The ShapeArray Field Power Unit (SAAFPU) is a portable, rugged, all-in-one power and communication device designed specifically for manual data collection and diagnostics in the field. The battery in Model 4 and above SAAFPUs can be field replaced in situations where the built-in battery is no longer working as expected. A replacement battery should have the following approximate specifications:
- Voltage: 12 V
- Capacity: 6 - 7.2 Ah
- Length: 5.945" (151.0 mm)
- Width: 2.539" (64.5 mm)
- Height: 3.702" (94.0 mm)
- Total Height including terminals: 3.937" (100.0 mm)
- Terminal size: 0.187" (4.75 mm)
Model 4 SAAFPUs contain sealed lead acid batteries.
- Valve-Regulated Lead Acid (VRLA) battery (also referred to as Sealed Lead Acid battery or non-spillable battery)
- Example models: Panasonic LC-R127R2P, Zeus PC7-12F1, or Peak Energy PK12V7.2F1
Model 5 and newer SAAFPUs contain Lithium batteries
- Deep Cycle Lithium Iron Phosphate (LiFePO4) Battery
- Example models: Universal Battery LFP1260, or RoyPow S1206
NOTE: The front panel of the SAAFPU will indicate the battery chemistry. Either LiFePO4 or lead acid can be used in Model 4 SAAFPU and above. If replacing a Lead Acid battery with Lithium Iron Phosphate (or vice versa) the front panel battery description should have a new label applied to indicate the current battery chemistry.
Step 1 - Remove Screws from the Mounting Panel
Open the SAAFPU's water resistant enclosure and disconnect any hardware attached to ports on the mounting panel.
NOTE: The power cable is not removable and will remain attached.
Use a Phillips screw driver to remove the five screws holding the mounting panel in place.
Figure 1: Five Phillips screws (circled in green) hold the mounting panel in place
Step 2 - Remove the Mounting Panel
Slide the panel down slightly until you can reach your fingers under it and the battery. Gently lift and flip the panel assembly over and rest it upside down on the SAAFPU enclosure. Ensure you have firm grip on the panel assembly and that the battery is supported. Be careful that the RS232 connector for the Bluetooth adapter does not impact on the hardware for the strap bracket inside the enclosure.
WARNING: The mounting panel assembly is connected to ground wires and the Amphenol connector on the inside of the enclosure. Be careful not to pull these wires apart or disconnect them as you remove and flip the panel assembly.
Figure 2: Lifting the mounting panel and battery out of the enclosure
Step 3 - Disconnect and Remove the Battery
With the panel assembly and battery resting on the enclosure, lift the battery from the battery bracket in the mounting panel and reorient it so that the terminals are facing up. Remove the foam pieces around the battery for use on the new battery.
Figure 3: The battery after it has been lifted off the panel and reoriented with the terminals facing up
Disconnect the red wire connected to the positive terminal by pulling its blue plastic connector. Then, disconnect the black wire connected to the negative terminal by pulling its blue plastic connector.
Figure 4: Disconnect the red wire first and then the black wire
Remove the now disconnected battery from the panel.
Step 4 - Insert and Connect New Battery
Place the new battery in the battery bracket in the mounting panel with the terminals facing up, as shown in Figure 4 above. Connect the black wire to the negative terminal and then connect the red wire to the positive terminal. Lift the battery and place it on its side in the battery bracket in the mounting panel. Use the foam pieces removed in step 3 to ensure the battery fits snugly in the battery bracket. The battery should be positioned so that the terminals are facing the inside of the 'L' shape of the mounting panel. The foam pieces and battery orientation are shown in Figure 5 below.
Figure 5: The battery is set on its side in the battery bracket in the mounting panel. The foam pieces prevent the battery from moving around in the bracket.
Step 5 - Replace the Mounting Panel and Battery in the SAAFPU Enclosure
Lift the mounting panel, flip it over, and insert it into the SAAFPU's enclosure. Angle the mounting panel such that the RS232 connector for the Bluetooth adapter will fit under the hardware for the strap bracket inside the SAAFPU enclosure.
WARNING: Ensure you have a firm grip on the battery and support it. Ensure that no wires are pinched or pulled apart as you reinsert the mounting panel into the SAAFPU enclosure.
Figure 6: Flip the mounting panel while supporting the battery. Insert it into the SAAFPU enclosure.
Step 6 - Screw the Mounting Panel into Place
Slide the mounting panel back up to the top of the SAAFPU enclosure in the position it was in when it was first removed. Secure the mounting panel to the SAAFPU enclosure with five screws, as shown in Figure 1.
Step 7 - Charge the SAAFPU and Test the Battery
Once the SAAFPU has been reassembled, it should be plugged into a mains power source and charged overnight. Once charged, the battery should be tested with the battery meter on the mounting panel inside the enclosure.
WARNING: The battery meter on SAAFPUs Model 005 R.5B and newer will not turn off automatically and, if left on, will slowly drain the battery. Please turn off the battery meter after use by pressing the ON button a second time.