Replacing Batteries In A Screwdriver Battery

Do-it-yourself screwdriver battery repair with battery replacement
Hello! Today we will repair the battery of the screwdriver. Did you know that the history of the creation of the screwdriver goes back to the deep Middle Ages?

We continue to disassemble the battery of the Interskol screwdriver

This can be done in several ways. You can unsolder the wires that go to the board.

Replacing Batteries In A Screwdriver Battery

You can also simply remove the contacts from the top battery cover. Shown is the shape of the bent contacts so you can easily remove them yourself.

Under the plastic cover we see how the batteries are connected to each other. Them spot welded. This solution is used in almost any battery of another tool. This is a safe and gentle battery connection. In this case, the destructive heating of the lithium batteries themselves is minimal.

Gently tear off or bite off the metal tape with pliers to detach the cans from each other. From the side of the board, they were also connected together with a tape and put on glue on a cardboard pad. This is done so as not to short-circuit anything on the board. Remember to put it back in place when reassembling the battery.

Due to the lack of a spot welding machine, new lithium-ion batteries will be soldered very quickly with a well-heated powerful soldering iron. We remember that heating lithium-ion batteries reduces their service life and is generally explosive.

Pay particular attention to the condition of the wires inside the battery. They can be broken or frayed. They need to be qualitatively isolated or replaced with fresh ones. Since I was repairing a screwdriver battery on the road in the field, I had to apply a brilliant invention of the engineering mind. He took out a blue radio technical tape.

When disassembling the battery of the Interskol DA-10 / 10.8 ER screwdriver, I was pleasantly surprised. A thermal sensor was installed in the budget screwdriver to control the temperature of the batteries. It turns out that when the lithium cans overheat, the protection circuit turns off the power until the temperature recovers to normal. True, the owner never managed to drive him into such a regime. We carefully tear off this thermal sensor so as not to break it. Then we will place it in the same place on new cans.

Do-it-yourself screwdriver battery repair with battery replacement

Hello! Today we will repair the battery of the screwdriver. Did you know that the history of the creation of a screwdriver goes back to the deep Middle Ages. Already in the 15th century, when the knights put on armor before the battle, and the squires helped them twist parts of the armor, guess what? A screwdriver!

This went on for a long time, until in 1907 the Canadian inventor Peter Robertson patented the Robertson screw with a standard square hole into which the screwdriver tip was inserted. Since that time, screws have been produced on an industrial scale and used in households. Later, in 1934, inventor Henry Phillips redesigned the head of the screw and a Phillips screw was introduced into which the corresponding screwdriver was inserted. By that time, the engine had already been invented, and the idea of ​​creating a “screw and screw rotator” was in the air. However, there were big problems with the batteries. Their weight and dimensions. The problem was solved only in the 1980s, when the first nickel-cadmium Ni-Cd and lithium-ion Li-Ion rechargeable batteries appeared.

The USA and Japan were the first to master the production of household and professional cordless drills and screwdrivers. All this happened thanks to the emergence of new energy-intensive batteries of electricity. We will urgently change them inside the Interskol DA-10 / 10.8 ER cordless drill-screwdriver that fell into my hands. The malfunction was like this. When the button was pressed, the engine simply did not spin, but the LED lit up, the truth was weak.

Dismantling the screwdriver battery

Let’s start repairing the screwdriver battery. We remove the battery from the handle of the screwdriver and unscrew the three self-tapping screws that are located under the sticker below.

After unscrewing the screws, carefully push back the hooks of the latches, as on. And remove the bottom of the plastic battery case.

Inside we see lithium-ion cans Chinese company HighStar model ISR18650-1300 Li-Ion. This means that the batteries have never been changed. Because it is known that Interskol purchases batteries from this company and inserts them into almost all of its battery tools.

Below you can see the insides of the screwdriver’s battery in all its glory with cans in the amount of three pieces, which were produced already in 2011. These batteries lasted five years during active use at a construction site. So the result is very decent. Usually they die earlier, probably they were not exploited in cold weather.

To replace the battery banks, you need to disassemble it even more. I advise you to remember the location of the plus, minus and charging contacts, so as not to confuse the wires when reassembling.

