How to rebuild a Li
Contents
1. Now it s time to continue to the step by step guide to see how we can safely reconstruct a Li lon pack How to rebuild a Li Ion battery pack Search Site WWW Search Upload Center Support us Advertising FAQ Profile Books Gadgets Add your link here Free Schematics Search Engine Top Selling Electronics at Amazon Best Buy Mobile Phones Electronics lab com 2002 2004 Any logo trademark and project represented here are property oftheir respective owner http www electronics lab com articles Li_Ion_reconstruct index html 7 of 7 13 07 2005 02 24 53 p m How to rebuild a Li Ion battery pack unicef DISASTER IN ASIA Donate NOW LECTRONICS LAE htp Awe electronics lab corm Home Projects Action Downloads Articles Links Community Contact Home Articles How to rebuild a Li lon battery pack Implemented for Fujitsu Siemens Lifebook S Series FPCBP25 battery pack source Electronics Lab com Warning If you are not completely sure what you are doing don t apply what is described below In any case www electronics lab com does not have any responsibility in any way to the consequences that this guide may have CAUTION aan CAUTION Explosion Read it at your own risk ee t eee reading if you don t agree Explosion risk WI e above risk page 2 4 Product i EPCEPOS 7Oo4a KO0A http www electronics lab com articles Li_Ion_reconstruct index_1 html 1 of 9 13 07 2005 02 25 09 p2. i lt gee ee unicef DISASTER 3 Pie haa a AA IN ASIA LECTRONICS LAG eo Home Projects Action Downloads Articles Links Community Contact Home Articles How to rebuild a Li lon battery pack Implemented for Fujitsu Siemens Lifebook S Series FPCBP25 battery pack source Electronics Lab com page 3 4 http www electronics lab com articles Li_Ion_reconstruct index_2 html 1 of 10 13 07 2005 02 26 17 p m How to rebuild a Li Ion battery pack Take a new cell As you see there is a small circuit board connected on top of the battery under the orange tape Start heating your soldering iron Remove the orange tape to free the board Desolder both contacts of the leads that are attached to the battery cell http www electronics lab com articles Li_Ion_reconstruct index_2 html 2 of 10 13 07 2005 02 26 17 p m How to rebuild a Li Ion battery pack http www electronics lab com articles Li_Ion_reconstruct index_2 html 3 of 10 13 07 2005 02 26 17 p m Now you battery should look like this Remove the white cable but don t remove the white coating that protects the battery terminals from short circuit How to rebuild a Li Ion battery pack Remove the double sided adhesive tape as it s too thick and needs to be removed so battery fits back to it s place Now take the old batteries and remove the top white coating http www electronics lab com articles Li_Ion_reconstruct
3. is reversed e Do not connect the positive terminal and the negative terminal of the battery to each other with any metal object e Do not carry or store the batteries together with necklaces hairpins or other metal objects e Do not pierce the battery with nails strike the battery with a hammer step on the battery or otherwise subject it to strong impacts or shocks e Do not solder directly onto the battery e Do not expose the battery to water or salt water or allow the battery to get wet e Do not disassemble or modify the battery The battery contains safety and protection devices which if damaged may cause the battery to generate heat rupture or ignite e Do not place the battery on or near fires stoves or other high temperature locations Do not place the battery in direct sunshine or use or store the battery inside cars in hot weather Doing so may cause the battery to generate heat rupture or ignite Using the battery in this manner may also result in a loss of performance and a shortened life expectancy reverse polarity heat above 100 degrees Celsius solder directly on the metal can Dispose them following Use common sense precautions Do not short circuit overcharge crush mutilate nail penetrate incinerate A local batteries disposal rules Safety circuits inside a Li lon battery pack Inside a Li lon pack there is always a safety circuit that consists of four main sections 1 The controller IC that monitors e
4. positive electrode material is ionized during charge and moves from layer to layer in the negative electrode as illustrated to the left image During discharge Li ions move to the positive electrode where embodies the original compound Specialty Carbon Features of lithium lon batteries gt High energy density that reaches 400 Wh L volumetric energy density or 160Wh Kg mass energy density High voltage Nominal voltage of 3 6V or even 3 7V on newer Li lon batteries gt No memory effect Can be charged any time but they are not as durable as NiMH and NiCd batteries gt High charge currents 0 5 1A that lead to small charging times around 2 4 hours gt Flat discharge voltage allowing the device to stable power throughout the discharge period gt Typical charging Voltage 4 2 0 05V gt Charging method constant current constant voltage CV CC Typical operation voltage 2 8V to 4 2V Recommended temperature range 0 40 C Charging Characteristics Charging method is constant current constant voltage CV CC This means charging with constant current until the 4 2V are reached by the cell or 4 2V x the number of cells connected in series and continuing with constant voltage until the current drops to zero The charge time depends on the charge level of the battery and varies from 2 4 hours for full charge Also Li lon cannot fast charge as this will increase their temperature above limits Charging
