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Zenith SupersPORT battery rebuild

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  • GiGaBiTe
    replied
    I dug around for a bit and couldn't find anything in that connector style with that pin pitch. You could probably replace that connector with screw terminal headers like this that have the same 3.5mm pin pitch:

    https://www.ebay.com/itm/183246642379

    Leave a comment:


  • thenzero
    replied
    My buddy had the idea of replacing both parts of the connector so that I’m guaranteed a mating connector. Thoughts on that idea?

    Leave a comment:


  • thenzero
    replied
    Ah yes. The pitch is about 3.5 mm, see photo.
    You do not have permission to view this gallery.
    This gallery has 1 photos.

    Leave a comment:


  • GiGaBiTe
    replied
    It looks like a Molex KK series connector, but yours looks to be bigger?

    https://www.mouser.com/Connectors/He...lex+kk&FS=True

    You'd need to measure the pin pitch and pin diameter to find a match. I guess if you have any 3 or 4 pin computer fans sitting around, you could see if the connector fits.

    Leave a comment:


  • thenzero
    replied
    Ok the battery pack is all together (12.87V! Oh yeah!). I looked at reusing the connector/wiring but it is absolutely soaked in corrosion, wicked up the wire just like you said. So now I need to order another connector…any idea what this connector is called or where to buy one?

    Leave a comment:


  • thenzero
    replied
    Looks like I missed a critical element in my earlier photos. This thyristor is presumably what reacts to that pepi c thermostat switch.

    904E05E8-DAA5-4D4B-A9DE-8C432F503448.jpeg

    Leave a comment:


  • thenzero
    replied
    Tested the pepi c with a heat gun and multimeter and it seems to be functioning as indicated in that sheet I posted so I’m gonna say it’s still fine.

    Leave a comment:


  • thenzero
    replied
    Looks like the middle pin thing is this:
    E424D9E3-AE86-4CCE-A68E-8954157EA893.jpeg

    Leave a comment:


  • thenzero
    replied
    Dismantled the old battery pack in preparation for rebuilding. Took some extensive pictures. The circuit board almost looks burnt around the battery connector. Should I just make a replacement? See various attached pictures.
    You do not have permission to view this gallery.
    This gallery has 14 photos.

    Leave a comment:


  • GiGaBiTe
    replied
    Not bad. Hope they work out.

    Leave a comment:


  • thenzero
    replied
    The C size nimh cells I was eyeing on amazon for this went on sale today, got 10 cells and the strips for $43.

    Leave a comment:


  • GiGaBiTe
    replied
    If it's something like a thermistor, it'll be in circuit with a transistor/mosfet to cut power to the battery, you can't slap a thermistor across the full current of the battery, it wouldn't work. The white wire should connect to one of those transistors/mosfets on the board that's all corroded.

    Leave a comment:


  • thenzero
    replied
    Any idea why the thermal fuse is on its own separate wire instead of directly in line with the battery? There also appears to be a thermal fuse at the other end of the pack between the groups of cells.

    Leave a comment:


  • GiGaBiTe
    replied
    Yeah, pretty sure that's a thermal fuse, which is why it's bonded right up against the battery. If it's still good, you'll want to use it on the new pack, if not you'll need a replacement.

    Leave a comment:


  • thenzero
    replied
    Ah! Here's a better picture for kicks.
    4B71340C-CC05-4D0A-867E-90AF8E9F0E66.jpeg

    Leave a comment:

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