Pay attention to the voltage control board on the batteries. Stabilizers and protective diodes especially often fail on it. It is imperative to ring suspicious radio elements on this board with a multimeter.

We check the voltage at the output of the battery. It turned out 4.4 volts, and it should be 3.7 x 3 = 11.1 volts in the norm and 10.8 volts with the minimum battery charge. In general, the banks are dead. They need to be changed unambiguously.

Solder batteries

Can be done in different ways, for example with thick wires. I decided to solder a torn-off metal strip taken from old cans. First, I tinned the tapes in the places of future contacts on both sides. Later I tinned the battery contacts with a well-heated soldering iron with a drop of solder. But so that they do not get too hot. Let them cool down. Then he pressed the tape to the contacts of the cans and soldered the tape again without overheating the battery cans.

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The minus leads are the hardest to solder, but with a good flux, things go very quickly. True, then it is better to wash the flux afterwards to clean the insides of the battery.

When assembling, do not forget to replace the cardboard gasket between the banks and the board. This is so that the fresh soldering does not short-circuit anything on the board.

This completes the repair and restoration of the lithium-ion battery of the Interskol DA-10 / 10.8 ER screwdriver. Almost all batteries are repaired in much the same way. Popular manufacturers of screwdrivers: Bosch, Makita, DeWALT, Metabo, Hitachi, Elitech, Skil and my favorite Bison. This concludes my story about the repair of a screwdriver battery. Ask questions in the comments. Better yet, in the appropriate thread on our forum or write to the Solder Master personally by mail.

Best regards, Solder Master. Happy repairs!

Dismantling the screwdriver battery

Let’s start repairing the screwdriver battery. We remove the battery from the handle of the screwdriver and unscrew the three self-tapping screws that are located under the sticker below.

After unscrewing the screws, carefully push back the hooks of the latches, as on. And remove the bottom of the plastic battery case.

Inside we see lithium-ion cans Chinese company HighStar model ISR18650-1300 Li-Ion. This means that the batteries have never been changed. Because it is known that Interskol purchases batteries from this company and inserts them into almost all of its battery tools.

Below you can see the insides of the screwdriver’s battery in all its glory with cans in the amount of three pieces, which were produced already in 2011. These batteries lasted five years during active use at a construction site. So the result is very decent. Usually they die earlier, probably they were not exploited in cold weather.

To replace the battery banks, you need to disassemble it even more. I advise you to remember the location of the plus, minus and charging contacts, so as not to confuse the wires when reassembling.

Pay attention to the voltage control board on the batteries. Stabilizers and protective diodes especially often fail on it. It is imperative to ring suspicious radio elements on this board with a multimeter.

We check the voltage at the output of the battery. It turned out 4.4 volts, and it should be 3.7 x 3 = 11.1 volts in the norm and 10.8 volts with the minimum battery charge. In general, the banks are dead. They need to be changed unambiguously.

Do-it-yourself screwdriver battery repair with battery replacement

Hello! Today we will repair the battery of the screwdriver. Did you know that the history of the creation of a screwdriver goes back to the deep Middle Ages. Already in the 15th century, when the knights put on armor before the battle, and the squires helped them twist parts of the armor, guess what? A screwdriver!

This went on for a long time, until in 1907 the Canadian inventor Peter Robertson patented the Robertson screw with a standard square hole into which the screwdriver tip was inserted. Since that time, screws have been produced on an industrial scale and used in households. Later, in 1934, inventor Henry Phillips redesigned the head of the screw and a Phillips screw was introduced into which the corresponding screwdriver was inserted. By that time, the engine had already been invented, and the idea of ​​creating a “screw and screw rotator” was in the air. However, there were big problems with the batteries. Their weight and dimensions. The problem was solved only in the 1980s, when the first nickel-cadmium Ni-Cd and lithium-ion Li-Ion rechargeable batteries appeared.

