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How do I change the battery of my RT 6-100 / maintain and care for the endcap O-ring seal in the process?

RT 6-1000 is designed to have field replaceable battery packs, which can be changed by a suitably qualified person without any specialist equipment. A very important part of having a field serviceable unit is proper maintenance and care of the O-ring seals. This step-by-step guide shows just how easy it is to change the battery pack and how you should care for your O-rings in the process.

 

Opening up the unit

To replace the battery of your RT 6-1000, the transponder must be disabled and then removed from the outer housing and the endcap removed by following these steps:-

  1. Find a clean (dust-free), dry and well-ventilated environment. It is important to make sure that you are working in a clean, dry and well-ventilated environment. The latter is necessary in case of toxic gases and liquids being released when operating the pressure relief vent valve. Being dust free is particularly important when it comes to proper care of O-ring seals.
    A beige cylindrical Sonardyne RT 6-1000 acoustic transponder with blue labels and white rope attached, lying on a gray surface.
  2. Disable the transponder. The transponder is disabled by disconnecting the battery, which can be done using the RT 6-1000 app. Open the app, connect to the release and click disconnect. Note the battery can also be disconnected using Deck Topside and NFC Configurator, and you can find details of all three methods in the manual.
    Mobile app screen showing 'BATTERY OPTIONS' heading, a back button, and orange buttons labeled Check, Connect, Disconnect, and Change Address.      A person's hands holding a smartphone displaying an NFC control app and a cylindrical Seascape RT6-1000 device.
  3. Operate the pressure relief vent valve. Before removing the transponder from the housing, operate the pressure relief vent valve to equalise the internal/external pressure. You would expect the pressure relief vent to be flush with the endcap face, but if there is any reason to suspect there may be pressure inside the transponder or it is not flush with the endcap face, the pressure relief vent valve must be operated. Use a pair of pliers on the relief valve by carefully withdrawing the vent valve as far as it will extract and wait for any internal pressure to be released. Once any pressure is released be sure to return the pressure relief valve to its flush state by pushing it fully back into its recess. Note that if the battery pack has failed or water has penetrated the internal housing, the battery pack may vent gasses causing the build-up of internal pressure.
    Close-up of hands using an RS PRO tool to tighten a screw on a beige and black cylindrical device with a label '3'.
  4. Remove the endcap shackles. Remove the two shackles from the endcap housing (if they are installed), by unscrewing the retaining screws.
    Close-up of hands inserting a small metal piece into the end of a light grey cylindrical object.
  5. Unscrew the M3 retaining screws. Using a 3 mm Allen key, unscrew the two M3 retaining screws a few turns to allow the two retaining pins to be removed.
    Close-up of hands using a hex screwdriver on a cylindrical device with a black top panel and a label '3'.
  6. Push the retaining pins out from the outer housing. Using your thumb and suitable tool, push the two retaining pins out for the outer housing.
    Hands inserting a metal pin into a cylindrical device with a black faceplate and number 3.
  7. Remove the inner housing. Carefully slide the inner housing completely out of the outer housing.
    Close-up of a hand gripping a black and silver cylindrical precision tool with a square end and a small silver ball.
  8. Remove the endcap. To remove the endcap, grip the transponder and separate the endcap from the housing with a gentle pulling and side-to-side motion. DO NOT over-rotate the endcap when separating the endcap from the housing as this will twist and damage the internal wiring. You can now carefully remove the endcap from the housing, but note the transducer wiring is attached to the internal PCB so take extra care NOT to pull or tension these wires and ensure the endcap is supported at all times, if this care isn’t take you could detach the transducer wiring from the internal PCB.
    Two hands holding a silver cylindrical object with black caps, one hand wearing a blue anti-static wrist strap.    A person's hands assembling a silver and black cylindrical device on a gray surface. A blue anti-static wrist strap is visible on the right wrist.

 

Replacing the battery pack

You’re now ready to change your battery pack by following the next set of steps:-

  1. Remove the old battery. To remove the old battery, support the housing and endcap. Next, pull down the circular rubber gasket to gain clear access to the connectors and carefully remove the connectors. You can now withdraw the battery pack from the housing using the red pull-cord.
    Close-up of hands assembling a silver and black cylindrical device, placing a white ring into the opening. A blue ESD wrist strap is visible on the left wrist.  Two hands working with cylindrical components. The right hand holds a black cylinder with wires, and the left hand holds a silver cylinder. A blue anti-static wrist strap is on the left wrist. Hands holding two cylindrical devices, one black and one silver, with internal wiring and circuit board visible.  A person's hands pulling a red tab from the top of a black cylindrical object, which is partially inserted into a grey tube.
  2. Insert a new battery. To install a new battery, install the pack into the housing and ensure the battery connector mates to the PCB. Insert the circular rubber gasket against the PCB, and finally push the endcap fully into the housing ensuring there is no gap between endcap and housing.
    A person's hands assembling electronic components. A silver tube holds a brown component with a red wire, while a black connector with wires is held nearby.

