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TS-440S Battery Replacement

Discussion in 'General Technical Questions and Answers' started by W9GB, Aug 13, 2005.

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  1. W9GB

    W9GB Ham Member QRZ Page

    The lithium battery (memory backup) used in the Kenwood TS-440S can found on the control board (X53-1450-00) (B/2) - which is behind the front panel. This battery sits right above IC50 (MB8418-20LP).
    This battery is rated at 220 mAh and is used in a variety of Kenwood radios.  The Kenwood part number for the Sanyo lithium battery is (W09-0599-05) and currently sells for $ 6.00 USD at Kenwood Parts.  
    W09-0326-05 referenced in K0ZL's notes has been discontinued by Kenwood Parts - and W09-0599-05 is the substitute part number.
    http://www.kenwoodparts.com/

    Bill Leahy, K0ZL recently posted instructions and photos for replacing the Kenwood TS-440S lithium coin battery on the FAQ for the TS-440S Yahoo group as well on the MODS.DK web site. Kenwood part number F20-0521-04 is the battery insulator - BUT not mentioned in these instructions - see later post for proper installation.
    http://www.mods.dk/

    Additional information and comments regarding battery replacement for the Kenwood TS-440S radios.
    Coin-type lithium batteries (Sanyo & Panasonic) are available in two types:

    Poly-carbonmonofluoride lithium (BR series): For uses that require extended reliability and safety. The BR series batteries are for applications exposed to extended temperature ranges and harsh operating conditions - operational temperature range: -40°C (-40°F) ~ 125°C (257°F). This series has excellent leakage resistance and is commonly found in automotive electric systems; tollway transponders and RFID units.
    http://www.panasonic.com/industr....iew.pdf

    Manganese dioxide lithium (CR series): For uses that require high voltage and strong load pulse characteristics. The CR series batteries have a temperature range of -30ºC ~ +60ºC. This series
    is used for high voltage requirements and strong load pulse characteristics. These are commonly found in memory back-up applications (with tab terminals), cameras, watches and calculators.
    http://www.panasonic.com/industrial/battery/oem/chem/lith/coin1.htm

    The specific battery that Kenwood uses (W09-0326-05) is a Sanyo CR2032 battery with solder tabs - Panasonic CR2032/1F2 is equivalent to the Sanyo. The "1F2" suffix is the ID designation for the 7 mm solder tabs horizontal to the battery and with insulation wrap (yellow). This battery is rated at 220 mAh and easily fits the 35mm spacing between the PC board connections.
    http://www.panasonic.com/industr....fig.pdf

    Bill Leahy's (K0ZL) battery replacement instructions list DigiKey part number P025-ND as an alternative battery.  This battery is shown (photos) in his replacement instructions.  This battery is actually Panasonic BR2330A/FA. The "FA suffix is the ID designation for a 7 mm and 5 mm solder tab horizontal to the battery and with insulation wrap (lime green). This battery is rated at 255mAh and easily fits the 35 mm spacing between the PC board connections.
    http://www.panasonic.com/industr....fig.pdf

    One additional battery that will physically fit is Panasonic CR2330/IF3.  The "IF3" suffix is the ID designation for a 7 mm and 5 mm solder tab horizontal to the battery and with insulation wrap (yellow).  This battery is rated at 265mAh and easily fits the 35 mm spacing between the PC board connections.
    http://www.panasonic.com/industr....fig.pdf

    This information should assist international/global TS-440S owners in finding a suitable replacement from a Panasonic or Sanyo battery distributor or dealer.
    http://www.panasonic.com/industrial/battery/oem/about/index.html

    Greg
    w9gb
     
  2. WA9SVD

    WA9SVD Ham Member QRZ Page

    The MAJOR difference between the "BR" and "CR" series battreries is the capacity, as stated in the mA/H rating, as well as the temp. tolerances. Obviously, in an extremely low current requirement, both would function equally well initiially, but the long-term performance would be the major difference. The various suffixes will determine the attachment capability; most if not all manufacturers, especially of mobile equipment, will specify a "solder-in" battery, with solder lugs attached, to assure positive contact with the battery despite vibration or rough handling..
    If you are adept at "mods," you can probably make some sort of mod to accomodate the standard CR2032 battery, and insulate it with electrical tape. But beware of any other size battery; a "2330" battery WILL have a larger diameter, and may or may not fit your radio. The nimbers of the batteries denote the diameter as well as the "thickness" of the battery; while substituting a different battery (size/number) MAY be feaseable, as they are all Lithium batteries with a nominal 3.0 volt rating, the longevity with a replacement other than the original may be different, and a different "size" battery may or may not physically fit the space available. (The same goes for computers with the "coin cell" type battery; a different battery type may not fit the holder from the original.)
    The best solution?

    1. Back up ALL memories! (Those may, and probably will) be lost when you replace the battery.
    2. Replace the battery with the original type battery; if it's solder-in, you can probably get by with most types of solder terminals, even if not the exact original type...
    3. If the original battery was insulated, you can do the same with either electrical tape or (carefully) with heat-shrink tubing.

    I've NOT had to do this to any of five radios YET, (crossed fingers here!) but after almost 15 years for some, it's just a matter of time. I just hope the original battery types are still manufactured!
     
  3. K8ERV

    K8ERV Ham Member QRZ Page

    Great link for coin batt info, been looking for that. Also has links to other batt types. Tnx.

    TOM K8ERV Montrose Colo
     
  4. WA2ZDY

    WA2ZDY Guest

    Thanks Greg, finally, battery designators explained in English.  Great info.  

    And SVD I'm with you on batteries.  I just had the CMOS battery in a 1990 era laptop go.  The battery is integral to the CMOS chip!  Needless to say, 15 years is all we're getting out of that puter.  I'm glad the TS480 has no backup battery at all.  Good engineering improvement - hopefully!
     