The USA and Japan were the first to master the production of household and professional cordless drills and screwdrivers. All this happened thanks to the emergence of new energy-intensive batteries of electricity. We will urgently change them inside the Interskol DA-10 / 10.8 ER cordless drill-screwdriver that fell into my hands. The malfunction was like this. When the button was pressed, the engine simply did not spin, but the LED lit up, the truth was weak.

We continue to disassemble the battery of the Interskol screwdriver

This can be done in several ways. You can unsolder the wires that go to the board.

You can also simply remove the contacts from the top battery cover. Shown is the shape of the bent contacts so you can easily remove them yourself.

Under the plastic cover we see how the batteries are connected to each other. Them spot welded. This solution is used in almost any battery of another tool. This is a safe and gentle battery connection. In this case, the destructive heating of the lithium batteries themselves is minimal.

Gently tear off or bite off the metal tape with pliers to detach the cans from each other. From the side of the board, they were also connected together with a tape and put on glue on a cardboard pad. This is done so as not to short-circuit anything on the board. Remember to put it back in place when reassembling the battery.

Due to the lack of a spot welding machine, new lithium-ion batteries will be soldered very quickly with a well-heated powerful soldering iron. We remember that heating lithium-ion batteries reduces their service life and is generally explosive.

Pay particular attention to the condition of the wires inside the battery. They can be broken or frayed. They need to be qualitatively isolated or replaced with fresh ones. Since I was repairing a screwdriver battery on the road in the field, I had to apply a brilliant invention of the engineering mind. He took out a blue radio technical tape.

When disassembling the battery of the Interskol DA-10 / 10.8 ER screwdriver, I was pleasantly surprised. A thermal sensor was installed in the budget screwdriver to control the temperature of the batteries. It turns out that when the lithium cans overheat, the protection circuit turns off the power until the temperature recovers to normal. True, the owner never managed to drive him into such a regime. We carefully tear off this thermal sensor so as not to break it. Then we will place it in the same place on new cans.

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Solder batteries

Can be done in different ways, for example with thick wires. I decided to solder a torn-off metal strip taken from old cans. First, I tinned the tapes in the places of future contacts on both sides. Later I tinned the battery contacts with a well-heated soldering iron with a drop of solder. But so that they do not get too hot. Let them cool down. Then he pressed the tape to the contacts of the cans and soldered the tape again without overheating the battery cans.

The minus leads are the hardest to solder, but with a good flux, things go very quickly. True, then it is better to wash the flux afterwards to clean the insides of the battery.

When assembling, do not forget to replace the cardboard gasket between the banks and the board. This is so that the fresh soldering does not short-circuit anything on the board.

This completes the repair and restoration of the lithium-ion battery of the Interskol DA-10 / 10.8 ER screwdriver. Almost all batteries are repaired in much the same way. Popular manufacturers of screwdrivers: Bosch, Makita, DeWALT, Metabo, Hitachi, Elitech, Skil and my favorite Bison. This concludes my story about the repair of a screwdriver battery. Ask questions in the comments. Better yet, in the appropriate thread on our forum or write to the Solder Master personally by mail.

Best regards, Solder Master. Happy repairs!

Repairing the screwdriver battery Replacing the old Ni-Cd screwdriver battery with Li-Ion cells

It happened in my case as well. The RYOBI CMD-1202 screwdriver was purchased by me on the occasion of repairs in the kitchen and served with faith for 3 years, after which the battery charge was enough to screw in a pair of medium self-tapping screws. This screwdriver was equipped with two 12 V, 1.7 Ah Ni-Cd rechargeable batteries. The cost of two new batteries turned out to be more than the cost of a new screwdriver of the same class with two batteries included. The latter was purchased for household needs. The old screwdriver went to a well-deserved rest in the closet.

Recently, on the Internet, I came across an article about replacing the nickel-cadmium battery cells of a screwdriver with lithium-ion (Li-ion) batteries of the 18650 format. Fortunately, the latter have accumulated in a decent amount, mainly from licked laptop batteries. After spending several hours studying the issue, it turned out that there are several options for implementing such a replacement.

