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