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Service Manual

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Table Of Contents
SeeOperator’sManualforadditionalinformation.
BatteryArchitecture
Insidethebatterypackarethecell/powerpackandBMS(BatteryManagement
System)combinedtoensurethebatteryinthetoolworksthewayit’ssupposed
to.
Cell/PowerPack
Therstcomponentofthebatterypackisthecellpack.Cellpackscomeina
varietyofformats,differentshapesandsizes,fordifferentapplications.Many
factorsimpactwhattypeofbatteryformatisusedinanyparticularproductas
eachformathasadvantagesanddisadvantages.T orodesignsthebatteries
withinthecontextofhowthebatterywillbeusedintheproductsandconsider
everythingfrommanufacturingcoststoheatdissipationandefcientuseof
spacetoweightconcerns.
Someoftheadvantagesofusingcylindricalcellpacksisthattheyhavegood
mechanicalstability.Cylindricalcellpackstypicallyhavelongercalendarlifeand
cyclingabilityandhigherenergydensity.
BatteryArchitecture
Whilethebatteryisdischargingandprovidinganelectricalcurrent,theanode
(-)releaseslithium-ionstothecathode(+),generatingaowofelectronsfrom
onesidetotheother.Whenplugginginthedevice,thelithium-ionsarereleased
bythecathode(-)andreceivedbytheanode(+).
BatteryMakeup
Abatteryismadeupofananode,cathode,separator,electrolyteand2current
collectors(positiveandnegative).
•Theanodeandcathodestorethelithium.
•Theanodereleasesthelithium-ionswhenthebatteryisdischarging.The
cathodereleaseslithium-ionswhenthebatteryischarging.
•Theelectrolytecarriespositivelychargedlithium-ionsfromtheanodetothe
cathodeandviceversathroughtheseparator.
•Themovementofthelithium-ionscreatesfreeelectronsintheanodewhich
createsachargeatthepositivecurrentcollector.
•Theelectricalcurrentthenowsfromthepositivecurrentcollectorthrougha
devicebeingpoweredtothenegativecurrentcollector.
•Theseparatorblockstheowofelectronsinsidethebattery.
BMS(BatteryManagementSystem)
ThesecondcomponentofthebatterypackistheBMS.TheBMSservesasthe
controllerofthebatterypackandcommunicateswiththecontrolofthetoolto
ensurethetoolandbatteryareworkingoptimally.
FeaturesManagedbyBMS
FeaturesmanagedbytheBMSincludethestate-of-chargeindicatorlights,
monitoringofvoltageandtemperature,andcommunicationbetweenthebattery,
thecharger,andthetool.TheBMSdeterminesiftheconditionsarerightto
chargeordischargeanditauthenticatesthecorrectbatteryforthetool.
60vBatteryServiceManual
Page4–5
TheoryofOperation:ServiceandRepairs
3439-480RevA