How to Install Aether Battery System in a Prosthetic Socket

The Aether Battery System from Aether Biomedical powers the Zeus bionic hand from inside the socket. You make most of the important decisions before you connect a single wire: where the cells sit, where the charging port goes, and how the cable between them runs.

Get those right, and the wiring is straightforward. Get them wrong, and you may be rebuilding the socket. This guide walks through the installation in the order you'll do it, based on the current Aether Battery System Instructions for Use (version 8.0).

Who may install the Aether Battery System?

Only qualified personnel. The patient's job is to use the system day to day, and yours is to hand it over in a state they can manage safely. That means the patient has to understand how it works and how to keep it safe, and be able to act on that.

Which compatibility checks come before installation?

The system is intended for use exclusively with the Zeus hand. Before you cut anything, check the full prosthetic configuration against the Compatibility Guide that comes in the box. It takes a few minutes now, and it's much harder to put right once the socket is built.

What should clinicians inspect before starting?

Unpack everything and make sure it's all there. The kit contains:

• System parts: the battery pack, the charging port, the connector board, and the USB cable and power supply for charging.
• Fabrication tools: dummies, cutting guides, charging-port covers, and a 5 mm drill.

It doesn't include the adhesive or insulating compound you'll need. Both are covered below.

Which dimensions affect the socket layout?

The battery pack sets most of the layout. It is two cells joined by a 110 mm cable, and that cable needs a route that won't bend or strain it, because stress on the cable can break parts.

The charging port and connector board are both small. The connector board still needs thought, though: it's the hub that everything plugs into.

Which materials are needed beyond the supplied kit?

You'll need two things that aren't in the box:

• A biocompatible adhesive to fix the components. A silicone rubber-based adhesive is recommended.
• An electrically insulating compound for the connector board's 7-pin and 4-pin headers.

How should the AET-CHR charging port be mounted?

Use the supplied dummy to form the opening, then mount the port. It has to go in before any electrical connection is made.

Its position matters beyond fabrication. The charging port is the only part of the system the patient touches every day. They use its button to switch on and check the charge, and its USB-C socket to charge.

Where should the AET-BAT battery pack be positioned?

Somewhere the cells can't touch the user's skin and won't be squeezed or stressed.

Think about the socket as it will be worn, not as it sits on the bench. The cells must never be bent, and continued force on them can cause unwanted chemical effects. A spot that looks clear now may not be once the patient is wearing the prosthesis and moving.

When should the insulating compound be applied?

After both components are mounted and before anything is plugged in. Apply it to the 7-pin and 4-pin headers on the connector board while they're still exposed.

What is the correct electrical connection sequence?

Every connector fits only one way. If one resists, don't push it.

1. Connect the charging port to the connector board (7-pin).
2. Connect the battery pack to the connector board (4-pin).
3. Connect the connector board to the coaxial plug with the 2-pin kidney-style connector.
4. Attach the electrodes to the EMG/signal inputs on the coaxial plug.
5. Secure the connectors with the supplied screw.

Using a 6-band coaxial plug? Step 3 is the one to double-check. Power goes into the power supply input, not the accessory port.

What should clinicians verify before closing the socket?

This is your last clear view of the assembly. Check that:

• Power is in the power supply input.
• No connector was forced.
• The cells are clear of the skin and aren't bent or under pressure.
• No cable is kinked or pulled tight.

Which functional checks follow installation?

Hold the button for 1.5 seconds. The four LEDs should light in sequence as the system powers on. A single press then shows the charge level, from one LED when it's under a quarter full to all four when it's full.

Then test charging with the prosthesis off the patient. Charging starts on its own, and a full charge takes up to five hours.

Which installation mistakes should clinicians avoid?

The one to watch for comes after installation: trying to fix a fault yourself. Cables, cells, and connectors aren't repairable in the clinic. A broken charging cable, a faulty power supply, or any other malfunction goes to the manufacturer or distributor.

What should the patient handover cover?

Show the patient how to switch the system on, read the LEDs, and connect the charger. Then make sure they understand the rules that keep the battery safe:

• Charging: charge only with the prosthesis off, using the supplied cable and power supply. The hand has no power while the system charges. A power bank is for exceptional situations only, and never while it's plugged into an outlet.
• Batteries: never remove them while the system is in use.
• Water and heat: keep water out of the USB-C socket, never submerge the system, and make sure it's dry before use. Keep it away from fire and from temperatures below 0°C or above 50°C.
• Warning signs: if the battery pack gets hot, gives off gas, changes color, or looks abnormal, remove the prosthesis, store the battery somewhere safe, and contact Aether Biomedical.
• Faults: never attempt a repair. Contact the manufacturer or distributor.

What follow-up should clinicians plan?

Inspect the battery and wiring every few months for broken wires or connectors. The battery pack lasts up to two years or 500 charge cycles, and only qualified personnel can replace it. If a system goes unused, recharge it every six months, because the cells slowly lose charge on their own.

Frequently asked questions

Can the Aether Battery System power any prosthetic bionic hand?

No. It is intended for use exclusively with the Zeus hand.

What does it mean if one LED blinks six times?

If the system is off and you press the button, six quick blinks on the last LED mean the charge is critically low.

How should the system be disposed of at the end of life?

Do not dispose of the Aether Battery System with household waste. At the end of its service life, it should be disposed of through the WEEE (waste electrical and electronic equipment) process, as set out in the Aether Battery System Instructions for Use.

Conclusion

Check compatibility first, then plan the socket around the cells, their cable, and a charging port the patient can use. Mount the parts before wiring anything, never force a connector, and test the system before the patient leaves.

For compatibility questions, a faulty charger, or anything else that isn't behaving as expected, contact Aether Biomedical or your distributor before the prosthesis goes back into service.