5. the polarity lt lt back to page 2 Proceed to page 4 gt gt Search Site WWW Search Upload Center Support us Advertising FAQ Profile Books Gadgets Add your link here Free Schematics Search Engine Electronic Kits Best Buy Mobile Phones http www electronics lab com articles Li_Ion_reconstruct index_2 html 10 of 10 13 07 2005 02 26 17 p m How to rebuild a Li Ion battery pack fan ao ee ee eo a oe i lt gee ee unicef DISASTER 3 Pie haa a AA IN ASIA LECTRONICS LAG eo Home Projects Action Downloads Articles Links Community Contact Home Articles How to rebuild a Li lon battery pack Implemented for Fujitsu Siemens Lifebook S Series FPCBP25 battery pack source Electronics Lab com page 4 4 http www electronics lab com articles Li_Ion_reconstruct index_3 html 1 of 8 13 07 2005 02 27 03 p m How to rebuild a Li Ion battery pack bd E a cL 7s ot AT Fy pevai Place the Sap with the hatferies ked in ithe original plastic box You should have try if they fit the bol in your sides while soldering Use a multimeter to check for short http www electronics lab com articles Li_Ion_reconstruct index_3 html 2 of 8 13 07 2005 02 27 03 p m How to rebuild a Li Ion battery pack circuits Measuring the cells you will see that are not fully discharged it s recommended to store Li lon cells in a 40 50 charge level http www e
6. to remove it Take a screwdriver and put it in the split between the two covers of the battery pack that s beside the cover Try to turn the screwdriver and unglue a small side You may need to apply enough force to achieve this Continue this operation to the entire pack That s not too difficult but for sure you will scratch the plastic After some minutes you are victorious i M4 TT gi b Ka E http www electronics lab com articles Li_Ion_reconstruct index_1 html 2 of 9 13 07 2005 02 25 09 p m How to rebuild a Li Ion battery pack a 3 6v 2600mAh http www electronics lab com articles Li_Ion_reconstruct index_1 html 3 of 9 13 07 2005 02 25 09 p m 10a 2600 rt e a 2600man ____ Safety Circuit board Now you have a clear view of the interior You see that the pack comprises from 6 Li lon cells and a circuit board that contains all the safety circuits After a more detailed examination you will find that the batteries and connected in three series of two batteries each one Look at the following image to understand the actual structure As you see the expected characteristics of each cell according to the connection and the entire pack characteristics are 3 6V and 1300mAnh capacity Identifying the cells On top of each cell is a part number CGP345010 click for the datasheet that s a Panasonic s Li lon prismatic cell As you can see in the datasheet thi
7. your own replacing each individual cell inside the pack But before step on this you must consider many parameters messing around Li lon batteries about the way they are charged and the way you must handle them How to rebuild a Li Ion battery pack Special precautions must be taken to avoid Li lon battery fire up or explosion that can cause serious injuries This is because Lithium when comes in contact with air burns violently In this article we will discuss how to handle Li lon batteries to avoid any malfunction the precautions you must take the way Li lon batteries are charged the protection circuits used and finally you can find a step by step guide on how to reconstruct a Fujitsu Siemens Lifebook S Series FPCBP25 battery pack This guide can also be read as a tutorial on how to rebuild other kind of Li lon battery packs except the one we will use here It s recommended to read the following details in order to understand how a Li lon battery must be handled to avoid any injury before proceed to the reconstruction of the pack Overview Li lon and Li Po batteries are leading edge battery technology and consists ideal selection in use on portable computers and cellular phones due to their high energy density and high voltage A typical Li lon cell is rated at 3 6V and this is three times more than the typical NiCd or NiMH cell voltage 1 2V rs Structure Prismatic Cell made with Lithium Cobalt oxide cathode a nega
