Busch + Müller Toplight 2C permanent battery replacement

简介

The manufacturer told me by email that the device is not repairable. We are doing it anyway. The cost of a new better battery is about half the purchase value for a new lamp.
The housing has a waterproof ultrasonic weld. To open the housing, it must be sawed open or destroyed. Subsequently, it is glued back together so that it becomes watertight.

Busch + Müller Toplight 2C permanent

你所需要的

步骤 1 Sawing to open the housing

Busch + Müller Toplight 2C permanent battery replacement, Sawing to open the housing: 步骤 1 中的图像 1，2

Busch + Müller Toplight 2C permanent battery replacement, Sawing to open the housing: 步骤 1 中的图像 2，2

Saw the lamp along the ultrasonic welding seam with a fine saw (e.g. Japanese saw).
A total of four straight cuts must be made
Saw carefully so that the electronics or the battery do not get damaged

翻译

步骤 2 Open housing

Busch + Müller Toplight 2C permanent battery replacement, Open housing: 步骤 2 中的图像 1，3

Busch + Müller Toplight 2C permanent battery replacement, Open housing: 步骤 2 中的图像 2，3

Busch + Müller Toplight 2C permanent battery replacement, Open housing: 步骤 2 中的图像 3，3

The housing should fall apart into two halves after sawing

翻译

步骤 3 Remove battery

Busch + Müller Toplight 2C permanent battery replacement, Remove battery: 步骤 3 中的图像 1，2

Busch + Müller Toplight 2C permanent battery replacement, Remove battery: 步骤 3 中的图像 2，2

Pull the old battery out of the socket
The plug may be relatively tight in the socket. Simply wiggle it until it can be pulled out or use pliers

翻译

步骤 4 Disassemble & recycle battery

Busch + Müller Toplight 2C permanent battery replacement, Disassemble & recycle battery: 步骤 4 中的图像 1，3

Busch + Müller Toplight 2C permanent battery replacement, Disassemble & recycle battery: 步骤 4 中的图像 2，3

Busch + Müller Toplight 2C permanent battery replacement, Disassemble & recycle battery: 步骤 4 中的图像 3，3

Under the black foil there are two Li-Io cells in AAA size.
At the two outer ends are the negative terminals, which are connected with a metal clip
Remove the round stickers and the long metal clip
Remove the cables including the socket

翻译

步骤 5 Prepare new batteries

Busch + Müller Toplight 2C permanent battery replacement, Prepare new batteries: 步骤 5 中的图像 1，3

Busch + Müller Toplight 2C permanent battery replacement, Prepare new batteries: 步骤 5 中的图像 2，3

Busch + Müller Toplight 2C permanent battery replacement, Prepare new batteries: 步骤 5 中的图像 3，3

Buy 2x ICR10440 with solder tag
(The batteries used here are ICR10440; 3,7V each 320mAh with Z-solder tag)
Put the batteries with the positive side to each other and solder the lugs
Now solder the red connection cable

翻译

步骤 6 Soldering and packing new batteries together

Busch + Müller Toplight 2C permanent battery replacement, Soldering and packing new batteries together: 步骤 6 中的图像 1，3

Busch + Müller Toplight 2C permanent battery replacement, Soldering and packing new batteries together: 步骤 6 中的图像 2，3

Busch + Müller Toplight 2C permanent battery replacement, Soldering and packing new batteries together: 步骤 6 中的图像 3，3

The outer solder lugs are soldered to the sheet metal (paper clip as soldering aid).
The black connection cable is also soldered to the sheet metal
Stick the yellow adhesive tape on the open contacts
Stick the circular red stickers on the outer positive terminals again
Fix the new battery pack with insulating tape.

翻译

步骤 7 Assembly / Mounting

Busch + Müller Toplight 2C permanent battery replacement, Assembly / Mounting: 步骤 7 中的图像 1，3

Busch + Müller Toplight 2C permanent battery replacement, Assembly / Mounting: 步骤 7 中的图像 2，3

Busch + Müller Toplight 2C permanent battery replacement, Assembly / Mounting: 步骤 7 中的图像 3，3

Plug the power connector into the socket of the board
Insert the board into the black housing with the USB socket pointing downwards
Put on the reflector
To make the housing watertight again, the previously sawed seam must be glued together with a gap-filling adhesive. This can be done for example with Sikaflex