A secondary lithium battery performs similarly to other primary batteries and their various chemistries in that it powers other devices (this is called discharging), but then can be charged so you can use it again. If you are looking for a full breakdown of the differences between SLA (sealed lead acid) and Lithium batteries, you can read about it here. This blog will delve deeper into lithium cells, their configurations, what they mean in practical applications, and how the construction of a lithium battery better aligns it to perform for specific applications.

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LITHIUM CELL FORM FACTOR

When you take off the top of a lithium battery pack, you’ll first notice the individual cells and a circuit board of some kind. There are three types of cells that are used in lithium batteries: cylindrical, prismatic, and pouch cells. For the purpose of this blog, all cells are lithium iron phosphate (LiFePO4) and 3.2 volts (V).

CYLINDRICAL LITHIUM CELLS

A cylindrical cell looks most like what you think of with a traditional household battery – like a AA battery – and that is exactly where this form factor drew it’s inspiration for shape when they first came to market in the mid-s. Cylindrical lithium cells come in different widths and lengths, varying amp-hours and as energy or power cells. These types of cells can be used for large and small battery packs of varying capacities and voltages. However, cylindrical cells are most ideal for applications like smaller Ah batteries, power tools, drones, children’s toys, and medical equipment where space is limited and weight is a factor in overall performance.

PRISMATIC LITHIUM CELLS

If you think about the size of the compartments where batteries go, you’ll find most of them to be square in shape. This is where the prismatic form factor comes from. A prismatic cell is what you will find inside your laptop – it offers a larger capacity in a small foot print, and is rectangular in shape. Also available in power and energy cells, these types of cells can be used in batteries designed to meet sealed lead acid battery dimensions. While dimensionally larger than a cylindrical cell, prismatic cells pack more amp-hours per cell by having more lithium by volume, allowing for larger battery pack configurations and single-cell options. For this reason they are commonly used to build larger battery packs and are a top-choice for batteries used in energy storage devices.

LITHIUM POUCH CELLS

The non-power sport lithium products Power Sonic provide feature either a prismatic or cylindrical cell. However, our Hyper Sport Pro line of power sport batteries feature a pouch cell. A pouch cell is just what is sounds like, an aluminum foil pouch which houses a lithium iron phosphate polymer chemistry, with two terminal tabs coming out of one end. This cell form factor allows for the most lithium by volume and is designed to be directly placed into it’s application without a cell case. With the use of lithium polymer (powder), pouch cells can pack more power density in than other types of cells due to their construction and size.

TYPES OF LITHIUM CELLS

In addition to the lithium cell form factor, you will also need to decide if you need a lithium power cell or a lithium energy cell. A power cell is, you guessed it, designed to deliver high power. Likewise, an energy cell is designed to deliver high energy. But what exactly does that mean and how are lithium power cells and energy cells different?

WHAT IS THE DIFFERENCE BETWEEN A POWER CELL AND AN ENERGY CELL?

First, we should note that all types of cells cycle – it just varies to how deeply and how quickly (See battery C ratings). Power cells are design to deliver high current loads over a short period of time at intermittent intervals, making them ideal for use in high rate and starter applications or power tools which generate high loads/torques. Energy cells are designed to deliver sustained, continuous current over a long period of time, making them ideal for use in motive cyclic applications like scooters, e-bikes, etc.. All lithium cells are good for cyclic applications – even power cells – but as noted above, the length of the cycle varies. For example, in a power tool the user expects the tool to run for a total of an hour or so before charging, but a scooter user would not be happy if their scooter died after one hour of use.

HOW TO CONFIGURE A LITHIUM PACK (BATTERY)

When building a lithium battery, once you have selected the type of cell you’ll be using, you will need to decide the amp-hours and voltage needed for your application. When building a pack, you’ll also need to decide the amperage required for your application.

For example, if you are using a 25 amp-hour (AH) 3.2 V prismatic cell to build a 125 AH 12.8 V battery, you will need a battery pack built in a 4S5P configuration. This means the cells need to be arranged in 4 master packs of 5 cells in parallel (5P), and the 4 master packs are placed in series (4S) for a total of 20 cells. The parallel connection is to increase the amp-hour capacity, and the series connection is to increase the voltage. Learn how to connect batteries in series or parallel.

The reason for different form factors of lithium cells is two-fold. One reason is because you need different sizes, shapes, and flexibility levels depending on the battery you are building. The other reason is that you may need flexibility in the capacity and voltage of your battery, and may find that building a 24 amp hour battery with many cylindrical cells better fits your need than building a battery with a fewer prismatic cells (and vice-versa).