8. How to rebuild a Li Ion battery pack http www electronics lab com articles Li_Ion_reconstruct index html 1 of 7 13 07 2005 02 24 53 p m unicef DISASTER IN ASIA LECTROAICS LAE myrr ee f Home f Projects f acton T powmoass areles f Lrs T Community Comat o Home Articles How to rebuild a Li lon battery pack Implemented for Fujitsu Siemens Lifebook S Series FPCBP25 battery pack source Electronics Lab com page 1 4 Did you recently notice poor performance of your notebook Li lon battery Don t be taken aback this is happening even to the best battery Now days Li lon batteries are widely used in portable devices due to there excellent energy to weight ratio and for the reason they are not suffering from memory effect These two reasons make them the best choice on portable devices but not suffering from memory effect doesn t mean it will last for ever Chemical conversions inside the battery make it to produce electric energy but these chemical reactions aim to attenuate as time and charge cycles pass over When the battery life drops significantly it s time to search for a replacement but you will recently find out that most of notebook batteries cost almost 1 3 to 1 2 the price of the laptop at the time you will need to replace the battery So if you want to keep your laptop but don t want to spend much money for battery replacement it s time to think about rebuild it
9. Li_Ion_reconstruct index_3 html 8 of 8 13 07 2005 02 27 03 p m
10. ach cell or parallel cells voltage and prevents the cells to overcharge or overdischarge controlling accordingly the cutoff switches Also the voltage across the switches is monitors in order to prevent over current 2 The control switches that usually comprises FET structures that cutoff the charge or discharge depending on the control signals of the controller IC 3 The temperature fuse that cutoff the current if the control switches experience abnormal heating This fuse is not recoverable 4 The thermistor usually PTC that measure the battery temperature inside the pack It s terminals are connected to the charger so it can sense the temperature of the pack and control the charge current until the battery it s full charged How to rebuild a Li Ion battery pack lt lt Back to articles Proceed to page 2 gt gt http www electronics lab com articles Li_Ion_reconstruct index html 6 of 7 13 07 2005 02 24 53 p m Battery Pack image Panasonic A typical structure of Li lon battery pack block diagramm Battery packs made from Li lon cells always have protective circuits and PTC elements to monitor battery status any time Never remove this circuitry as this will cause ignition Now you have read and understand all the above information you see that charging a Li lon pack can t be done with simple charge methods used in other type of batteries So never charge a Li lon cell if you are not completely sure what you do
11. f the contact that goes to the pcb I Continue cutting the other edge of the contact http www electronics lab com articles Li_Ion_reconstruct index_1 html 6 of 9 13 07 2005 02 25 09 p m How to rebuild a Li Ion battery pack Continue removing the next cells in series In the final cell you must pay more attention because there is a PTC attached on top of it Carefully remove the adhesive tape and free it from the cell Now you can also remove this cell http www electronics lab com articles Li_Ion_reconstruct index_1 html 7 of 9 13 07 2005 02 25 09 p m How to rebuild a Li Ion battery pack Place all cells in a distance so there is no chance to short circuit them Don t throw away old ones as you will need them later Finally remove carefully the safety circuit board without damaging it as we will use it again http www electronics lab com articles Li_Ion_reconstruct index_1 html 8 of 9 13 07 2005 02 25 09 p m How to rebuild a Li Ion battery pack lt lt Back to page 1 Proceed to page 3 gt gt Search Site WWW Search Upload Center Support us Advertising FAQ Profile Books Gadgets Add your link here Free Schematics Search Engine Electronic Kits Best Buy Mobile Phones http www electronics lab com articles Li_Ion_reconstruct index_1 html 9 of 9 13 07 2005 02 25 09 p m How to rebuild a Li Ion battery pack fan ao ee ee eo a oe
12. index_2 html 4 of 10 13 07 2005 02 26 17 p m How to rebuild a Li Ion battery pack and the blue heat shrinkable plastic as we are going to use it to the new batteries http www electronics lab com articles Li_Ion_reconstruct index_2 html 5 of 10 13 07 2005 02 26 17 p m How to rebuild a Li Ion battery pack Now place the blue plastic on a new battery so the cut side faces the thin adhesive tape that we haven t removed http www electronics lab com articles Li_Ion_reconstruct index_2 html 6 of 10 13 07 2005 02 26 17 p m How to rebuild a Li Ion battery pack Press the plastic to glue on top of the tape http www electronics lab com articles Li_Ion_reconstruct index_2 html 7 of 10 13 07 2005 02 26 17 p m How to rebuild a Li Ion battery pack Next attach the white protective coating you have removed from the old batteries Repeat all the steps for all the http www electronics lab com articles Li_Ion_reconstruct index_2 html 8 of 10 13 07 2005 02 26 17 p m How to rebuild a Li Ion battery pack batteries Now you must have six ready to solder batteries Solder the batteries in series of two As on the diagram in page one Repeat this step to make three sets of two batteries in series http www electronics lab com articles Li_Ion_reconstruct index_2 html 9 of 10 13 07 2005 02 26 17 p m How to rebuild a Li Ion battery pack Now solder the sets on the circuit board paying attention to
