25.2 V, Li-Ion)
05.001.240
Small Battery Drive 532.010 532.003 (12 V, NiCd)
532.033 (14.4 V, NiCd)
Small Battery Drive II 532.110 532.103 (14.4 V, Li-Ion)
If required, Battery Power Line battery (530.620) and Small
Battery Drive batteries (532.003, 532.033) can also be
refreshed with the charger (see page 8).
Compatibility
The Small Battery Drive batteries (532.003, 532.033) can be
used with Small Battery Drive II handpiece (532.110).
The Small Battery Drive II battery (532.103) can be used with
the Small Battery Drive handpiece (532.010).
The Battery Power Line battery (530.620) can be used with
the Battery Power Line II handpieces (530.705, 530.710,
530.715).
The Battery Power Line II battery (530.630) can be used with
the Battery Power Line handpieces (530.605, 530.610,
530.615).
Precaution: The battery for the Power Drive (530.200)
cannot be charged with the UBC II. Please use the UBC
item number 530.601.
Abbreviations
Please note the below mentioned items are abbreviated
throughout the document as follows:
Items Abbreviation
Small Battery Drive SBD
Small Battery Drive II SBD II
Power Module for Trauma Recon System Power Module
Universal Battery Charger II UBC II

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools 3
Safety precautions
The device may only be used with the supplied power cord.
The device may only be operated on an even, dry surface
that is sufficiently strong to hold its weight.
Avoid contact with fluids.
The device is designed to be operated and stored in closed
rooms. Ensure that the device is not operated in the direct
vicinity of radiators or other heat emitting devices (please
refer to page 23 for details on environmental conditions).
Please observe the information on the electromagnetic
compatibility, see page 25.
The device may only be used for the authorized
DePuy Synthes Power Tools batteries.
Before operating the device, check that it is in sound
condition and is working properly.
If it is not in perfect working order, contact the
DePuy Synthes Power Tools representative. Do not use
a damaged or faulty device.
Precautions:
xOnly use the DePuy Synthes Power Tools Universal Battery
Charger II (05.001.204) to charge batteries. Using a charger
that is not from DePuy Synthes Power Tools can damage
the battery/power module.
x
Do not open device. Risk of fatal injury due to electric
shock!
xDo not use the device in the sterile area of the operating
room.
xThe device must not come into direct or indirect contact
with the patient.
xDo not use the device in patient vicinity. The patient
vicinity is an area 2.5 m above and 1.5 m next to the
patient (see Fig. on the right).
xDo not wash the device in a washer/disinfector. The device
must not be sterilized. Please see page 15 for information
on cleaning and maintenance.
xDo not operate the device in the presence of a flammable
anesthetics mixture with air or oxygen or with nitrous oxide.
xDo not expose the device to direct sunlight or moisture.
xThe charging station should always be turned on when
a battery is in the charging bay. This ensures availability
and prevents discharge.
Introduction
General Information
Scope of delivery
The Universal Battery Charger II consists of the charger
(05.001.204), power cord (05.001.140), and four slot covers
set (05.001.228). The device may only be used with the
supplied power cord.
Storage and transport
All batteries/power modules should be removed for
transporting the charger.
Use the original packaging for shipping and transport.
If this is no longer available, please contact the
DePuy Synthes Power Tools representative.
The same environmental conditions apply for transport as
for storage, see page 23.
Warranty
The warranty for the device is null and void if the device has
not been used properly or the guarantee seal has been
damaged. The manufacturer does not accept liability for
damage resulting from repairs or maintenance carried out by
unauthorized sites. For a complete warranty statement, please
contact the DePuy Synthes Power Tools Customer Service.
1.5 m1.5 m
1.5 m
2.5 m

