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Tornado eCig Battery Repair

This is just a few notes on the repair of an eCig battery (1Ah Tornado).

These batteries seem to have a flaw in which they will randomly stop working, while still displaying all the normal activity of the battery.
Here is what I have found.

Control PCB
Control PCB

Here the battery has been partially disassembled, with the control circuitry exposed here at the end of the unit. All the wiring here is fine & the electronics themselves are also OK, due to the LEDs still operating as normal when the button is pushed. The 1000mAh Li-Poly cell is to the right.

Ground Wire
Ground Wire

Here the end cap has been removed from the opposite end of the battery & the problem is found: the short wire here is the GND return for the atomiser, normally connected to the negative terminal of the battery in the tube, however here it has broken off.
This is most likely due to either the cell moving inside the tube during normal operation, weakening the solder joint, or simply a bad solder job from the factory. (This lead-free ROHS bullshit is to blame).

Repaired
Repaired

Here the wire has been successfully soldered back on to the battery tab. I have also added a small dab of hot glue to hold the battery in place on the inside of the tube, & replaced the solder on the joints with real 60/40 leaded solder. £15 saved.

 

 

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Garmin eTrex

Front
Front

Pocket sized GPS navigator. Here is shown the greyscale dot matrix LCD.

Interface
Interface

Serial interface on the back of the unit. Pinout from left is +3v, Rx, Tx, GND.

PCB Back
PCB Back

PCB Removed from the casing. RTC backup battery in the centre of board, CPU & flash ROM on the left. GPS chipset is under the shield on the right.

PCB Front
PCB Front

Front of the PCB, GPS antenna on the right, LCD panel left.

LCD Removed
LCD Removed

LCD folded back from the PCB. Driver IC can be seen attached to the ribbon.

Electroluminescent Panel
Electroluminescent Panel

LCD Panel backlight. Requires 200v AC at 20kHz to glow green.

GPS Reciever
GPS Reciever

GPS chipset with the shield removed.