How to make a 2000XR+ battery pack

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Work in progress:

The following pictures and explanation follow my attempts to build a 2000XR+ battery pack. The pack is a 5S4P (five serial, four in parallel) rated at 9.2aH. It is based on using two DeWALT DC9360 36v packs.

The DeWALT DC9360 36v packs come with 10 - A123 - 3.3V - 2.3Ah Cells, and you can buy the packs for about $100 on ebay.

Note: the new A123 18V Dewalt packs are the much smaller 1.1Ah cells. My next project may to be use several 18V packs without disassembling, because the Dewalt packs contain built in balancers, fuses and over temperature sense. It is a shame not to reuse these parts.

Caution, do not attempt to do this unless you are familiar with high amperage batteries and take all the standard precautions.


Disassembling the DeWALT DC9360

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Side view of DeWALT DC9360 36v pack
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Front view of DeWALT DC9360 36v pack
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Back view of DeWALT DC9360 36v pack
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Cutting side screws
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Cutting back screws
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Cutting front screws
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One of two connectors of balancer
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Location of over temperature sense on cell
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Cut main power lines (dangerous) and disconnect balancer
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Remove cell pack with flat screwdriver
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Cell pack removed from case
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Close up of spring balancer contacts
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Close up of wiring of balancer
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Stretching out string of cells
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Cutting long string of cell in two
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Strings of cells ready for assembly

DeWALT connections to balancer

DeWALT connections to balancer

The connections of the balancer in the original DeWALT DC9360 36v pack is as follows. See picture to the right.

The balancer has two black wires (B1) and (B2), one red wire (R) and two connectors (R1)(G2)(G3)(G4)(G5) and (R6)(G7)(G8)(G9)(G10). (G9) is not connected.

  • (B1)->CELL1->2 (G5)
  • 3->CELL2->4 (R6)
  • 5->CELL3->6 (G4)
  • 7->CELL4->8 (G7)
  • 9->CELL5->10 (G3)
  • 11->CELL6->12 (G8)
  • 13->CELL7->14 (G2)
  • 15->CELL8->16 (G10)
  • 17->CELL9->18 (R1)
  • 19->CELL10->20 (R)

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