4 DePuy Synthes Power Tools Universal Battery Charger II User’s Manual
8
7
9
6
4
3
5
1
2
Front view
1Charger bays (24)
2Symbols for battery type
3ON/OFF display
4Control display for each charging bay
5Ventilation holes
DESCRIPTION OF THE CONTROLS
Rear view
6Ventilation holes
7ON/OFF power switch
8Fuses: 225 AT / 250 V
9Power cord connection
11
12
10
Charger bay
The device is fitted with four independent charger bays. Each
of these has three slots for the following batteries:
10 Battery Power Line and Battery Power Line II batteries
(530.620, 530.630)
11 Trauma Recon System Power Module (05.001.202)
12 SBD and SBD II batteries (532.003, 532.033, 532.103)

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools 5
Before starting for the first time, ensure that the power
switch is set to . The device can only be connected to the
power supply using the supplied power cord. Set the power
switch to Ito turn the device on (Fig. 1). The ON/OFF display
light on the front of the device will illuminate (Fig. 2). If the
display flashes, the device must be sent in for repair.
Note: If the red display light for a single charger bay
lights up (Fig. 3) before the battery is inserted, this
charger bay is faulty. In this case, batteries can still be
charged in the other charger bays, but it is recommended
that the device be sent to the DePuy Synthes Power Tools
Service Department for repair.
Precautions:
xPlace the device on a non-slip, stable base. Ensure
that the ventilation holes in the base of the device are
not covered by towels or other objects.
xDo not position the device so that it is difficult to
separate the power cord from the supply mains.
xDo not operate the device in the direct vicinity of
radiators or other heat emitting devices, as these can
affect the device.
xDo not expose the device to direct sunlight or moisture.
xDo not cover the side ventilation holes on the device.
xConnect only to a power supply with grounding, a
rated voltage between 100 V and 240 V and a
network frequency range of 50 or 60 Hz.
OPERATING INSTRUCTIONS
Starting the System
Fig. 1
Fig. 2
Fig. 3

6 DePuy Synthes Power Tools Universal Battery Charger II User’s Manual
Operating Instructions
CHARGING THE BATTERY/POWER MODULE
Fig. 1
Fig. 2
Charging the battery
Place the battery to be charged in the proper direction into
the corresponding slot of an empty charger bay. Only one
battery can be charged in each charger bay at a time.
All charger bays can, however, be used simultaneously with
any combination of battery types.
Once the battery types have been identified the charging
process starts automatically. This is signalled by the yellow
charger display (Fig. 1).
Depending on the charge status and type of battery, it can
take from about 15 minutes to around 60 minutes to charge.
Once the battery is fully charged, the green display lights
up and the charger switches to maintenance charge (Fig. 2).
The battery can be left in the charger. Leave the device
switched on to ensure that the battery is always fully charged.
If the battery is removed from the charger before the green
display lights up, it will not be fully charged.
Precautions:
xInsert the battery into the correct slot.
xEnsure that the battery is fitted correctly and is
identified by the device (yellow charger display
lights up).
xIf the display does not light up after the battery is
inserted, remove the battery and insert again or
insert into another charger bay.
xDo not insert any objects other than batteries into the
charger, as the contacts may otherwise be damaged.

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools 7
flashing
Temperature monitoring
The battery and the charger heat up during the charging
process. The ventilation holes should therefore not be
covered.
If the battery temperature is too high, the yellow charger
display starts flashing (Fig. 3). To protect the battery, the
device stops charging until the battery has cooled down.
Do not remove the battery from the charger if this occurs
until the yellow charger display lights up constantly. The
charging time will be longer in this case.
Charging new batteries or batteries not recently used
Battery Power Line battery (530.620) or SBD batteries
(532.003, 532.033) that have not been used for a long
period of time and that have not been stored in an activated
charger do not reach their maximum performance for several
charging and discharging cycles. In case of doubt, the
charger can be used to check the battery status and to
refresh the battery (see page 8).
Errors during charging
The following errors may occur while charging a battery:
Yellow display light flashes (Fig. 3)
The battery is too hot and has to cool down before the
charging process can be automatically resumed. The battery
can be left in the charger.
Red display light lights up (Fig. 4)
The battery is faulty and has to be replaced.
No display light
The battery has not engaged in the charging bay or has
not been recognized by the device. Remove the battery and
insert again or use another charger bay.
Precautions:
xDo not charge mechanically damaged batteries in the
charger.
xOnly charge batteries authorized for the device
(see page 29).
xOnly use fully charged batteries to avoid delays
during surgery.
Operating Instructions
Charging the Battery/Power Module
Fig. 3
Fig. 4