Additionally, as noted above, the type of application needs to be considered. For example, while you could use lithium energy cells to build a starter battery, it would be wiser to use power cells as they will provide more power in this application than an energy cell would. Just like with a lead acid battery, a lithium battery won’t last as long if you don’t use if for the intended application – cyclic, starter, or high rate.

In the PSL-FP line of lithium cells, you will see that we offer both power and energy cells. This is to allow customization of your battery pack to fit your higher capacity, high rate, or deep cycle application needs. We also offer prismatic and cylindrical cells, to allow for further customization of your pack.

As you can see, there are many things to take into consideration when building a lithium battery. From the application it is intended for, to physical size restrictions, down to the voltage and amp hour requirements, understanding the lithium configuration options before you build a battery pack will help you build a better battery. If you have any questions on this topic, please feel free to contact us.

10 Frequently Asked Questions about DeWalt Batteries

Last updated: April 15,

DeWalt batteries are renowned for their durability, reliability, and performance, making them a staple power source for a wide range of tools and equipment in various industries. However, with their popularity comes a multitude of questions from users seeking to optimise their usage and understand the intricacies of these power packs. Whether it’s about charging, compatibility, or longevity, this article addresses ten frequently asked questions (FAQs) surrounding DeWalt batteries to provide users with the knowledge they need to make informed decisions and maximise the efficiency of their tools.

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How to know when the Battery is charged?

Determining when a DeWalt battery is fully charged depends on the specific charger model you’re using. However, most DeWalt chargers have indicators to signal the charging status. Typically, these indicators will change colour or display specific patterns to show the progress of the charging process. When the battery is fully charged, the indicator will typically change to a steady red light or display a specific signal indicating that the charging process is complete. It’s essential to refer to the user manual of your DeWalt charger for specific instructions on interpreting the charging indicators for accurate information about your battery’s charging status. The following notes are for most DeWalt Batteries:

Insert the battery into the power tool and test its power level. If it is underpowered, it needs to be charged.

• Check the LED light on the charger.
• If it is flashing red, the battery is charging.
• If it is continuously red, the battery is fully charged.
• If it flashes fast or shows red and yellow, the charger has a problem.

What is a DeWalt Powerstack Battery?

DeWalt Powerstack batteries represent a paradigm shift in power source technology, tailored specifically for DeWalt’s renowned 18V XR line of tools. Harnessing the latest advancements in lithium-ion polymer pouch cell design, these batteries offer unmatched performance, efficiency, and longevity in a compact design compared to traditional cylindrical cell counterparts.

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How to Charge without a Charger?

Charging a DeWalt battery without a charger is not recommended, as it can lead to damage to the battery or pose safety risks. DeWalt batteries are designed to be charged using specific DeWalt chargers that are compatible with their voltage and capacity requirements.

However, if you find yourself in a situation where you need to charge a DeWalt battery without a charger, here are a few alternatives you might consider:

• Using a Compatible Charger: If you have access to another DeWalt charger that is compatible with your battery, you can use it to charge the battery. Ensure that the charger’s voltage and current ratings match those of your battery to avoid damaging it.
• External Power Source: If you have access to an external power source, such as a generator or an inverter connected to a car battery, you might be able to rig up a makeshift charging setup. Again, ensure that the voltage and current are appropriate for your battery to prevent damage.
• Professional Service: If you’re unable to charge the battery yourself, consider taking it to a professional repair or service centre. They may have the equipment and expertise to safely charge the battery or diagnose any issues it may have.
• Contact DeWalt Support: If you’re unsure about how to proceed or have questions about charging your battery, consider reaching out to DeWalt’s customer support for guidance and assistance.

NOTE: Attempting to charge a DeWalt Battery without a proper charger can be risky and may void any warranties or guarantees. It’s always best to use the appropriate charging equipment and follow the manufacturer’s recommendations to ensure the safety and longevity of your battery.

How to fix the DeWalt Battery?

• Clean the Contacts: Make sure the battery contacts are clean and free from dirt or debris. Use a soft, dry cloth to gently wipe the contacts to ensure good connectivity.
• Reset the Battery: Some DeWalt batteries have a built-in reset function. Try removing the battery from the tool and then reinserting it to see if this resolves the issue.
• Charge the Battery: If the battery is not holding a charge, try charging it using a compatible DeWalt charger. Make sure the charger is plugged into a functioning power outlet and that the battery is properly seated in the charger.
• Test with Another Charger: If you have access to another DeWalt charger, try charging the battery with it to see if the issue is with the charger rather than the battery.
• Check for Firmware Updates: In some cases, firmware updates may be available for DeWalt batteries. Check the manufacturer’s website for any available updates and follow the instructions to install them if necessary.
• Contact Customer Support: If none of the above steps resolve the issue, consider contacting DeWalt customer support for further assistance. They may be able to provide additional troubleshooting steps or recommend repair or replacement options.

