Cordless Power Tool Batteries that contain Nickel Cadmium (NiCd) Cells can be
Re-Conditioned to perform as well as new or close to new. There is a slight loss of capacity
due to this process but proper maintance after the proceedure will insure years of usable life.
The First and most common procedure for Re-Conditioning a NiCd cell is by using a
Technique called "VOLTAGE SURGING". Over time the crystals within a NiCd cell begin to
combine and get larger. This causes them to loose capacitance and also break through the
inner seals of the cell. Surging the NiCd cell using a higher voltage causes the crystals
within the NiCd cell to shatter and become smaller. These smaller crystals have a greater
surface area and therefore contain a greater capacitance for energy. Crystals primarily grow
larger during "OVER CHARGING". Over Charging is the enemy of a NiCd Cells so
Remember to leave your batteries on the charger for only the minimum charging time OR
LESS! This is usually an hour or less for Rapid Chargers or 2 to 4 hrs for standard chargers.
It is also best to only charge your batteries immediately before you use them. Storing your
batteries with a full charge encourages crystal growth. Storing your batteries on a low charge
is best. Follow these maintenance techniques to insure years of dependable use.
The "VOLTAGE SURGING" Technique below may be repeated until the battery holds a
dependable charge but wait atleast 15 minutes between "SURGING" to allow for the vapors
within the cell to cool. Surging the battery without waiting will result in the cell EXPLODING!
Most batteries will only require one or two "VOLTAGE SURGES".
For batteries up to 9.6 volts you will want to run two wires from a good 12 volt battery, such
as a car battery or two 6 volt lantern batteries run in series. Clamp the ground wire from the
car battery to the negative side of the tool battery. Small alligator clamps work good for this
application. The positive terminal on the tool battery is usually golden in color and the
negative is usually silver in color. Use a voltage meter to be sure. One end of the positive
wire should be rigidly attached to the car battery and the other end of the positive wire should
be stripped at the end. Then simply tap the stripped end of the positive wire against the
positive terminal on the tool battery for about 10 seconds tapping at a rate of 2 to 3 times per
second. See charts below for exact recomended "SURGE TIME" for your battery pack size
and your specific power source voltage. Check the voltage of the tool battery with a voltage
tester and if it does not give a voltage equal to or slightly higher than the tool batteries rated
voltage, then repeat these steps for a few more seconds until it does (waiting 15 minutes
between surges). See Fig. A. For batteries of 9.7 volts to 19.9 volts you will need atleast 24
volts. Four 6 volt lantern batteries run in series also works. It is also possible to use other
tool batteries wired together in series as a power source, but if you are using two 18 volt tool
batteries in series you will generate 36 volts and 10 seconds will be to long. Shorten
re-conditioning process to 6 or 7 seconds. You can also use 2-18 volt tool batteries in series
for re-conditioning 24 volt tool batteries. Using other DC power sources such as welders can
also be used for the "VOLTAGE SURGING". Refer to Fig. B. Use lamp cord thickness wire
or larger and always use safety goggles!
Re-Conditioned to perform as well as new or close to new. There is a slight loss of capacity
due to this process but proper maintance after the proceedure will insure years of usable life.
The First and most common procedure for Re-Conditioning a NiCd cell is by using a
Technique called "VOLTAGE SURGING". Over time the crystals within a NiCd cell begin to
combine and get larger. This causes them to loose capacitance and also break through the
inner seals of the cell. Surging the NiCd cell using a higher voltage causes the crystals
within the NiCd cell to shatter and become smaller. These smaller crystals have a greater
surface area and therefore contain a greater capacitance for energy. Crystals primarily grow
larger during "OVER CHARGING". Over Charging is the enemy of a NiCd Cells so
Remember to leave your batteries on the charger for only the minimum charging time OR
LESS! This is usually an hour or less for Rapid Chargers or 2 to 4 hrs for standard chargers.
It is also best to only charge your batteries immediately before you use them. Storing your
batteries with a full charge encourages crystal growth. Storing your batteries on a low charge
is best. Follow these maintenance techniques to insure years of dependable use.
The "VOLTAGE SURGING" Technique below may be repeated until the battery holds a
dependable charge but wait atleast 15 minutes between "SURGING" to allow for the vapors
within the cell to cool. Surging the battery without waiting will result in the cell EXPLODING!
Most batteries will only require one or two "VOLTAGE SURGES".
For batteries up to 9.6 volts you will want to run two wires from a good 12 volt battery, such
as a car battery or two 6 volt lantern batteries run in series. Clamp the ground wire from the
car battery to the negative side of the tool battery. Small alligator clamps work good for this
application. The positive terminal on the tool battery is usually golden in color and the
negative is usually silver in color. Use a voltage meter to be sure. One end of the positive
wire should be rigidly attached to the car battery and the other end of the positive wire should
be stripped at the end. Then simply tap the stripped end of the positive wire against the
positive terminal on the tool battery for about 10 seconds tapping at a rate of 2 to 3 times per
second. See charts below for exact recomended "SURGE TIME" for your battery pack size
and your specific power source voltage. Check the voltage of the tool battery with a voltage
tester and if it does not give a voltage equal to or slightly higher than the tool batteries rated
voltage, then repeat these steps for a few more seconds until it does (waiting 15 minutes
between surges). See Fig. A. For batteries of 9.7 volts to 19.9 volts you will need atleast 24
volts. Four 6 volt lantern batteries run in series also works. It is also possible to use other
tool batteries wired together in series as a power source, but if you are using two 18 volt tool
batteries in series you will generate 36 volts and 10 seconds will be to long. Shorten
re-conditioning process to 6 or 7 seconds. You can also use 2-18 volt tool batteries in series
for re-conditioning 24 volt tool batteries. Using other DC power sources such as welders can
also be used for the "VOLTAGE SURGING". Refer to Fig. B. Use lamp cord thickness wire
or larger and always use safety goggles!
