DeWalt 20V Li-Ion battery adapter for Pinecil/TS100 soldering iron
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This adapter converts a DeWalt tool battery into a portable soldering station for a Pinecil or TS100 iron.
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- Printables
- Kategoria
- Electronics
- Licencja
- Creative Commons — Attribution
Design Intent
This adapter includes under-voltage protection. Rechargeable lithium ion batteries can be severely damaged or completely destroyed if allowed to discharge too low. DeWalt tools have internal electronics that signal the battery to disconnect from the tool when the charge falls below a given voltage. It is very easy to ruin these expensive batteries if used to power non-DeWalt accessories without any protection. This adapter allows you to use DeWalt batteries to safely power a Pinecil/TS100 soldering iron but it can also be used to power any accessory that can run on 20V DC.
Credits and modifications
The design of this adapter, although a complete remodelling, was inspired by Jankiel's DeWalt battery adapter.
Filament and settings used for this project
- Sparta3D ABS+ - Yellow
- Polymaker Polylite ABS - Black
- 0.4mm nozzle, 0.2mm layer height, 20% infill
Bill Of Materials
You will need additional items to assemble this adapter. Please note that the source links are provided for reference only. They might not be the best possible source for you.
Hardware
| Quantity | Description | Source |
| 16 | M3x5x4mm heat set inserts | Amazon |
| 4 | M3x6 Button Head Cap Screws (BHCS) | Amazon |
| 2 | M3x8 Button Head Cap Screws (BHCS) | Amazon |
| 2 | M3 Nylock nuts | Amazon |
| 6 | M3x6 Socket Head Cap Screws (SHCS) | Amazon |
| 6 | M3x10 Socket Head Cap Screws (SHCS) | Amazon |
| 4 | M3x20 Socket Head Cap Screws (SHCS) | Amazon |
| 70mm | 10mm O.D. Aluminum tube | Amazon |
| 70mm | 10mm I.D. Silicone tubing | Amazon |
Electronics
| Quantity | Description | Source |
| 2 | 14-16AWG (Blue insulation) 0.250" width spade terminals | Amazon |
| 4 | 16AWG (Black insulation) ferrules | Amazon |
| 1 | SPST Rocker switch (may include 16AWG wires) | Amazon |
| 400mm | 16AWG 2-Conductor Silicone wire (if not included with switch) | Amazon |
| 1 | ATC/ATO Fuse holder | Amazon |
| 1 | 5A ATC/ATO Fuse | Amazon |
| 2 | Red Anderson Powerpole connector housings | Amazon |
| 2 | Black Anderson Powerpole connector housings | Amazon |
| 4 | Anderson Powerpole 15A crimp terminals | Amazon |
| 1 | Power cable semi assembled w/DC5525 power plug | Amazon |
| 1 | Programmable XH-M609 Low Voltage Disconnect Module | Amazon |
Assembly
The assembly and wiring steps of this adapter are identical to the ones for my Milwaukee Tools M18 Li-Ion battery adapter for Pinecil/TS100 soldering iron design. There are only 4 differences:
- There are 2 extra supports to remove from the bottom part of the adapter.
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- M3x10 SCHS are used instead of M3x16 SHCS to fasten the top part of the adapter to the bottom part.
- M3x20 SHCS are used instead of M3x25 SHCS to fasten the iron stand to the adapter assembly.
- The PCB compartment on this adapter is a bit shallower than on the Milwaukee adapter so the power switch leads are closer to the component leads sticking out from the bottom of the PCB. The clearance is OK but to be on the safe side, I recommend trimming the leads on the PCB before you assemble it into the adapter.