Danger
Potentially Dangerous
Injury may result if this procedure is not followed properly. Use caution and follow all warnings.
Danger

Parts

No parts required.

Disconnect the DC power banana plugs from any power source. When not powered, the chargers screen will be blank.
  • Disconnect the DC power banana plugs from any power source.

  • When not powered, the chargers screen will be blank.

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Press down on the tab located on the top of the white molex connector and firmly pull away from the charger body. Press down on the tab located on the top of the white molex connector and firmly pull away from the charger body. Press down on the tab located on the top of the white molex connector and firmly pull away from the charger body.
  • Press down on the tab located on the top of the white molex connector and firmly pull away from the charger body.

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Remove the four screws located on the right side cover of the charger. Remove the four screws located on the right side cover of the charger. Remove the four screws located on the right side cover of the charger.
  • Remove the four screws located on the right side cover of the charger.

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Remove the four screws located on the right side panel. Do not pull on the panel, the DC power cables are rigidly attached to the panel by the black plastic grommet, this grommet is removed in the next step. Do not pull on the panel, the DC power cables are rigidly attached to the panel by the black plastic grommet, this grommet is removed in the next step.
  • Remove the four screws located on the right side panel.

  • Do not pull on the panel, the DC power cables are rigidly attached to the panel by the black plastic grommet, this grommet is removed in the next step.

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Locate the smaller, secondary part of the grommet. Using needle nose pliers, gently sqeeze on the secondary part of the grommet and the opposite side of the grommet while pushing the grommet through the hole towards the exterior side of the panel. Once pushed through the hole, the grommet can be removed from the wires and set aside.
  • Locate the smaller, secondary part of the grommet.

  • Using needle nose pliers, gently sqeeze on the secondary part of the grommet and the opposite side of the grommet while pushing the grommet through the hole towards the exterior side of the panel.

  • Once pushed through the hole, the grommet can be removed from the wires and set aside.

  • The smaller, secondary part of the grommet is connected to the main part of the grommet by a thin piece of plastic, ensure this piece is not severed during this process.

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One by one, pass both banana connectors through the hole in the left side panel. One by one, pass both banana connectors through the hole in the left side panel. One by one, pass both banana connectors through the hole in the left side panel.
  • One by one, pass both banana connectors through the hole in the left side panel.

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Remove the two screws located on the front side of the charger. Remove the two screws located on the back side of the charger, above the fan screws. Remove the two screws located on the back side of the charger, above the fan screws.
  • Remove the two screws located on the front side of the charger.

  • Remove the two screws located on the back side of the charger, above the fan screws.

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Desolder the two wires connected to the female banana plug ports for both channel 1 and 2 (left and ride sides of the charger). Too high temperature setting will cause the plastic banana plug port covers to melt, use only as much heat as needed to flow the solder.
  • Desolder the two wires connected to the female banana plug ports for both channel 1 and 2 (left and ride sides of the charger).

  • Too high temperature setting will cause the plastic banana plug port covers to melt, use only as much heat as needed to flow the solder.

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The top cover is still connected by three ribbon cables to the mainboard. Gently lift the top cover until you can slide your fingers or a spudger into the charger to disconnect the three molex connectors. LCD Segment Display Connector
  • The top cover is still connected by three ribbon cables to the mainboard. Gently lift the top cover until you can slide your fingers or a spudger into the charger to disconnect the three molex connectors.

    • LCD Segment Display Connector

    • Backlight Power Connector

    • Front Panel Buttons Ribbon

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Use a spudger or shim to gently separate the top plastic bar from the large lower piece. Once separated, the ribon cable can be slipped out of the housing. Disconnect the two white molex connectors from the board mount plugs. Disconnect the two white molex connectors from the board mount plugs.
  • Use a spudger or shim to gently separate the top plastic bar from the large lower piece. Once separated, the ribon cable can be slipped out of the housing.

  • Disconnect the two white molex connectors from the board mount plugs.

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The top faceplate can now be separated from the lower charger assembly. Be sure to separate the two parts slowly, checking for snagged wires and other hazards that could cause damage to the charger. Inside you'll find:
  • The top faceplate can now be separated from the lower charger assembly.

  • Be sure to separate the two parts slowly, checking for snagged wires and other hazards that could cause damage to the charger.

  • Inside you'll find:

    • PIC24HJ128GP310 16-bit Microcontroller

    • PIC ICSP Programming Pins (6 Pins)

    • KA324AD Quad Operational Amplifiers (4 total)

    • 24LC32A 32K I2C Serial EEPROM

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Finish Line

2 other people completed this guide.

David Hoyt

Member since: 04/09/2010

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44 Guides authored

Team

Cal Poly, Team 25-89, Amido Spring 2010 Member of Cal Poly, Team 25-89, Amido Spring 2010

CPSU-AMIDO-S10S25G89

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52 Guides authored

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