STEP BY STEP INSTRUCTIONS
1.) Using a voltage tester to
determine polarity (pos. & neg.)
2.) Use Tables E, F & G to
determine the "Surge Time" for
your particular battery size and
power source.
3.) Surge battery for suggested
time and allow to cool for 15 min.
4.) Use a voltage tester after
15min. and if voltage drops below
normal voltage then repeat steps
3 & 4.
5.) Charge battery as normal. If
battery fails to charge, repeat
steps 3 & 4. This process can be
repeated up to 25 times.
ALWAYS USE SAFETY GOGGLES
1.) Using a voltage tester to
determine polarity (pos. & neg.)
2.) Use Tables E, F & G to
determine the "Surge Time" for
your particular battery size and
power source.
3.) Surge battery for suggested
time and allow to cool for 15 min.
4.) Use a voltage tester after
15min. and if voltage drops below
normal voltage then repeat steps
3 & 4.
5.) Charge battery as normal. If
battery fails to charge, repeat
steps 3 & 4. This process can be
repeated up to 25 times.
ALWAYS USE SAFETY GOGGLES
TABLE
E
E
TABLE
F
F
TABLE
G
G
Wiring batteries together in series
sounds dangerous because
directly connecting a positive to a
negative usually is. In the case of
DC batteries, this is not true.
Connecting the positive of one
battery to the negative actually
increases voltage (see fig.B).
There is no risk of explosion when
properly connected. This principle
can be seen in flashlights where
the batteries are also ran in series
where the positive of one battery is
butted to the negative of the next
battery.
sounds dangerous because
directly connecting a positive to a
negative usually is. In the case of
DC batteries, this is not true.
Connecting the positive of one
battery to the negative actually
increases voltage (see fig.B).
There is no risk of explosion when
properly connected. This principle
can be seen in flashlights where
the batteries are also ran in series
where the positive of one battery is
butted to the negative of the next
battery.
The previous Re-Conditioning
method will work 90% of the time but
occasionally a battery will still not
retain its rated voltage. For those of
you who are mechanically inclined,
there is another option. Remove the
battery cell cluster as shown in Fig. C.
Test each individual cell for voltage
with a voltage tester. If an individual
cell fails to register at least one volt,
that particular cell will need to be
Re-Conditioned. There may be a
fibrous insulator on top and/or bottom
of the cells that will need to be drilled
to reach the individual cells, but do
not drill into the battery cells
themselves! NOTE: Each cell will
have to be tested for Polarity (+ or -),
the cells are rotated so the positve
end of the cell on some will be facing
up and others will be facing down.
Once you locate the bad cell(s) use a
12 volt car battery to Re-Condition the
individual cell by holding the Negative
wire to the Negative side of the cell
and then hold the Positive wire to the
Positive side of the cell for 2 to 3
seconds, but no longer. Repeat this
process for each cell that doesn't
register at least on volt. This process
will work on 18v and 24v batteries as
well as lower voltages because the
individual cells are the same.
method will work 90% of the time but
occasionally a battery will still not
retain its rated voltage. For those of
you who are mechanically inclined,
there is another option. Remove the
battery cell cluster as shown in Fig. C.
Test each individual cell for voltage
with a voltage tester. If an individual
cell fails to register at least one volt,
that particular cell will need to be
Re-Conditioned. There may be a
fibrous insulator on top and/or bottom
of the cells that will need to be drilled
to reach the individual cells, but do
not drill into the battery cells
themselves! NOTE: Each cell will
have to be tested for Polarity (+ or -),
the cells are rotated so the positve
end of the cell on some will be facing
up and others will be facing down.
Once you locate the bad cell(s) use a
12 volt car battery to Re-Condition the
individual cell by holding the Negative
wire to the Negative side of the cell
and then hold the Positive wire to the
Positive side of the cell for 2 to 3
seconds, but no longer. Repeat this
process for each cell that doesn't
register at least on volt. This process
will work on 18v and 24v batteries as
well as lower voltages because the
individual cells are the same.
VersaPak Batteries
VersaPak batteries have three 1.2 volt cells
inside of them so they should register 3.6
volts. If they are bad they will typically
register 0, 1.2 or 2.4 volts. The VersaPak
batteries are very simple to Re-Condition.
Simply hold the negative wire from the
battery to the outside housing of the
battery which is its ground. Then hold the
Positive wire to the inside of the battery for
3 seconds but no more. Repeat after 15
minutes in necessary. Its that Easy!
VersaPak batteries have three 1.2 volt cells
inside of them so they should register 3.6
volts. If they are bad they will typically
register 0, 1.2 or 2.4 volts. The VersaPak
batteries are very simple to Re-Condition.
Simply hold the negative wire from the
battery to the outside housing of the
battery which is its ground. Then hold the
Positive wire to the inside of the battery for
3 seconds but no more. Repeat after 15
minutes in necessary. Its that Easy!
Use the tables below to determine proper "SURGE TIME" for your particular battery size and power
source. For example; If you have an 18v battery pack and a 36v power source (3 car batteries in series)
then you would surge the battery for 6 seconds (see table E). If you only have 2 car batteries in series
then the recommended surge time would increase and be 10 seconds (see table F).
source. For example; If you have an 18v battery pack and a 36v power source (3 car batteries in series)
then you would surge the battery for 6 seconds (see table E). If you only have 2 car batteries in series
then the recommended surge time would increase and be 10 seconds (see table F).
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Written and Copyrighted by J.Meloni