8 DePuy Synthes Power Tools Universal Battery Charger II User’s Manual
Operating Instructions
CHECKING AND REFRESHING BATTERIES/
POWER MODULE
Battery Power Line and SBD batteries
The charger enables Battery Power Line battery (530.620)
and SBD batteries (532.003, 532.033) to be refreshed and
checked.
It will be indicated if the battery performance is sufficient or
if the battery needs to be replaced.
The following factors will affect the battery performance
xUnused, new battery
xBattery not used for a longer period
In these cases a battery will only reach its maximum
performance after several charging and discharging cycles.
The check and refresh function ensures that the battery
regains its maximum performance again.
xOld battery
The battery performance declines with age and usage.
With the check function it can be seen if the battery
performance is sufficient. However, due to the age of the
battery it is no longer possible to refresh it.
When required, the check and refresh function is started
manually, as outlined below.
After the battery is inserted, the yellow charger display
lights up. To refresh and check the battery, press the button
with the exclamation mark for at least 2 seconds (Fig. 1)
until the yellow display light lights up (Fig. 2). The device
then carries out the process. The yellow display lights up
throughout this time.
Fig. 1
Fig. 2

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools 9
Operating Instructions
Checking and Refreshing Batteries/Power Module
Completion of the process is indicated as follows:
xGreen display light (Fig. 3): Battery has been
successfully refreshed, checked, and charged.
xRed display light (Fig. 4): Either the battery is faulty
or performance is insufficient. The battery must be
disposed of.
The entire process (refreshing and checking battery
status) takes around 10 hours and should only
be carried out if there is enough time to do so.
A battery can be charged, checked, or refreshed
independently in each charger bay.
Precautions:
xTo recharge batteries normally, do not press the
exclamation mark button .
xChecking the battery status and refreshing the battery
have an impact on the battery. If this is carried out
frequently the lifespan of the battery can be affected.
xDo not remove the battery from the charger bay as
long as the yellow display lights up (Fig. 2 on
previous page). Wait until the process has ended and
the green or red display lights up. Only then is
the battery status clearly assessed.
xThe process is interrupted if there is a power cut or a
switch to the emergency power supply and will then
have to be restarted.
Fig. 3
Fig. 4

10 DePuy Synthes Power Tools Universal Battery Charger II User’s Manual
Battery Power Line II and SBD II batteries
The charger enables Battery Power Line II and SBD II batteries
(530.630, 532.103) to be checked. It will be indicated if the
battery performance is sufficient or if the battery needs to be
replaced.
Due to the very low self-discharging rate of Lithium-based
batteries a refresh function is not required.
When required, the check function is started manually, as
outlined below.
After the battery is inserted, the yellow charger display
lights up. To check the battery, press the button with the
exclamation mark for at least 2 seconds (Fig. 5) until the
yellow display light lights up (Fig. 6). The device then
carries out the process. The yellow display lights up
throughout this time.
Fig. 5
Fig. 6
Operating Instructions
Checking and Refreshing Batteries/Power Module

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools 11
Operating Instructions
Checking and Refreshing Batteries/Power Module
Completion of the process is indicated as follows:
xGreen display light (Fig. 7): Battery has been
successfully checked and charged.
xRed display light (Fig. 8): Either the battery is faulty or
performance is insufficient. The battery must be disposed of.
The entire process (checking battery status) takes
around 3 hours and should only be carried out if there
is enough time to do so.
A battery can be charged or checked independently in each
charger bay.
Precautions:
xTo recharge batteries normally, do not press the
exclamation mark button .
xChecking the battery status has an impact on the
battery. If this is carried out frequently the lifespan
of the battery can be affected.
xDo not remove the battery from the charger bay as
long as the yellow display lights up (Fig. 6 on
previous page). Wait until the process has ended and
the green or red display lights up. Only then is
the battery status clearly assessed.
xThe process is interrupted if there is a power cut or a
switch to the emergency power supply and will then
have to be restarted.
Fig. 7
Fig. 8