13. lectronics lab com articles Li_Ion_reconstruct index_3 html 3 of 8 13 07 2005 02 27 03 p m How to rebuild a Li Ion battery pack If everything looks good apply some glue around the plastic case http www electronics lab com articles Li_Ion_reconstruct index_3 html 4 of 8 13 07 2005 02 27 03 p m How to rebuild a Li Ion battery pack g 4 You can also use clamps to glue the plastic encloser tautly As long as the glue takes to dry http www electronics lab com articles Li_Ion_reconstruct index_3 html 5 of 8 13 07 2005 02 27 03 p m How to rebuild a Li Ion battery pack http www electronics lab com articles Li_Ion_reconstruct index_3 html 6 of 8 13 07 2005 02 27 03 p m pma le ae place the old cell on a separate small plastic bag and depose to a battery recycling bucket Don t throw them along with ordinary rubbish How to rebuild a Li Ion battery pack Now it s the big time Place the pack back in your notebook If everything is ok the indicator should saw that the battery is charging normally The arrow in the above image shows this The first charge took around 2 30 hours to complete and the first discharge last about 2 45 hours That s good results Now your notebook looks like new _ During the first 3 4 charges cycles don t let the notebook charge in another room that this you are so you can A observe for any malfunctions that can cause excess heat during charging discharging Resou
14. m How to rebuild a Li Ion battery pack The Li lon battery pack we will rebuild replacing it s individual cells it s a FRCBP25 battery pack manufactured from Fujitsu Siemens and used in Lifebook S Series notebooks like Fujitsu Siemens 4510 84542 4546 84572 and 84576 ect S series of Fujitsu Siemens notebooks are really nice so that s another reason you may don t like to replace your notebook with a new one You may also find this pack listed with the number FMVNBP104 or CP024486 01 The nominal voltage is 10 8V and capacity is 2600mAh The battery pack looks like in the above photo You can read on the label the product number and the type of the battery Li lon You must also read all warnings listed and be sure to follow them expect the disassemble one that we can t do it in another way ZA DANGER Do not incinerate Do not disassemble Do not expose to high temperatures 140 F 60 C Do not impact pierce ov crush the battery eLise specified charger only Dispose of properly May cause overheating fire or bursting It is strongly recommended not to proceed to the following operations if you are not sure what are you doing or A you have not fully understand the precautions previously talked about Continue reading with your own risk We advice you to work in a fire safe place and take all the necessary fire safety measures Disassemble The pack is sealed to make it s disassemble hard The cover is glued so it may be hard
15. rces Download the article in PDF format 1 6MB References about Panasonic CGP345010 Cell Panasonic rechargeable lithium ion battery OEM products Online Li lon cells at AllElectronics com CGP345010 3 7V 1400mAh Panasonic Prismatic Cell Datasheet Li lon rechargable Cell Thermal Vacuum Test Results An Innovative Low Cost Communication Sattelite using CGP345010 cells PDF Nanosatellite Final Design Report Li lon Charger Application Notes Charging Simplified for High Capacity Batteries Microchip application note A Li lon battery charger using TSM102A ST Microelectronics Highly Integrated Single Cell Li ion Li Polymer battery charger Intersil Off line Li lon battery charger with P89LPC916 Philips LM3647 Reference Design User s Manual National How to Design Battery Charger Applications that Require External Microcontrollers MAX846A Other Sites http www surfbaud co uk Power ICs Charge Ahead In One Cell Li lon Applications More Li lon Charger ICs lt lt back to page 3 Go to articles index gt gt http www electronics lab com articles Li_Ion_reconstruct index_3 html 7 of 8 13 07 2005 02 27 03 p m How to rebuild a Li Ion battery pack Search Site WWW Search Upload Center Support us Advertising FAQ Profile Books Gadgets Add your link here Free Schematics Search Engine Electronic Kits Best Buy Mobile Phones http www electronics lab com articles
