How to rebuild a Li-Ion battery pack

Implemented for Fujitsu - Siemens Lifebook S-Series FPCBP25 battery pack
source: Electronics-Lab.com

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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. Read it at your own risk. Please don't continue reading if you don't agree with the above.

 

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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.

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.

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

and the blue heat shrinkable plastic as we are going to use it to the new batteries.

Now place the blue plastic on a new battery so the cut side faces the thin adhesive tape that we haven't removed.

Press the plastic to glue on top of the tape

Next attach the white protective coating you have removed from the old batteries.

Repeat all the steps for all the 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.

Now solder the sets on the circuit board paying attention to the polarity.

 

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