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New Life for Old Battery Pack

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New Life for Old Battery Pack

#1

New Life for Old Battery Pack

Bill Grumbine, Kutztown PA

>Good morning all

As many of you know, when I turn I use a PAPR, or as I refer to it, an air helmet. It is a great tool, and does a very good job of protecting my face and lungs. Since I have a great face for radio, I guess you might say it also protects others when I have it on. But anyway...

It is not a cheap tool, and one of the more expensive consumable components is the rechargable battery pack. Mine went belly up about 18 monts ago or so, and I replaced it with a new one to the tune of about $125.00. I hung on to the old pack for a combination of reasons. In the first place, I am too lazy to investigate disposing of it properly, and too conscientious to throw it out in the trash. In the second, I thought that maybe someday I would rejuvenate it somehow. Well now someday has come. The second pack turned out to be much less vigorous than the first, and was showing signs of dying. So, I began some research to see what could be done.

After a lot of reading on the nature of NiCd batteries, a few posts on the main board here and elsewhere, I have ended up with a Tim Taylor sort of battery pack. The original pack was rated for 4.8V and 2300MAh. I have souped it up to 4.8V and 5000MAh. What that means in English is that my old 4 hr battery is now at least an 8 hr battery. I have a smart charger for it that is capable of handling 8 hr batteries, so no worries there. It will not fit back in the old casing, but duct tape will take care of that. ;-) And the best part is, I was able to purchase it locally, and instead of $125 - $150 for a new pack, I spent $40.00 for new batteries.

I don't know if this solution would work for everyone who has a PAPR. It was easy for me because my battery pack is completely external, and I was not constrained by any size requirements other than the proper voltage. I could have purchased 1/2 D sized batteries that would have fit back in the case, but I opted for more power (hence the Tim Taylor reference). If anyone is contemplating the same course of action, I would be glad to share more of my experiences.

Oh yeah, one last thing. The only reason I even knew about this electronics store local to me (which is not Radio Shack) was through previous questions here and on Badger Pond. Gerry Meekins, if you are reading, thanks once again for letting me know about Barbey's.

Bill

Re: New Life for Old Battery Pack

#2

40 Bucks and Some Duct Tape

Gerry in Maryland

>Those good folks in Reading have helped me out a time or two.. Glad to hear they could help you again Bill.

Take Care,

Gerry

Re: New Life for Old Battery Pack

#3

Re: New Life for Old Battery Pack

Fog Tanner

>You can pick up a copy of Model Aviation from an RC Hobby shop. There are a number of places that sell nicad type batteries cheaper than going back to 3M and most of the time cheaper than an electronics parts house. They wanted $70 for the pack in my Powervisor, I replaced it for $2.50. The 4 cell packs used in the Airstream are a stanard receive pack in large model ariplanes. The 3 cell packs used in the Powervisor are an oddball and have to be built. But you can buy the connector to plug in to the helmet, some wire and velcro and attach the battery "outside" the helmet. I bought all the componets for a multi battery charger (normal and tricle), connectors, and batteries for less than a third of the price of a battery pack from 3M. The Airstream would be even cheaper as I have 3 smart chargers, plus a dozen fixed rate.

The best solution is to have multiple packs, one in use, one on standby, and one charging. You don't really want to run the batteries until they go flat. You take a chance on one of the cells going into polarity reversial (i.e. swapping psoitive and negative). When that happens, you can almost never get it back - and you can never charge the pack up again. Its better on the cells to never go below around 60%-70% or 4.4 volts (with a load) on a 4 cell pack. If you know anyone in model airplanes, you can find out more than you want to know. If the batteries don't work in that application, its the quickest way to re-kit and airplane. Its not the takeoffs that are the problem - its that last landing.

Re: New Life for Old Battery Pack

#4

Re: New Life for Old Battery Pack

Fred L. - North Carolina

>An outboard battery pack can be made from a battery holder (from Radio Shack and other places). Such a pack will hold ordinary rechargeable batteries that are easier to get, and much cheaper than the ones with a solder tab on them. The batteries can then be charged in an ordinary charger.

Best bet for batteries is the C size. They hold the most power usually. Some D batteries are nothing but a smaller battery in a larger case.

I remember news cameramen had battery packs in the form of a belt. I suppose a belt to contain the battery holders could be made easily.

Fred

Re: New Life for Old Battery Pack

#5

Re: New Life for Old Battery Pack

Peter Teubel

>I did the same with an old AirMate 3 that a friend gave me. After I split the battery case, removed the old corroded batteries, installed the new NiMH D cells, glued it back together and installed it in the unit....I found out the fan motor was dead. Oh well, at least I found out it was an easy swap.

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