 

Maintaining and caring for the O-ring seals

Before restoring the endcap to the housing, care should be given to the O-ring seals. Full maintenance and care for the O-rings can be achieved following these basic but very important steps:-

  1. Understand why proper care of O-rings is important. Without the correct maintenance and care of O-rings water could leak into the unit and cause it to fail. Signs of water ingress are clear, including salty residue and staining on the electronics. Incorrect care of O-rings includes using damaged, badly fitted or un-greased O-rings. In most cases of water ingress, the unit will be damaged beyond economic repair (BER).
  2. Have spare O-rings available. It may be prudent to replace your RT 6-1000 O-rings every time you replace the battery, and you should always have the correct O-rings on hand in case they need replacing. O-ring spares for the RT 6-1000 are available from Sonardyne, and the correct part numbers can be found in the user manual. New O-rings should always be stored in a clean, dark bag, and NEVER use second-hand O-rings.
  3. Have the correct lubrication to hand. Sonardyne O-rings are made of nitrile, so you will need petroleum jelly (Vaseline) to lubricate them properly.
  4. Remove O-rings from the endcap. With the endcap removed, the O-rings can be inspected, but they need to be removed from the endcap first. Do this using your hands only because using a tool could damage the O-ring and the machined surface of the endcap. As the RT 6-1000 has a double O-ring seal, remove the outer O-ring first. Using your fingers, push the O-ring sideways until it begins to rise up out of the channel, and at this point you can pinch the O-ring, allowing you to remove it completely. Repeat the process for the second O-ring.
    A person's hands, wearing a blue ESD wrist strap, manipulate a small dark cylindrical object with visible internal wiring against a gray background.
  5. Inspect the O-rings. Perform a thorough visual inspection of the O-rings, looking for any signs of damage. Even the slightest nick or imperfection could cause a leak. If you’re happy with the integrity of the O-ring, set it aside on a clean surface. If you do find any damage, however small, the O-ring should be replaced for new.
  6. Lubricate the O-rings. Before re-fitting the O-rings, they need to be properly greased along their whole surface with a THIN layer of Vaseline. Apply the Vaseline with clean fingers by working the O-ring through your fingers, taking care not to apply to much Vaseline and this could cause clumps. The inner bore of the housing also needs to be lubricated, again using a clean finger.
  7. Re-fit O-rings. With the endcap ready, take a greased O-ring and fit it directly to the inner-most O-ring groove because this helps minimise the risk of damaging the second O-ring. Locate one side of the O-ring into the groove and slightly stretch the O-ring to locate it fully into the O-ring groove. Make sure the O-ring is not twisted, and you can check this by looking at the mould line – it should be in the centre all the way around. Repeat the process for the second O-ring.
    A person's hands inserting wires into a black cylinder. A container with a yellow substance and a blue lid are also on the gray surface.
  8. Re-fit the endcap. With both O-rings fitted you’re ready to re-fit the endcap. As the endcap is inserted back into the housing watch out for any debris like hair and dirt.
    Hands assembling a black and silver cylindrical device, with a blue anti-static wrist strap on the right wrist.

Closing up the unit

You’re almost done, all that is left is to close up the unit, which can be done simply following these final steps:-

  1. Replace the transponder into the housing. Push the transponder fully into the outer housing until it reached the retaining flange.
  2. Secure the unit. Insert the two retaining pins, and using a 3 mm Allen key, tighten the two M3 screws to lock the retaining pins.
      Close-up of hands using a screwdriver to work on a cylindrical electronic device with a beige casing and black interior. A blue wristband is visible on one wrist.
  3. Replace the shackles. If you have shackles, replace this pair on the endcap housing if required.
  4. Check the battery. The battery status of the RT 6-1000 should be checked, and this can be done quickly using the RT 6 app. Once connected, click Quick Check and then Get – the battery voltage will be displayed on the battery icon, which for a new battery will have a start voltage of >7.5 V, whilst end-of-life voltage is <4.5V.

You may also want to run a Self-Test using Quick Check to confirm the instrument is working correctly. In the RT 6 app, simply click Quick Check, Get, then Test – Self Test Passed! Will be displayed if the test is successful.

Note there are other methods to check the battery, including with an iWand, Deck Topside or NFC Configurator.
Mobile app screen showing 'BATTERY OPTIONS' with buttons: Check, Connect, Disconnect, and Change Address. 

You can also refer to the RT 6-1000 user manual for correct battery change procedure, and we recommend reviewing the Sonardyne ‘Maintenance and Care Procedures for O-Ring Seals’ video: https://www.youtube.com/watch?v=c4kmvLoCksM for guidance on O-rings.
Contact [email protected] for further information.

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