Document 126

G4 IMB Battery Replacement Procedure

Products: SX-2000(A/T)R, SX-3000

Software: All versions

This article documents how to remove and replace the batteries on a G4 IMB.

Please read the COMPLETE document very carefully before starting the battery replacement

General Information on G4 IMB batteries

1. Each IMB has 2 batteries.
   
2. Service technicians should measure the battery voltage at service calls and check their records for the life of the batteries regularly. If the battery life is more the 3.5 years OR the voltage is below the Min Voltage Limit, the batteries should be replaced.
   
3. Please refer to “How to Measure The Battery Voltage” section at the end of this document
   
4. If the batteries are not replaced on time, the battery voltage will drop to below the Min Voltage Limit and the secure information from the IMB will be destroyed, rendering the IMB unusable in the field.
   

Procedure for Battery Replacement

VERY IMPORTANT:

EACH IMB HAS 2 BATTERIES

BATTERIES SHOULD BE REPLACED ONE AT A TIME

!!! DO NOT REMOVE BOTH BATTERIES AT THE SAME TIME !!!

DOING SO WILL DESTROY THE SECURE INFORMATION FROM THE IMB, RENDERING THE IMB UNUSABLE IN THE FILED

Determine the board type

1. Carefully remove the IMB from the projector (See Caution note on handling G4 IMBs)
   
2. Always place the IMB on an anti static surface like the packing in which the IMB is shipped.
   
3. Locate the edge of the IMB PCB near the power gold finger connector at the rear side of the IMB as shown in the picture below:
   

4. Identify the board type by the hardware revision no. printed on the PCB edge There are 2 types of G4 IMB boards: R9 & R8
   
5. Depending on the type of board, please follow the appropriate procedure for battery replacement mentioned below
   

Caution note on Handling G4 IMBs

Replacement procedure for R9 boards

Table of Contents

1. Requirements
   
2. Battery replacement procedure
   

Requirements

• Insulating gloves
  
• Anti-static strap
  
• Prying tool (flat-head screwdriver or similar)
  
• Replacement batteries (Tadiran TL-2450) from GDC Technology
  

Battery replacement procedure

1. Put on the insulating gloves and anti-static strap.
   

2. Connect the anti-static strap to ground.
   

3. Using a volt/ohm meter (VOM) measure the battery voltages, start by replacing the battery with the lowest voltage first.
   

Please refer to “How to Measure The Battery Voltage” section at the end of this document

4. Remove the four screws at the bottom of the board, and then remove the stiffener bar on top of the board.
   

Precaution:

When stiffener bar is being removed, both batteries could possibly stick to the bumpers and be removed together with the stiffener bar. Always press and hold the batteries while removing the stiffener bar to prevent both batteries being removed at the same time

Important Note:

Early versions of G4 R9 boards have plastic barbs on the battery holders as shown in the figure 1.

The plastic barbs make it impossible for the batteries to be removed from the holders.

1. In this case, remove plastic barbs from the battery holder by clipping them off just above the top surface of the holder as shown if figure 1 of “Rubber Bumper Installation.
   
2. Install the new batteries as mentioned in the points (5) to (7) below
   
3. Install rubber Bumper P/N 104677-00 onto metal stiffener bar P/N 104175-00 as shown in figure 2 of “Rubber Bumper Installation.
   
4. The Rubber Bumpers can be requested in advance from GDC
   
5. While installing the metal stiffener onto PCBA with screws as mentioned in point (8), the bumper should be position and centred over battery holder as shown in figure 3 of “Rubber Bumper Installation.
   

Rubber Bumper Installation

5. Using the prying tool (flat-head screwdriver), separate the "B1" battery from the retainer to remove the battery. Make sure not to touch the leads under the battery when doing this.
   

6. Replace the battery with a new one. Insert the new battery back into the "B1" retainer. Make sure the leads under the battery are aligned with the holes on the retainer, and be careful not to bend the leads under the battery.
   

7. Repeat steps 5 & 6 for the "B2" battery.
   
8. Attach the stiffener bar back to its original location on the board, using the four screws.
   
9. The battery replacement procedure is complete.
   

Replacement procedure for R8 boards

Table of Contents

1. Requirements
   
2. Battery replacement procedure
   

Requirements

• Insulating gloves
  
• Anti-static strap
  
• Pair of tweezers
  
• Replacement batteries (Panasonic CR2354) from GDC Technology
  

Battery replacement procedure

1. Please follow points (1) & (2) of “Battery replacement procedure” for R9 boards
   
2. CAUTION: Care should be taken to prevent the  shorting on the  metal  stiffener bracket or the circuitry of the PCB.
   
3. Using a volt/ohm meter (VOM) measure the battery voltages, start by replacing the battery with the lowest voltage first.
   

Please refer to “How to Measure The Battery Voltage” section at the end of this document

4. To remove the battery use a tweezer or small flat blade screw driver to reach behind the battery and push it out of the battery holder. See pictures 1A-1C. Now using the
   

tweezer at the side of the front opening push the battery out of the holder far enoughso that you can grab it with your fingers. Replace with a fresh new battery making

sure that the plus sign on the battery is facing up then slide the battery into the holder as shown in picture 2.

5. The battery replacement procedure is complete.
   

Examples of tools to use to remove the batteries.

Using the tweezer pointed end carefully push the battery out of the battery holder

With the pointed tips of the tweezer move the battery out of the holder so that you can grab it with your fingers.

CAUTION:

While removing one of the batteries, the IC (indicated by green circle in the Picture 1 D) would block the way.

Please do not push the battery directly out as it can possibly damage the IC.

Please slightly pull the battery up a bit and gently move the battery out from the battery holder above the IC

With the battery + side facing up install the battery into the battery holder.

Be aware that the stiffener bar on the  top side of the  battery  may make  it difficult to get behind the battery with your tool, the curved tweezer eliminates this issue or you may need to remove the stiffener bar temporarily while you remove and replace the battery.

How to measure the Battery Voltage

For R9 Boards

1. Please refer to Picture 3 below to locate the measurement points for voltage measurement on a G4 R9 board, located on the underside of the PCB
   

2. Using a DC voltmeter, measure the voltage of each battery as shown in Picture 4
   
3. The Voltage of a G4 R9 board battery should be greater than 3.5V. If any of the batteries measure less than 3.5V please replace both batteries
   

For R8 Boards

1. Note the location of the batteries on a G4 R8 board from Pictures 5 & 6 below. The two batteries are located on the either side of the PCB as shown in Picture 6.
   
2. Please refer to Picture 5 below to measure the voltage of one of the batteries on a G4 R8 board. Touch the probes of the DC Voltmeter directly to the positive terminals of the battery and the negative probe to the Silver metal heat sink as shown.
   
3. Follow the same method to measure the voltage of the other battery