NOTE: It’s important to note that attempting to repair or modify a DeWalt battery yourself may void any warranties or guarantees. If the battery is still under warranty and none of the above steps resolve the issue, it’s best to contact DeWalt for assistance.

How long does it take to Charge?

The charging time for a DeWalt battery can vary depending on factors such as the battery capacity, the charger model, the current charge level of the battery and the age of the battery. Typically, DeWalt batteries take around 1 to 2 hours to charge fully, but this can vary. It’s best to consult the specific product manual or manufacturer’s recommendations for accurate charging times for your particular battery and charger combination. This are a few examples:

To Charge a DeWalt 18V 5.0Ah XR Lithium-Ion using DeWalt XR Flexvolt 18/54V Fast Charger: 50min

To charge a DeWalt 18V 1.7Ah XR Powerstack Battery using DeWalt 8V/54V XR Flexvolt Charger: 27min

To charge a DeWalt XR 18V 4.0AhLi-Ion using DeWalt XR Flexvolt Universal Dual Port Charger: 60min

Are the Chargers Interchangeable?

DeWalt chargers are typically designed to be compatible with specific battery packs produced by DeWalt. However, it’s essential to ensure compatibility by checking the specifications of both the charger and the battery pack. While some DeWalt chargers may be interchangeable within a certain range of battery packs, it’s not guaranteed for all models.

Using an incompatible charger can potentially damage the battery pack or pose safety risks. Therefore, it’s always recommended to use the charger provided by the manufacturer for the specific battery pack you have. If you need to replace a charger or battery pack, it’s best to consult with DeWalt’s official documentation or customer support to ensure compatibility and safety. 

Which DeWalt Battery lasts the longest?

The typical estimated lifespan of a Lithium-Ion battery ranges from two to three years or 300 to 500 charge cycles, whichever comes first. A charge cycle is defined as the process of using the battery from fully charged to fully discharged and then fully recharging it again. For batteries that do not undergo complete charge cycles, a life expectancy of two to three years is typically assumed.

DeWalt Powerstack batteries are proving to offer the longest duration in terms of the tasks achievable per single charge.

Why won’t the Battery Charge?

There could be several reasons why a DeWalt battery won’t charge:

• Faulty Charger: The charger itself could be malfunctioning. Try charging the battery with a different charger to see if the issue persists.
• Dirty Contacts: Check the contacts on both the battery and the charger for any dirt, debris, or corrosion. Clean them with a dry cloth or a small brush if necessary.
• Battery Temperature: Some DeWalt chargers won’t charge the battery if it’s too hot or too cold. Ensure the battery is within the appropriate temperature range for charging.
• Battery Age or Condition: If the battery is very old or has been heavily used, it may have reached the end of its lifespan and may no longer hold a charge effectively. In this case, you may need to replace the battery.
• Battery Protection Circuit: DeWalt batteries often have built-in protection circuits that prevent charging if the battery is damaged or if there is a safety issue. If the battery is damaged or has exceeded its safe operating limits, it may refuse to charge.
• Power Source Issues: Make sure the charger is plugged into a working power outlet and that there are no issues with the power source.
• Software Issue: In rare cases, there could be a software issue with the charger or the battery. You can try resetting the charger or updating its firmware if applicable.

If none of these steps resolve the issue, it may be best to contact DeWalt customer support or take the battery and charger to a professional for further diagnosis and repair.

Will the DeWalt battery fit… Bauer, Makita, Black and Decker, Milwaukee, Craftsman? 

DeWalt batteries are generally not compatible with tools from other brands like Bauer, Makita, Black and Decker, Milwaukee, or Craftsman. Each brand typically has its own proprietary battery system with specific connectors, voltages, and communication protocols. Mixing different brands’ batteries and tools can potentially damage both the battery and the tool, and it may also be unsafe.

It’s always best to use batteries and chargers specifically designed for your power tools. If you need compatibility across multiple brands, you might consider investing in an adapter or a universal battery system if available, although compatibility with such systems can still be limited. Always consult the user manual or contact the manufacturer for guidance on compatible batteries and accessories for your tools.

What is the Warranty for a DeWalt Battery?

It comes with a 3-year limited warranty and 1 year of free service. However, in order to activate and benefit from this warranty, you need to register your warranty after buying the product.

At Toolden, we offer a wide range of DeWalt Batteries to suit a wide range of domestic and commercial applications.

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