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X5105 Battery rebuild

 

All

I suffered the battery failure most of us have or will soon experience. ?Found a source but it has been out of stock for months. ?Who knows when they will be back on stock. ?So I pulled my battery out so I would not suffer a worse fate of that bad battery leaking.

Stuck it on my bench for a good month. ?I thought what the heck and carefully took it apart.

No big deal three lipo batteries in series with a battery management board on top. ?The replacement batteries were easy. ?Replacement shrink wrap sleeve easy. ?Soldering iron got many. ?It was the battery management board I worried about. ?

Long story short don’t throw away your old battery if you ever want to rebuild your battery. ?The original battery management board will reset and the total cost is half of what the stores are selling them for when and if you can get them in stock. ?Plus I got the added advantage of getting 4ah batteries vs the stock 3.7ah. ?I took pictures and figured out how to wake up the battery management board.?

--
Tom
AE5NF
 

Tom, I'd love to see your photos and info on resetting the management board!

Thanks,
Roy
WA0YMH?

On Tue, Jan 2, 2024, 3:39?PM Tom Flynn via <tflynn6693=[email protected]> wrote:

All

I suffered the battery failure most of us have or will soon experience.? Found a source but it has been out of stock for months.? Who knows when they will be back on stock.? So I pulled my battery out so I would not suffer a worse fate of that bad battery leaking.

Stuck it on my bench for a good month.? I thought what the heck and carefully took it apart.

No big deal three lipo batteries in series with a battery management board on top.? The replacement batteries were easy.? Replacement shrink wrap sleeve easy.? Soldering iron got many.? It was the battery management board I worried about. ?

Long story short don’t throw away your old battery if you ever want to rebuild your battery.? The original battery management board will reset and the total cost is half of what the stores are selling them for when and if you can get them in stock.? Plus I got the added advantage of getting 4ah batteries vs the stock 3.7ah.? I took pictures and figured out how to wake up the battery management board.?

--
Tom
AE5NF
 

No problem. ?l have so Christmas ornaments I need to take down then I’ll write up a battery rebuild procedure.

--
Tom
AE5NF
 

No hurry and thank you very much for being willing to help us with your experience doing this. My X5105 is starting to get long in the tooth and so it'll be good to have this information.

Roy
WA0YMH?

On Thu, Jan 4, 2024, 1:36?PM Tom Flynn via <tflynn6693=[email protected]> wrote:
No problem. ?l have so Christmas ornaments I need to take down then I’ll write up a battery rebuild procedure.

--
Tom
AE5NF

 

Same here.? My? battery still is taking a charge but it's running down more quickly after 4 years.

Best,
W2NC
 

Inevitable for every X5105 TXRX is the battery will die and if you are not in the EU or willing to wait for the one other supplier in north America to get them in stock you have two choices.? Use an external battery and remove your internal battery or leave the battery inside of the radio and hope it will not rupture.?

I chose to remove the battery and avoid the risk of accidently charging it or it rupturing inside the radio. I waited to see if connect systems received a shipment with no luck.

I had nothing to lose and the battery was on my bench so I decided to take it apart.?

To rebuild the battery, you will need to order new batteries.? I ordered everything on ebay:

1)????? 3 X 3.7 V 4000Ah Polymer Li Battery Model code PL 3766125; cell size 3.7mm (thick) x 66mm (width) X 125mm (Length) the capacity is 4000mAh.? The battery has a PCM installed and I asked the vendor to remove them.


2)????? Some replacement Kapton tape

3)????? Double stick tape

4)????? Blue PVC Shrink wrap for battery packs 30mm X 400mm X 1 meter (smallest length you can order).? It is a very low temperature shrink wrap so you need enough to resolve a mistake.

?

5)????? A soldering iron.

With an xacto carefully remove the outer shrink wrap skin and do not cut a battery!? This is what is inside.?


?

Keep everything you can, reuse it except for the shrink wrap skin.? If it is sticky it will stick on the new battery.

Remove the cardboard on top of the Battery Management board and unsolder the board from the battery.

BE CAREFUL ALWAYS TO NOT SHORT OUT THE BATTERY!!!!!? Rebuild the Battey exactly the way you took it apart!

The battery is a series pack:

?


?


?


This the bottom of the Battery Manager.? The top of the manager has 4 solder points.? One for 0v or neg, one for 3.7v, 7.4v and 11.1.? When replacing the Battery manager ensure the battery connection to the board equals the appropriate voltages on the battery. ?REMEMBER the battery will arrive nearly fully charged!!!!! So do not short it out soldering the battery to the board!!!!!

?

