Danger
Potentially Dangerous
Injury may result if this procedure is not followed properly. Use caution and follow all warnings.
Danger

Introduction

Rebuild a dead Rollei battery with modern LiFePO4 cells.

Note that the voltage of a fully charged LiFePO4 drops slightly when power is used by the camera. This causes the camera to display an almost depleted battery (at least my 6008AF does that). This is nothing to worry about, especially since LIFePO4 batteries keep their voltage level pretty well during discharge.

Video Overview

Save the tiny screws. They are easily lost and hard to replace. Watch out the cables inside may very short. Watch out the cables inside may very short.
  • Save the tiny screws. They are easily lost and hard to replace.

  • Watch out the cables inside may very short.

Add Comment

Depending on battery type this may look a bit different. Sometimes the batteries have a very tight fit and are not to easy to remove. Try pulling with pliers Sometimes the batteries have a very tight fit and are not to easy to remove. Try pulling with pliers
  • Depending on battery type this may look a bit different.

  • Sometimes the batteries have a very tight fit and are not to easy to remove. Try pulling with pliers

Add Comment

The original NiCd batteries had two additional cables for a temperature sensor. See yellow one, which also has the original plastic housing. Be sure to dispose the old battery pack properly. They contain harmful chemicals and need special treatment for waste disposal!
  • The original NiCd batteries had two additional cables for a temperature sensor. See yellow one, which also has the original plastic housing.

  • Be sure to dispose the old battery pack properly. They contain harmful chemicals and need special treatment for waste disposal!

Add Comment

This step helps later to have the solder stick to the batteries This step helps later to have the solder stick to the batteries This step helps later to have the solder stick to the batteries
  • This step helps later to have the solder stick to the batteries

Add Comment

I had to turn around one of the batteries later in the guide to allow easier soldering... depends on the wiring though. I had to turn around one of the batteries later in the guide to allow easier soldering... depends on the wiring though.
  • I had to turn around one of the batteries later in the guide to allow easier soldering... depends on the wiring though.

Add Comment

The PCB/BMS Board plus wiring diagram The wiring diagram may be different depending on the PCB used. But the principle is the same for all types. The wiring diagram may be different depending on the PCB used. But the principle is the same for all types.
  • The PCB/BMS Board plus wiring diagram

  • The wiring diagram may be different depending on the PCB used. But the principle is the same for all types.

Add Comment

Check the size of the battery pack together with the BMS Board. It should easily fit with a bit of space inside the housing. Otherwise you may get problems down the road of this guide.
  • Check the size of the battery pack together with the BMS Board. It should easily fit with a bit of space inside the housing. Otherwise you may get problems down the road of this guide.

Add Comment

You can also use normal thin wire, but be aware that the space within the housing is limited. You can also use normal thin wire, but be aware that the space within the housing is limited. You can also use normal thin wire, but be aware that the space within the housing is limited.
  • You can also use normal thin wire, but be aware that the space within the housing is limited.

Add Comment

This is based on the specific PCB used and my be different for others This is based on the specific PCB used and my be different for others This is based on the specific PCB used and my be different for others
  • This is based on the specific PCB used and my be different for others

Add Comment

Add a bit of solder on the connector you want to use next. I started with B+ and connected it to the + pole of the first battery. Test again if everything fits in the housing. Warning! The housing is metal. Make sure not to short-cut something!
  • Add a bit of solder on the connector you want to use next. I started with B+ and connected it to the + pole of the first battery.

  • Test again if everything fits in the housing.

  • Warning! The housing is metal. Make sure not to short-cut something!

Add Comment

Black Friday
Broken doesn't stand a chance.
Again do not short cut anything! The hilium connector helps here to save lots of space compared to wires The hilium connector helps here to save lots of space compared to wires
  • Again do not short cut anything!

  • The hilium connector helps here to save lots of space compared to wires

Add Comment

Fold the hilium and use pliers to flatten it Use scissors to cut to the right length Again add a bit of solder before soldering the hilium connector
  • Fold the hilium and use pliers to flatten it

  • Use scissors to cut to the right length

  • Again add a bit of solder before soldering the hilium connector

Add Comment

See the finalised soldering of Step 12 Use electric tape to isolate the finished work (this prevents shortcuts) Use electric tape to isolate the finished work (this prevents shortcuts)
  • See the finalised soldering of Step 12

  • Use electric tape to isolate the finished work (this prevents shortcuts)

Add Comment

Try to isolate but do not cover the writings on the PCB so you can still see, what is already wired. Try to isolate but do not cover the writings on the PCB so you can still see, what is already wired. Try to isolate but do not cover the writings on the PCB so you can still see, what is already wired.
  • Try to isolate but do not cover the writings on the PCB so you can still see, what is already wired.

Add Comment

It is hard to get the orientation if all batteries correct on first try. But the tape allows cutting and reorientation if needed. This is only needed to use less of the connector and allow easier wiring without crossings
  • It is hard to get the orientation if all batteries correct on first try. But the tape allows cutting and reorientation if needed.

  • This is only needed to use less of the connector and allow easier wiring without crossings

Add Comment

Again add a bit of solder to the poles. And use fold the connector tape. Watch out for shortcuts
  • Again add a bit of solder to the poles.

