Synthes Universal Battery Charger II User manual

This publication is not intended for
distribution in the USA.
Instruments and implants
approved by the AO Foundation
Instructions for Use
Universal Battery Charger II.

Universal Battery Charger II Instructions for Use DePuySynthes 1
Table of Contents
Introduction
Description of the Controls
Operating the Device
General Information 3
– Intended use 3
– Compatibility 3
– Abbreviations 3
– Safety precautions 4
– Scope of delivery 5
– Storage and transport 5
– Warranty 5
– Front view 6
– Rear view 6
Starting the System 7
Charging the Battery 8
– Charger bay 8
– Charging the battery 9
– Temperature monitoring 10
– Charging new batteries 10
or batteries not recently used
– Errors during charging 10
Checking and Refreshing Batteries 11
– Battery Power Line and Colibri / 11
Small Battery Drive batteries
– Battery Power Line II and Colibri II /
Small Battery Drive II batteries 13
– Trauma Recon System power module 15
Storing Batteries 16
Slot Covers Set 17

2 DePuySynthes Universal Battery Charger II Instructions for Use
Care and Maintenance
Troubleshooting
Technical Data
Explanation of Symbols Used
Ordering Information
Cleaning 18
Repair and Technical Service 19
Disposal 20
21
Device Specifications 24
Minimum required Firmware version of UBC II 25
Environmental Conditions 26
Applicable Standards 27
Electromagnetic Compatibility – 28
Accompanying Documents in Accordance with
EN/ IEC 60601-1-2, Clause 5.2.2
Permissible Battery Types 32
– Battery for Battery Power Line 32
– Battery for Battery Power Line II 32
– Power module for Trauma Recon System 32
– Batteries for Colibri / Small Battery Drive 33
– Battery for Colibri II / Small Battery Drive II 33
Symbols for Operating the Charger 34
Symbols on the Charger 35
36
Table of Contents

Universal Battery Charger II Instructions for Use DePuy Synthes 3
Intended use
The Universal Battery Charger II (05.001.204), referred to
henceforth as the charger or device, allows the following
Synthes 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
Colibri / Small Battery Drive 532.001 532.003 (12 V, NiCd)
532.010 532.033 (14.4 V, NiCd)
Colibri II / Small Battery Drive II 532.101 532.103 (14.4 V, Li-Ion)
532.110
If required, Battery Power Line battery (530.620) and Colibri /
Small Battery Drive batteries (532.003, 532.033) can also be
refreshed with the charger (see page 11 ff).
Compatibility
The Colibri / Small Battery Drive batteries (532.003, 532.033)
can be used with Colibri II / Small Battery Drive II handpiece
(532.101, 532.110).
The Colibri II / Small Battery Drive II battery (532.103) can be
used with the Colibri / Small Battery Drive handpiece
(532.001, 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 530.600 or 530.601.
Abbreviations
Please note the below mentioned items are abbreviated
throughout the document as follows:
Items Abbreviation
Colibri / Small Battery Drive Colibri/ SBD
Colibri II / Small Battery Drive II Colibri II / SBD II
Power Module for Trauma Recon System Power Module
Universal Battery Charger II UBC II

4 DePuySynthes Universal Battery Charger II Instructions for Use
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 26 for details on environmental conditions).
Please observe the information on the electromagnetic
compatibility, see page 28 ff.
The device may only be used for the authorized Synthes
batteries.
Before operating the device, check that it is in sound condi-
tion and is working properly.
If it is not in perfect working order, contact the Synthes
representative. Do not use a damaged or faulty device.
Introduction
General Information