12 DePuy Synthes Power Tools Universal Battery Charger II User’s Manual
Trauma Recon System power module
To ensure that the Trauma Recon System (05.001.201,
05.001.240) is operating properly, the Trauma Recon System
power module (05.001.202) has to be checked at periodical
intervals. It will be indicated if the power module performance
is sufficient or if the power module needs to be replaced.
The charger will indicate the necessity, but the user can
choose a convenient time to check the power module,
as this can take around 4 hours.
When it needs to be checked, the yellow display light flashes
(Fig. 9). The check needs to be carried out within the next
3 charging cycles. This is done by pressing the exclamation mark
button for at least 2 seconds (Fig. 10). The yellow charger
display goes out and the display changes from flashing to
lighting up (Fig. 11). If the check is not carried out within the
next 3 charging cycles, the device carries out the check
automatically.
Completion of the process is indicated as follows:
xGreen display light (Fig. 7 on previous page): power
module has been checked, charged and is ready to use.
xRed display light (Fig. 8 on previous page): power
module has been checked, is not charged and cannot be
used; the red service indicator lamp on the power module
lights up. Send in the power module for servicing.
A power module can be charged or checked independently
in each charger bay.
Precautions:
xIf the check is not carried out within the next 3
charging cycles, the charger starts this process auto-
matically. The yellow display lights up (Fig. 11).
xIt takes around 4 hours to check the power module.
Fig. 9
Fig. 10
Fig. 11
flashing
flashing
Operating Instructions
Checking and Refreshing Batteries/Power Module

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools 13
Immediately recharge batteries and the power module after
each use.
Any SBD batteries (532.003, 532.033) or Battery Power Line
battery (530.620) that are not used should always be stored in
the activated charger (maintenance charge). This guarantees
that the batteries are always fully charged and ready to use.
Precautions:
xDo not use batteries/power modules that are not fully
charged. A partial charge may not be sufficient for
the intended use.
xUnusable or faulty batteries/power modules should
not be used. They should be disposed of (see section
“Disposal” on page 17).
Operating Instructions
STORING BATTERIES

14 DePuy Synthes Power Tools Universal Battery Charger II User’s Manual
The Slot Covers Set (05.001.228) consists of three plastic
elements which were developed to cover the unused slots of
the charger (Fig. 1). A Slot Cover helps to insert a battery or
power module much easier into the Universal Battery Charger II
because it covers the unused slots of the charger (Fig. 2).
Therefore, it prevents the insertion of a battery or power
module into the wrong slot.
Operating Instructions
SLOT COVERS SET
Fig. 1
Fig. 2

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools 15
The device must be unplugged before it is cleaned.
Occasionally wipe down the device with a dry cloth. If it
is very dirty the device can be cleaned with a slightly damp
cloth. Dry well. Do not use solvents.
Whenever it is cleaned the device should be checked to
ensure it is working properly and is not damaged.
Maintenance of the device is not required.
If there are any faults, please send the device to the
DePuy Synthes Power Tools Service Department for repair.
Precautions:
xDanger of electric shock! Unplug before cleaning.
xDo not wash the device in a washer/disinfector.
xDevice must not be sterilized.
xMake sure that no solution enters the device.
xIf necessary, clean the contacts in the charger bays
using the utmost care.
CARE AND MAINTENANCE
Cleaning

16 DePuy Synthes Power Tools Universal Battery Charger II User’s Manual
The device should be sent to the DePuy Synthes Power Tools
Service Department for repair if it is faulty or malfunctions.
The same applies if the ON/OFF display does not light up or
flashes when the device is switched on.
To prevent damage during shipping use the original packaging
to return devices back to DePuy Synthes Power Tools. If this is
not possible, please contact the DePuy Synthes Power Tools
representative.
Users or third parties should not carry out repairs themselves.
Precaution: The manufacturer shall assume no respon-
sibility for damage resulting from unauthorized repair.
Care and Maintenance
REPAIR AND TECHNICAL SERVICE