16. s cell has a nominal voltage 3 7V and 1400mAh That s above the expected value of each cell as calculated according to the battery pack characteristics but the part number of each cell are identical and both manufactured by Panasonic So what s is happening The most possible explanation is that Fujitsu has rated it s battery pack a little bit lower than the actual nominal ratings for a reason The cell are for sure the same How to rebuild a Li Ion battery pack Find the cells Now we have identified the cells that comprises the pack it s time to check if we can find them in market Now you need to be lucky We found the cells on www AllElectronics com at a reasonable price That s exactly the cells we need with an additional protection circuit that we don t need and we are going to remove it Take the battery out With the help of a screwdriver lift the first battery and cut the first connector as seen on the left photo http www electronics lab com articles Li_Ion_reconstruct index_1 html 4 of 9 13 07 2005 02 25 09 p m How to rebuild a Li Ion battery pack Lift carefully the second cell trying not to damage the circuit board With the help of a cutter cut the remaining metallic contact and keep it as you will need it later http www electronics lab com articles Li_Ion_reconstruct index_1 html 5 of 9 13 07 2005 02 25 09 p m How to rebuild a Li Ion battery pack Now cut the other side o
17. time increases at lower temperatures How to rebuild a Li Ion battery pack 2000 945 mA max 2 hours 20 C 1600 E S 1200 on 800 g 400 z D g 2 5 Time h Typical charging characteristic Charge current is recommended to be set at 0 7CmA where C is battery capacity If voltage is below 2 9V per cell it s recommended to charge at 0 1CmA Charging environment must have a temperature between 0 40 Maximum discharge current must not exceeds 1 0CmA and discharge voltage must not go below 3 0V Capacity At a typical 100 charge level at 25 C Li ion batteries irreversibly lose approximately 20 capacity per year from the time they are manufactured even when unused 6 at 0 20 at 25 35 at 40 When stored at 40 charge level these figures are reduced to 2 4 15 at O 25 C and 40 respectively Every deep discharge cycle decreases their capacity also Capacity mAh Charge Conditions tagline yvoltage constant current 4 2 945 mA max 2 hours 2 Discharge Conditions Constant curent 1350 mA up to 3 0 at 20 C Charge Discharge Rest Period 20 min 0 100 200 300 400 500 Number of Cycles Cycles Typical capacity characteristic over charge cycles 100 cycles leave the battery with about 75 to 85 of the original capacity When used in notebook computers or cellular phones this rate of deterioration means that after three to five years the battery will have capacities too lo
18. tive electrode Li lon cell has a tree layer structure A positive electrode plate Positive lead plate made with specialty carbon anode and a separator layer Inside the battery also exists a electrolyte which is a lithium salt in an organic solvent Li lon is also equipped with a variety of safety measures and protective electronics and or fuses to prevent reverse polarity over voltage and over heating and also have a pressure release valve and a safety vent to prevent battery from burst Magative can Never short circuit reverse polarity disassemble A damage or heat over 100 degrees Celsius a Li lon cell That can be really dangerous Positive electrode i Insulator mage Sony Working Principle Lithium battery uses lithium cobalt oxide as positive electrode cathode and a high crystallized special carbon as negative electrode anode Also an organic solvent specialized to be used with the specific carbon works like electrolytic fluid The chemical reaction that takes place inside the battery is as follows during charge and discharge operation O CG a http www electronics lab com articles Li_Ion_reconstruct index html 2 of 7 13 07 2005 02 24 53 p m How to rebuild a Li Ion battery pack http www electronics lab com articles Li_Ion_reconstruct index html 3 of 7 13 07 2005 02 24 53 p m Positive Electrode Negative Electrode The main principle behind the chemical reaction is one where lithium in
19. w to be still usable Tip To increase battery life store it at 40 level at low temperatures even to the refrigerator but not below 0 A degrees Celsius and never discharge it full Charge it early and often Excess heat can damage the battery Also charge once a year to prevent overdischarge Self discharge One great advantage of Li lon batteries is their low self discharge rate of only approximately 5 per month compared with over 30 per month and 20 per month in nickel metal hydride batteries and nickel cadmium batteries respectively http www electronics lab com articles Li_Ion_reconstruct index html 4 of 7 13 07 2005 02 24 53 p m How to rebuild a Li Ion battery pack http www electronics lab com articles Li_Ion_reconstruct index html 5 of 7 13 07 2005 02 24 53 p m 1 2 1 2 2 1 3 6 Nominal Voltage V 3 6 3 7 3 6 Specific Energy Wh Kg 50 70 30 80 100 160 140 Specific Energy Wh L 150 200 250 360 Cycle Life Times 500 560 1000 1000 Environmental hazard low medium medium high high high Safety High High medium low low low Cost low medium low high high high Self Discharge Rate month 25 30 30 35 6 9 6 9 Memory Effect yes yes yes no no no Comparison table of the most common batteries types Precautions Be sure to follow the safety rules listed below PANASONIC recommendations e Do not place the battery in fire or heat the battery e Do not install the battery backwards so that the polarity
Download Pdf Manuals
Related Search