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Re: [OM] T45 battery pack rebuild

Subject: Re: [OM] T45 battery pack rebuild
From: John Hermanson <omtech1@xxxxxxxxxxx>
Date: Tue, 09 Dec 2008 09:01:47 -0500
Yes, very important.  Pretest all your cells before assembly to be sure 
they will all take a charge.
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Chuck Norcutt wrote:
> Quoting a note from Tim Hughes from 4 years ago on T45 rebuilds
> 
> Chuck Norcutt
> -----------------------------------------------------------
> Date: Sun, 5 Dec 2004 01:18:52 -0800 (PST)
> From: Tim Hughes <timhughes@xxxxxxxx>
> Subject: [OM] Re: T45 -- my solution
> 
> Here are the links to my schematic:
> http://olympus.dementia.org/Hardware/PDFs/T45_Chrg_1_0.pdf
> 
> And Bruce's physical layout sketch.
> http://olympus.dementia.org/Hardware/misc/T45_nicad.jpg
> 
> The reason your flash worked partly is that at least one of the strings 
> of cells,  probably only has a single defective cell. This allows that 
> invertor to charge up the flash cap to a lower voltage where it can 
> still be triggered albeit with low light etc.
> 
> 
> The cost to have the pack repaired is high because of tedious labour and 
> large number of cells.  With care you can cut open the pack along the 
> seams with a dremel cut blade (best) or a fine point dremel diamond 
> coated bit or even with the tip of a fine soldering iron.
> 
> If you do, do it yourself you need to find a source of tabbed cells. You 
> need to replace all cells, as mixing old and new ones does not last 
> long. My favourite place to deal with is the NiCdLady in southern CA. If 
> you ask nicely they will usually do the tabs for free, even though they 
> list a small fee for tabbing.  You still have to cut the tabs and solder 
> the cells together and fit it all in the small space.  I would recommend 
> you do not use NiMh cells as the charger will damage them quickly.
> 
> An alternative to replacing the NiCd cells would be to use just two 
> Hawker Sealed Pb, D cells connected in series and hook them up to all 
> the + terminals in parallel. You would have to make some sort of adapter 
> connector.  Although a pair of these D cells can fit inside the handle, 
> you would have to figure out how to hold them in.  You would also have 
> to make a voltage regulated charger with a voltage of exactly 4.7V. So 
> this is only an option if you have electronics skills. One advantage is 
> the hawker cells are about $6 ea ($12 tot), so a bit cheaper, although 
> you will not get so many flashes out, You could make 2 or three packs 
> for the cost of a single set of NiCd's.
> Beware of shorting the hawker cells they can deliver about 180A into a 
> short causing things to glow red hot.
> 
> Regards,
> Tim Hughes
> ---------------------------------------------------------
> 
> Mark Dapoz wrote:
>> On Mon, 8 Dec 2008, Ken Norton wrote:
>>
>>> 4. The shell of the battery is built in two halves, but are not separating.
>>> This is where I am stuck. I've tried prying them apart but haven't "forced"
>>> the issue too much yet.  But I'm not getting anywhere.
>> Yes, it's lightly glued along the edges.  If you work slowly with a very
>> sharp utility knife you can separate the two halves without damaging the
>> case.  A little bit of twisting of the pack also helps to break the bond.
>> When done you'll need 20 AA's to rebuild it and a bit of time to put it
>> all together.  Get AA's with tabs welded 90 degrees to each other, it
>> makes assembling the pack easier.
>>                                      -mark
>>
>>
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>>
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