1. Simple daisy chain connection of the required number of 18650 cells and use the native charger. A superficial knowledge of the peculiarities of charging batteries connected in series is sufficient to exclude such an option. Without delving into technical terms, we can say that Li-ion batteries cannot be heavily discharged and recharged, only work within 2.5. 4.2 V guarantees a long and safe battery life. Charging a battery converted in this way with a native charger will quickly disable Li-ion cells, and their destruction as a result of overheating is also possible.

2. Connection of elements with the addition of additional balancing wires, which are output to a separate socket. Smart chargers such as iMAX B6 and Turnigy Accucel-6 are used for charging. The charging process in this case turns out to be “correct”, however, as in the first case, the discharge of the batteries is not controlled in any way, and their excessive discharge will significantly reduce the battery life. In addition, it becomes necessary to purchase and use a special charger, which is extremely inconvenient in a construction site.

3. There are also extremely exotic implementations of this idea. Some people build miniature voltmeters into the battery case, according to the readings of which they determine the state of charge. Experienced radio amateurs design and manufacture charge and balancing controllers. These solutions are either difficult to replicate or do not provide adequate control and required reliability.

Having decided on the terms of reference: the use of a native charger to charge the batteries, no additional connectors and wires, the presence of charge control and balancing of elements, I began to look for implementation options. As always, our Asian friends did not disappoint, they offer a variety of options for charge control modules, both single and connected Li-Ion batteries. At this stage, we need to choose the nominal voltage for our Li-ion battery. Option 3S Li-ion batteries with a voltage range of 12.6. 7.5 V is not suitable for power engineering, as under heavy load there is a strong voltage drop even on a fully charged battery. Rechargeable battery of 4S Li-Ion batteries with a voltage range of 16.8. 10 V will ensure maximum continuous operation, and a slight excess of the operating voltage is not critical. The option suitable for me (bought here) has the following characteristics:

BMS 4S charge and protection controller for 4 x Li-Ion 18650 batteries
Charging voltage limiting: 4.25 V
Discharge cut-off: 2.5 V
Maximum charging current: 3A
Peak discharge current: 30A
Working discharge current: 15 A
Short circuit protection
Overcharge / overdischarge protection
Overcurrent protection

We proceed directly to the alteration

We disassemble the old battery and remove the Ni-Cd cells, as in most of these batteries, the contact pad is fixed directly on one of the cells, so as not to “farm” with the contacts in the future, we glue them together with this element using hot glue.

We collect 4 elements Samsung ICR18650-26C 2600 mAh in such a way as to ensure the most convenient location in the case. We connect the individual elements by soldering the wires; this must be done as quickly as possible so as not to overheat the battery. We connect the resulting battery to the protection board according to the connection diagram.

We install the battery into the case. The battery is ready.

The weight of the old batteries with Ni-Cd cells was 560 grams, the new Li-Ion battery “lost” 180 grams. And weighs 380 gr. At the same time, the energy capacity was almost doubled from 20.4 Wh (12V x 1.7 Ah) to 38.48 Wh (14.8 V x 2.6 Ah). A screwdriver converted in this way will serve as a faithful assistant for many more years in our service center.

First charge

The initial stresses on the elements are 3.85. 3.95 V, we charge it with a native charger. To monitor the current consumption, a multimeter is connected in the current measurement mode between the battery contact and the charge controller in the wire break. The voltage of the storage battery and a separate cell is monitored with two miniature digital voltmeters. Just in case, using an infrared thermometer, we control the temperature of the batteries and transistors on the charge controller board. Charging results are shown in the table and graphs.

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After the completion of the charging process, the voltage across the cells is 4.15. 4.17 V, battery voltage in general. 16.63 V. During charging, the battery temperature did not rise above 34.5 ° C, the charge controller board did not heat up at all.

How to calculate a non-working battery cell?

Battery composition.

Since the battery is presented in the form of a certain number of cells connected to each other, current flows through it completely. To find a non-working battery cell, you must initially fully charge the entire battery until it is clear that charging is over.

Further, it is recommended to measure the voltage on each individual bank. The voltmeter should not show values ​​below 1.2 Volts. If there are such indications, then the battery is not receiving adequate power or is not charging.

Important! In order to verify your measurements, you need to put a mark on the questionable element and make the assembly back.