Here is how it looks while reassembling the battery:

?

?

At this point I have a nearly fully charged battery connected to a battery management board so I should have 11.1v plus or minus at the connector but when I measured it I got zero volts.? My first thought was oh well failure… wait for replacement batteries to come from China.? But then I remembered to put a 12v 500ma charge on the + - for about 6 seconds and It turned on.? I replaced the battery in the radio using double stick tape on the back wall of the radio and charged it.

It charged to around 12.2230 v and proclaimed the battery was charged.

I then turned the radio on and let it run for what seemed like forever until the battery manager shut the battery down and the radio off.

I then charged it again until the battery manager proclaimed the battery was full and claimed victory.

I already had everything except the batteries and shrink wrap sleeve.? The total cost of the rebuild was $7.99 plus tax free shipping for the shrink wrap, and $11.31 plus $3.50 shipping and a little tax for the three batteries. The batteries shipped from China to Texas in 13 days during the Christmas shipping spree.

--
Tom
AE5NF

 

Thank you for this detailed post, images with tips&tricks.? Perfect!
--
- Stuart VE3SMF
 

Great Job!!!!
Phil Stewart
 

tOM, This detailed battery replacement instruction is well documented, thank you for your knowledge and willingness to share!

THANKS, Phil?
"The best things in life are not things"...

On Friday, January 5, 2024 at 11:31:35 AM PST, Tom Flynn via groups.io <tflynn6693@...> wrote:


Inevitable for every X5105 TXRX is the battery will die and if you are not in the EU or willing to wait for the one other supplier in north America to get them in stock you have two choices.? Use an external battery and remove your internal battery or leave the battery inside of the radio and hope it will not rupture.?

I chose to remove the battery and avoid the risk of accidently charging it or it rupturing inside the radio. I waited to see if connect systems received a shipment with no luck.

I had nothing to lose and the battery was on my bench so I decided to take it apart.?

To rebuild the battery, you will need to order new batteries.? I ordered everything on ebay:

1)????? 3 X 3.7 V 4000Ah Polymer Li Battery Model code PL 3766125; cell size 3.7mm (thick) x 66mm (width) X 125mm (Length) the capacity is 4000mAh.? The battery has a PCM installed and I asked the vendor to remove them.


2)????? Some replacement Kapton tape

3)????? Double stick tape

4)????? Blue PVC Shrink wrap for battery packs 30mm X 400mm X 1 meter (smallest length you can order).? It is a very low temperature shrink wrap so you need enough to resolve a mistake.

?

5)????? A soldering iron.

With an xacto carefully remove the outer shrink wrap skin and do not cut a battery!? This is what is inside.?


?

Keep everything you can, reuse it except for the shrink wrap skin.? If it is sticky it will stick on the new battery.

Remove the cardboard on top of the Battery Management board and unsolder the board from the battery.

BE CAREFUL ALWAYS TO NOT SHORT OUT THE BATTERY!!!!!? Rebuild the Battey exactly the way you took it apart!

The battery is a series pack:

?


?


?


This the bottom of the Battery Manager.? The top of the manager has 4 solder points.? One for 0v or neg, one for 3.7v, 7.4v and 11.1.? When replacing the Battery manager ensure the battery connection to the board equals the appropriate voltages on the battery. ?REMEMBER the battery will arrive nearly fully charged!!!!! So do not short it out soldering the battery to the board!!!!!

?

Here is how it looks while reassembling the battery:

?

?

At this point I have a nearly fully charged battery connected to a battery management board so I should have 11.1v plus or minus at the connector but when I measured it I got zero volts.? My first thought was oh well failure… wait for replacement batteries to come from China.? But then I remembered to put a 12v 500ma charge on the + - for about 6 seconds and It turned on.? I replaced the battery in the radio using double stick tape on the back wall of the radio and charged it.

It charged to around 12.2230 v and proclaimed the battery was charged.

I then turned the radio on and let it run for what seemed like forever until the battery manager shut the battery down and the radio off.

I then charged it again until the battery manager proclaimed the battery was full and claimed victory.

I already had everything except the batteries and shrink wrap sleeve.? The total cost of the rebuild was $7.99 plus tax free shipping for the shrink wrap, and $11.31 plus $3.50 shipping and a little tax for the three batteries. The batteries shipped from China to Texas in 13 days during the Christmas shipping spree.

--
Tom
AE5NF

 

Hi group!
?
Just an update on the battery rebuild thread.... I just did another battery rebuild and it went together perfectly.? I know it is a data point of two but I am certain if you are careful you will have the same success I have had.
?
?
--
Tom
AE5NF

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