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools 17
In most cases faulty chargers can be repaired (see previous
section “Repair and Technical Service”).
The European directive 2002/96/EC on waste
electrical and electronic equipment (WEEE) applies to
this device. This device contains materials that should
be disposed of in accordance with environment protection
requirements. Please observe national and local regulations.
Please send devices that are no longer used to the
DePuy Synthes Power Tools Service Department. This ensures
that they are disposed of in accordance with the national
application of the respective directive. The charger may not
be disposed of with household waste.
Faulty batteries may not be reused and should be disposed
of in an environmentally friendly manner and in accordance
with national regulations.
Care and Maintenance
DISPOSAL

18 DePuy Synthes Power Tools Universal Battery Charger II User’s Manual
TROUBLESHOOTING
ON/OFF display does not light up.
ON/OFF display flashes.
Although the battery/power module is
inserted there is no display light for
the charger bay.
Red display lights up when the
battery/power module is inserted.
Switch on power switch.
Connect power cord to the connection
on the charger and plug into the
wall socket. Then switch on the power
switch on the charger.
Check power supply. Replace fuse
(2 X 5 AT / 250 V) if necessary.
Send the charger to
DePuy Synthes Power Tools Service
Department for repairs.
Send the charger to
DePuy Synthes Power Tools Service
Department for repairs.
Ensure that the battery/power module
is inserted properly.
Carefully clean contacts.
Use another free charger bay.
Test the battery/power module in
another charger bay and dispose of
if necessary.
Send the charger to
DePuy Synthes Power Tools Service
Department for repairs.
Replace battery/power module.
Check firmware version on the sticker,
which is visible on the underside of
the charger and compare with the
minimum required firmware listed
on page 22. Send the charger to
DePuy Synthes Power Tools Service
Department for a software update.
Charger is switched off.
Power cord is not plugged in.
Power supply is interrupted
(e.g. faulty fuse).
Charger is faulty.
Charger is faulty.
Battery/power module is not fully
inserted.
Contacts in the charger bay are dirty.
Battery/power module was not recog-
nized by the charger.
Battery/power module is faulty.
Charger bay is faulty.
Battery/power module is faulty.
Firmware has to be updated
Problem Possible cause Solution

Universal Battery Charger II User’s Manual DePuy Synthes Power Tools 19
Troubleshooting
Red display lights up when the
charger is switched on before the
batteries/power modules are inserted.
Yellow display flashes during the
charging process.
Yellow display does not light up
when the button is pressed.
It is not possible to insert the battery/
power module into the slot.
Charger makes loud noises.
Problem Possible cause Solution
Charger bay is faulty.
Battery/power module is too hot.
Button was released too soon.
Charger bay is faulty.
Charger has an error.
Wrong slot.
Non-authorized battery/power
module.
Contacts in the slot bent.
Ventilation holes on the sides, back
or base are covered and/or the device
is next to a heat source. Automatic
cooling is on full power.
Use another free charger bay.
Send the charger to the
DePuy Synthes Power Tools Service
Department for repairs.
Leave battery/power module inserted in
the charger bay. Charger automatically
continues the charging process once the
battery/power module has cooled down.
Hold button down for at least
2 seconds.
Select another free charger bay.
Send the device to the
DePuy Synthes Power Tools Service
Department for repair.
Switch off charger, then switch back
on after 5 seconds. If the ON/OFF
display flashes, send the device to the
DePuy Synthes Power Tools Service
Department for repair.
Select correct slot and re-insert
battery/power module.
Check battery/power module type.
Use another free charger bay.
Send the charger to the
DePuy Synthes Power Tools Service
Department for repair.
Expose ventilation holes and/or ensure
that the device is not next to a heat
source.