  • And use fold the connector tape.

  • Watch out for shortcuts

Add Comment

Now you see why the electrical tape is needed for isolation. If the connector roll is touching the wrong parts you may get a short cut, that may brick your PCB. Now you see why the electrical tape is needed for isolation. If the connector roll is touching the wrong parts you may get a short cut, that may brick your PCB. Now you see why the electrical tape is needed for isolation. If the connector roll is touching the wrong parts you may get a short cut, that may brick your PCB.
  • Now you see why the electrical tape is needed for isolation. If the connector roll is touching the wrong parts you may get a short cut, that may brick your PCB.

Add Comment

The pliers help to not burn your fingers. See on 2nd picture how much space we save with the hilium connectors. On 3rd picture we see how solder punctured the electrical tape. In the next step we add another layer for security.
  • The pliers help to not burn your fingers.

  • See on 2nd picture how much space we save with the hilium connectors.

  • On 3rd picture we see how solder punctured the electrical tape. In the next step we add another layer for security.

Add Comment

I cut the electrical tape to not cover the markings on the PCB. I cut the electrical tape to not cover the markings on the PCB. I cut the electrical tape to not cover the markings on the PCB.
  • I cut the electrical tape to not cover the markings on the PCB.

Add Comment

Adding another layer of isolation as we have crossing hilium connectors here. Adding another layer of isolation as we have crossing hilium connectors here. Adding another layer of isolation as we have crossing hilium connectors here.
  • Adding another layer of isolation as we have crossing hilium connectors here.

Add Comment

Note from the wiring diagram the B3-connector of the PCB is unused. So we add electrical tape to isolate it. So we add electrical tape to isolate it.
  • Note from the wiring diagram the B3-connector of the PCB is unused.

  • So we add electrical tape to isolate it.

Add Comment

These are the charge/discharge ports of our battery pack Be sure that the length of the wire is long enough to wire it to the Rollei outlet later.
  • These are the charge/discharge ports of our battery pack

  • Be sure that the length of the wire is long enough to wire it to the Rollei outlet later.

  • If you use a multimeter to check the voltage you will see it's 0V

  • The PCB needs to be activated, we do this by doing some short charging

Add Comment

A bit of charging is sufficient. The MaHa charger shows the voltage of 10,4V Now also the multimeter shows the correct voltage.
  • A bit of charging is sufficient. The MaHa charger shows the voltage of 10,4V

  • Now also the multimeter shows the correct voltage.

  • The PCB is now activated and the battery pack correctly wired.

  • If this step is not working as expected, then check all wiring, soldering and diagrams again to validate there are no mistakes.

Add Comment

This is the most tricky soldering part. Make sure there is not anything connected that shouldn't.
  • This is the most tricky soldering part.

  • Make sure there is not anything connected that shouldn't.

  • The battery has two + and two - poles. Make sure the + (white cable) is connected to the right input. Have a look at the red cables. One is going directly to the camera connector. The other one is protected by a fuse that protects your camera.

Add Comment

Find out how much foam you need by putting the battery pack with foam layers outside of the housing. Keep space for wires and fuse at the top. Keep space for wires and fuse at the top.
  • Find out how much foam you need by putting the battery pack with foam layers outside of the housing.

  • Keep space for wires and fuse at the top.

Add Comment

Align battery pack, lid and housing Notice that the screws are on one side only. Two tiny squares snap into the other side.
  • Align battery pack, lid and housing

  • Notice that the screws are on one side only.

  • Two tiny squares snap into the other side.

  • Check that the lid is closing completely, without much pressure (Pic. 3). Otherwise remove a bit foam

Add Comment

Final assembly steps Final assembly steps
  • Final assembly steps

Add Comment

Note: the lid is now turned around (thus mirrored to the wiring diagram) It is expected that the two connectors to the right produce 0V Make sure you get roughly 10V with the right polarity
  • Note: the lid is now turned around (thus mirrored to the wiring diagram)

  • It is expected that the two connectors to the right produce 0V

  • Make sure you get roughly 10V with the right polarity

  • Repeat this step, to double-check. BEFORE inserting the battery into your camera.

Add Comment

Fill the two unused connectors (from the temp sensor) with hard glue. This prevents users from accidentally using a Rollei Charger N or G, which are not suitable for the battery type and might cause fire or explosion. Charge the battery with a Lithium capable LiFePO4 charger only! Notice that the battery has now only 81g compared to 210g for the old NiCd.
  • Fill the two unused connectors (from the temp sensor) with hard glue. This prevents users from accidentally using a Rollei Charger N or G, which are not suitable for the battery type and might cause fire or explosion.

  • Charge the battery with a Lithium capable LiFePO4 charger only!

  • Notice that the battery has now only 81g compared to 210g for the old NiCd.

  • Happy using your Rollei again!

Add Comment

Conclusion

Have fun with your Rollei again! :)

Markus

Member since: 11/16/2015

101 Reputation

1 Guide authored

0 Comments

Add Comment

View Statistics:

Past 24 Hours: 4

Past 7 Days: 24

Past 30 Days: 125

All Time: 618