1.5 m1.5 m
1.5 m
2.5 m
Universal Battery Charger II Instructions for Use DePuy Synthes 5
Precautions:
– Only use the Synthes Universal Battery Charger II
(05.001.204) to charge the batteries. Using a charger that
does not originate from Synthes can damage the battery.
– Do not open device. Risk of fatal injury
due to electric shock!
– Do not use the device in the sterile area of the operating
room.
– The device must not come into direct or indirect contact
with the patient.
– Do not use the device in patient vicinity. The patient vicin-
ity is an area 2.5 m above and 1.5 m next to the patient
(see fig. on the right).
– Do not wash the device in a washer/disinfector. The device
must not be sterilized. Please see page 18 for information
on cleaning and maintenance.
– Do not operate the device in the presence of a flammable
anesthetics mixture with air or oxygen or with nitrous
oxide.
– Do not expose the device to direct sunlight or moisture.
– The charging station should always be turned on when
a battery is in the charging bay. This ensures availability
and prevents discharge.
Scope of delivery
The Universal Battery Charger II consists of the charger
(05.001.204), the supplied, country-specific power cord and
four slot covers sets (05.001.228). The device may only be
used with the supplied power cord.
Storage and transport
All batteries should be removed for transporting the charger.
Use the original packaging for shipping and transport. If this
is no longer available, please contact the Synthes represen-
tative.
The same environmental conditions apply for transport as for
storage, see page 26.
Warranty
The warranty for the device is null and void if the device has
not been used properly or the guarantee seal has been dam-
aged. The manufacturer does not accept liability for damage
resulting from repairs or maintenance carried out by un-
authorized sites. For a complete warranty statement, please
contact Synthes Customer Service.

8
7
9
6
4
3
5
1
2
6 DePuySynthes Universal Battery Charger II Instructions for Use
Front view
1Charger bays (⳯4)
2Symbols for battery type
3ON/OFF display
4Control display for each charging bay
5Ventilation holes
Description of the Controls
Rear view
6Ventilation holes
7Power switch
8Fuses: 2⳯5 AT / 250 V
9Power cord connection

Universal Battery Charger II Instructions for Use DePuy Synthes 7
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 shows that it is working
properly (fig.2). If the display flashes, the device must be
sent in for control.
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 local Synthes representative for repairs.
Precautions:
– Place 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.
– Do not position the device so that it is difficult to separate
the power cord from the supply mains.
– Do not operate the device in the direct vicinity of radiators
or other heat emitting devices, as these can affect the
device.
– Do not expose the device to direct sunlight or moisture.
– Do not cover the side ventilation holes on the device.
– Only connect to a power supply with earthing, a rated
voltage between 100 V and 240 V and a network
frequency range of 50 or 60 Hz.
Operating the Device
Starting the System
Fig. 1
Fig. 2
Fig. 3

2
3
1
Operating the Device
Charging the Battery
8 DePuySynthes Universal Battery Charger II Instructions for Use
Charger bay
The device is fitted with four independent charger bays. Each
of these has three slots for the following batteries (fig.1):
1Battery Power Line and Battery Power Line II batteries
(530.620, 530.630)
2Trauma Recon System Power Module (05.001.202)
3Colibri/ SBD and Colibri II / SBD II batteries (532.003,
532.033, 532.103)
Fig. 1

Universal Battery Charger II Instructions for Use DePuy Synthes 9
Fig. 2
Fig. 3
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. 2).
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. 3). 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:
– Insert the battery into the correct slot.
– Ensure that the battery is fitted correctly and is identified
by the device (yellow charger display lights up).
– If the display does not light up after the battery is inserted,
remove the battery and insert again or insert into another
charger bay.
– Do not insert any objects other than batteries into the
charger, as the contacts may otherwise be damaged.

flashing
10 DePuySynthes Universal Battery Charger II Instructions for Use
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. 4). 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 Colibri / SBD batter-
ies (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 re-
fresh the battery (see page 11 ff).
Errors during charging
The following errors may occur while charging a battery:
Yellow display light flashes (fig.4)
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. 5)
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 in-
sert again or use another charger bay.
Precautions:
– Do not charge mechanically damaged batteries in the
charger.
– Only charge batteries authorized for the device
(see page 32ff).
– Only use fully charged batteries to avoid delays during
surgery.
Operating the Device
Charging the Battery
Fig. 4
Fig. 5