So, after several periods of operation of the instrument, it is necessary to reconnect the banks and measure the voltage. Practice shows that the previously mentioned bank will have even less stress than before, since it begins to lose its performance and “slow down” the screwdriver.

Stages of the battery replacement process in a screwdriver

Electric diagram of the screwdriver charger.

Given the fact that in the post-Soviet space, tools of the nickel-cadmium type of the screwdriver battery are most often used, this option will be considered in more detail using the example of the Bosch GSR 14 4 ve-2 professional screwdriver. In our case, a complete replacement of the elements of individual batteries of the screwdriver will be made.

  1. Remove the cover and take out the battery cells assembly.
  2. Loosen a few screws on the red upper case.

First, it is worth disassembling the screwdriver battery. It is as follows:

  1. Prepare new battery cells.
  2. Next, it is necessary to apply tin on all cans on one side and carefully wipe the soldering points with distilled water.
  3. You can use a previously tinned piece of copper foil to connect each battery cell in the screwdriver. In this case, at its edges it is necessary to make U-shaped notches for further soldering.
  4. So, attach the U-shaped foil to the battery contact, which was previously coated with liquid rosin, and solder. After a few simple manipulations, all the battery cells will be assembled and ready to be replaced.
  5. Install the assembly into the original screwdriver box. Done!

Types of restoration of the performance of previously used battery cells

Diagram of a lithium-ion battery for a screwdriver.

The method of reanimating previously used batteries is very often used, since during the operation of the screwdriver, in other words, during constantly high loads, some elements lose their tightness and become unusable. In this case, it is necessary to produce a short-term impact of a strong current on the required battery cell (bank), and, possibly, it will be possible to restore the battery’s performance.

You can also try to gently squeeze or slightly deform the screwdriver’s battery case. Because this way you can extend the battery life for a short period of time. But in most cases, this method does not guarantee the battery life of the screwdriver and is temporary.

Nickel-cadmium batteries are characterized by significant endurance, since they may not lose charge for a long time or discharge, but very slowly. But in the event that it did not work to restore their performance, it is worth performing such a process as replacing the batteries in the screwdriver device.

What is a screwdriver battery?

Charger circuit for a screwdriver.

Any battery is presented in the form of a small number of batteries, in other words, cans. The latter mostly have standard dimensions. A distinctive feature of these batteries is their SUB-C capacity.

The battery has four main contacts:

  1. Through the power contacts, of which there are two units, currents pass in the process of charging and discharging the entire battery of the screwdriver.
  2. There is always a control contact at the top, which is continuously connected to the tripping temperature sensor and is used to prevent overheating of the tool during charging. Because at this moment the device absorbs currents of a huge rating.
  3. The last but not least is the service contact. It is used to equalize the charge in all banks at the moment of the deepest discharge in the most structurally complex battery cells.

Ways to replace batteries in a screwdriver

All battery-type devices, including a screwdriver, have a significant drawback. A limited battery life.

Diagram of a cordless screwdriver device.

That is why every owner of such a tool at any time may face such a question as replacing batteries in a screwdriver. But before you get started, you should understand the variety of batteries and their features.

Battery types for power tools

There are a huge number of battery technologies, but the most common and popular among them are the following:

  1. Lead acid batteries are most popular in the automotive industry due to their ease of manufacture and low cost. But then, for use in power tools, they did not show themselves very much, since they have low power with large dimensions and high weight.
  2. Nickel-cadmium batteries have significantly outperformed lead-acid cells. After all, they are lightweight and compact in size, delivering great power. But, of course, there are negative aspects, in particular, the toxicity of the battery. Since the production of this kind of battery cells is harmful to the environment. For example, in the countries of the European Union, this type of battery is considered prohibited.
  3. Nickel-metal hydride cells are considered to be an improvement over the previous battery type. After all, they are completely safe for the outside world. But there is also a drawback in the form of high self-discharge current rates.
  4. Lithium-ion batteries, although they have almost ideal parameters, since they have a high capacity, small size and low weight, are not very popular. This is because such a progressive element has a high cost, and therefore is not affordable for every layman.