  5. W9GB

    W9GB Ham Member QRZ Page

    Here are some battery web links that you may wish to mark in your browser "Favorites" or "Bookmark"

    E-One Moli Energy — Lithium Ion
    http://www.molienergy.com
    LG Chemical Ltd. — Lithium Ion, Lithium Polymer
    http://www.lgchem.com
    Maxell — Lithium Ion, Lithium Polymer
    http://www.maxell.com
    Panasonic Industrial Company — Nickel Cadmium, Nickel Metal Hydride, Lithium Ion, SLA
    http://www.panasonic.com
    Sanyo Energy Corporation — Nickel Cadmium, Nickel Metal Hydride, Lithium Ion
    http://www.sanyo.com
    Sanyo GS Soft Energy USA — Lithium Ion, Lithium Polymer
    http://www.gsbattery.com
    B&B Battery Co. — SLA (Sealed Lead Acid)
    http://www.bb-battery.com
    Enersys/Hawker/Yuasa — Pure Lead, SLA
    http://www.hepi.com
    ====
    Need a custom battery pack made?

    National Power
    4330 W. Belmont Ave.
    Chicago, IL 60641
    (800) 813-9468
    (773) 685-2662
    Fax: 1-773-685-8316
    http://www.nationalpower.com/index.html
    ====
    w9gb
     
  6. K8ERV

    K8ERV Ham Member QRZ Page

    I think this is common in the TOD clock used in modern computers. Bad Dog!

    TOM K8ERV Montrose Colo
     
  7. K8ERV

    K8ERV Ham Member QRZ Page

    Speaking of batteries, does anyone have or know of a good part number cross reference for the small cells? Except for the Lithiums, there are so many numbers for the same cells!

    TOM K8ERV Montrose Colo
     
  8. WA9SVD

    WA9SVD Ham Member QRZ Page

    The Panasonic web site usually gives the cross reference numbers for most of the batteries, including the Lithium cells.
    But most of the current motherboards (at least for desktops) have moved away from the "rechargeable" NiCd battery for CMOS/BIOS backup, (and eliminated the "battery on [or in] a chip" type of clock) and now use a coin-cell type Lithium battery. Easily replaceable, but you still should copy (better: PRINT OUT) your BIOS settings before you replace a battery on the MB. It will save a LOT of headaches. (At least we've progressed from the daze of the IBM AT when you had to run a diagnostic program just to set the clock and input Hard drive parameters...)
     
  9. K8ERV

    K8ERV Ham Member QRZ Page

    Sounds good. How do I print out the bios?

    TOM K8ERV Montrose Colo
     
  10. WA9SVD

    WA9SVD Ham Member QRZ Page

    With the printer turned on, re-boot the computer and hit "DEL," F1, "ESC" or whatever key(s) your computer uses to enter the BIOS during the POST and before Windoze starts. From there page through the various options; at each page, just hit "PRINT SCRN" on the keyboard. That should be all there is to it.
    It's probably not a bad idea to do that for each screen that has customizable options in the BIOS. Then exit without changes and the machine will boot normally.
     
  11. K8ERV

    K8ERV Ham Member QRZ Page

    I don't recognize any of those options, but will try it. tnx. Tom
     
  12. WA9SVD

    WA9SVD Ham Member QRZ Page

    Tom:

    Microsoft's Hardware Design Guide "suggests" the user not be confused by unnecessary information, such as how to enter the BIOS. You may have to check with your dealer or manufacturer to find the exact key or combination of keys to activate the BIOS. Award and AMI usually use the "DEL" key, but may use another key or combination. (I've also seen the "ESC" key, and in at least one case, "CTRL+ALT+ESC" is needed to enter the BIOS. You can normally do this ONLY when the machine first is turned on or rebooted; once the "Windoze" startup screen is displayed, it's too late. (What kind of computer are you using???)
     
  13. K8ERV

    K8ERV Ham Member QRZ Page

    Haven't tried your suggestions yet. Gateway, BelArc reports main board is a Gateway Tabor3 WS440BX Tabor 3 4000608-215, and BIOS is Intel 4W4SBOXO.15A.0017.P12 12/21/1999. These numbers don't mean anything to me. I don't know if this is a flash bios. So far I have not needed to get any BIOS info. Tnx for your interest tho.

    TOM K8ERV Montrose Colo
     
  14. W9GB

    W9GB Ham Member QRZ Page

    I just completed the lithium battery replacement for the Kenwood TS-440S.  
    I replaced this battery with replacement parts from Kenwood Parts.  Some important notes for this battery replacement:

    Kenwood part number W09-0599-05 is a Sanyo CR-2032 with solder tabs (orange insulator).
    http://sanyo.wslogic.com/pdf/pdfs/CR2032.pdf
    This is IDENTICAL to the Kenwood battery (factory) removed from the TS-440S. Yes, its $6.00 - but it is the identical replacement.

    Kenwood part number F20-0521-04 is the battery insulator.  This part is rarely mentioned with TS-440S battery replacement instructions, BUT is a CRITICAL part. This insulator is placed on the positive (+) side of the Sanyo battery (where the battery number is etched). The insulator has adhesive on both sides - so it adheres to the battery as well as the top of the memory IC (IC50).

    The positive side of the battery (with insulator) must be DOWN (adhere to IC50) to prevent accidental battery shorting against the RFI shield. The negative (-) side of the battery must be UP. Rotate the battery so that the (+) solder tabs align for correct connection (polarity) to PC board (+) solder post.

    Even if you use the equivalent Panasonic battery - the usage of the battery insulator and correct alignment (negative side UP) is important for reliable operation after replacement.

    w9gb
     
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