Operating the Device
Checking and Refreshing Batteries
Universal Battery Charger II Instructions for Use DePuy Synthes 11
Battery Power Line and Colibri/ SBD batteries
The charger enables Battery Power Line battery (530.620)
and Colibri/ SBD batteries (532.003, 532.033) to be re-
freshed 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
– Unused, new battery
– Battery not used for a longer period
In these cases a battery will only reach its maximum per-
formance after several charging and discharging cycles.
The check and refresh function ensures that the battery
regains its maximum performance again.
– Old 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

12 DePuySynthes Universal Battery Charger II Instructions for Use
Operating the Device
Checking and Refreshing Batteries
Completion of the process is indicated as follows:
– Green display light (fig.3): Battery has been success-
fully refreshed, checked and charged.
– Red 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 independ-
ently in each charger bay.
Precautions:
– To recharge batteries normally, do not press the exclama-
tion mark button .
– Checking 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.
– Do 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.
– The 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

Universal Battery Charger II Instructions for Use DePuy Synthes 13
Battery Power Line II and Colibri II / SBD II batteries
The charger enables Battery Power Line II and Colibri II /
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

14 DePuySynthes Universal Battery Charger II Instructions for Use
Completion of the process is indicated as follows:
– Green display light (fig.7): Battery has been success-
fully checked and charged.
– Red 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:
– To recharge batteries normally, do not press the exclama-
tion mark button .
– Checking the battery status has an impact on the battery.
If this is carried out frequently the lifespan of the battery
can be affected.
– Do 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.
– The 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
Operating the Device
Checking and Refreshing Batteries

Universal Battery Charger II Instructions for Use DePuy Synthes 15
Trauma Recon System power module
To ensure that the Trauma Recon System (05.001.201,
05.001.240) can operate safely and reliably, 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 ex-
clamation 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:
– Green display light (fig.7 on previous page): power
module has been checked, charged and is ready to use.
– Red 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:
– If the check is not carried out within the next 3 charging
cycles, the charger starts this process automatically.
The yellow display lights up (fig.11).
– It takes around 4 hours to check the power module.
Fig. 9
Fig. 10
Fig. 11
flashing
flashing

16 DePuySynthes Universal Battery Charger II Instructions for Use
Immediately recharge batteries and the power module after
each use.
Any Colibri/ 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.
It is not necessary to store Trauma Recon System power
module (05.001.202), Battery Power Line II battery (530.630)
and Colibri II / SBD II battery (532.103) in the charger. Once
charged they can be stored outside the charger without any
noticeable charge difference due to a very low self-discharg-
ing rate of Lithium-based batteries.
Precautions:
– Do not use batteries / power modules that are not fully
charged. A partial charge may not be sufficient for the
intended use.
– Unusable or faulty batteries / power modules should not
be used. They should be disposed of (see section
“Disposal” on page 20).
Operating the Device
Storing Batteries

Universal Battery Charger II Instructions for Use DePuy Synthes 17
The Slot Covers Set (05.001.228) consists of three plastic ele-
ments which were developed to cover the non-used 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 to insert the appropriate bat-
tery or power module into the wrong slot.
Operating the Device
Slot Covers Set
Fig. 1
Fig. 2

18 DePuySynthes Universal Battery Charger II Instructions for Use
The device must be unplugged before it is cleaned. Occa-
sionally 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 a Synthes
representative (see next section).
Precautions:
– Danger of electric shock! Unplug before cleaning.
– Do not wash the device in a washer/disinfector.
– Device must not be sterilized.
– Make sure that no solution enters the device.
– If necessary, clean the contacts in the charger bays using
utmost care.
Care and Maintenance
Cleaning