Introduction
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
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Saw the lamp along the ultrasonic welding seam with a fine saw (e.g. Japanese saw).
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A total of four straight cuts must be made
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Saw carefully so that the electronics or the battery do not get damaged
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Pull the old battery out of the socket
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The plug may be relatively tight in the socket. Simply wiggle it until it can be pulled out or use pliers
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Under the black foil there are two Li-Io cells in AAA size.
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At the two outer ends are the negative terminals, which are connected with a metal clip
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Remove the round stickers and the long metal clip
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Remove the cables including the socket
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Buy 2x ICR10440 with solder tag
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(The batteries used here are ICR10440; 3,7V each 320mAh with Z-solder tag)
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Put the batteries with the positive side to each other and solder the lugs
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Now solder the red connection cable
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The outer solder lugs are soldered to the sheet metal (paper clip as soldering aid).
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The black connection cable is also soldered to the sheet metal
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Stick the yellow adhesive tape on the open contacts
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Stick the circular red stickers on the outer positive terminals again
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Fix the new battery pack with insulating tape.
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Plug the power connector into the socket of the board
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Insert the board into the black housing with the USB socket pointing downwards
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Put on the reflector
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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
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Apply glue carefully along the contour (e.g. Sikaflex)
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Make sure that the LEDs and the switch remain clean.
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Close the housing and let the glue harden.
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Work through the steps in reverse order to reassemble your device.
Work through the steps in reverse order to reassemble your device.
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