It can be repaired by a battery technician if you can find a business that is willing to risk it. The chemical resistance of the Lion charging creating thermal runaway or chain reaction associated with charging below that threshold. This protects everyone from risk of explosion and fire. If a single cell in any bank of drops below 2.8v pack will not charge. A circuit placed on top of the top row monitors each parallel battery block for minimum 2.8v and reports full charge at around 4.2v. Each row has a wire tapped at every 4.2v junction. This will creat 2Amp per row typical output of 2 row battery 4 to 5 Amp depending on what the manufacture rounds up the decimals or rounds down or adds 1 more cell a row ie 24v battery 5-6Amps can be achieved. It works out to a series of batteries connected end to end equates to packs output voltage(5cells×4.2v=20v) is a rounde figure of 21v. Looking at the hight of your pack and placing a dime on the side will give you an idea of the cell count. The bigger the pack is the more cells are stuffed in it. As a safety standard when that is detected by the charging unit it will go to error reporting and not charge battery. It only takes one of the cells to go bad in a pack to fail. As rule of thumb keep chargers inside in cold weather and the batteries will last a long time. You just cannot charge below the chemical limitations of that battery. This is not a dewalt only limitation as it pertains to all lithium ion battery cells made currently. Has any of those batteries been exposed to freezing weather? They will get fried when charged below 40☏ as stated on the bottom of charging station and both the manuals that came with each item, 1 for charer and 1 for battery. The two that only reach 16v will never reach a full charge. The last one charged continuously destroying the batteries. The one showing fully charge d will charge a dead battery for a minute or 2 the show fully charged. The only one functional was the one with the intermittent pause during charging. I tried the 4ah Dewalt battery that I had put aside and got the same results on the 3 chargers. Charging with an intermittent pause( light off for 5 seconds). While testing with the 3 Dewalt 20v chargers I have, this off brand 20v battery did 3 different things on each charger. After 1 year one of those has failed ( 1 bar) indicating fully charged yet will not power anything. The good 4ah battery( 3 bars) is 19.58 v. One of the 4ah batteries has now failed to charge(1 bar) charge light is solid. The 2ah batteries fail to charge and were replaced with 4ah batteries. I have several 20v Dewalt charger and several Dewalt batteries. If putting the battery on requires the same amount of force with the pin up, as it does if the pin is down? You probably have bent either the charger pins, or the receptacles in the battery. Not much more so than pushing a 3-prong plug into an outlet. The metal pins offer little to no resistance to make contact for charging. Lock lever is in position to pull up on as you insert the battery. Which causes many to think you have to press hard. The resistance is from trying to force the lock pin over the edge. If you look at the charger base, you will notice a notch in the center that lock pin lines up with. Whether you have that lock release lever depressed or not, you still have push the battery with the same amount of force” “That is why you do not need to press the release to remove the battery from the charger (again with the exception of their fan cooled chargers). Big Richard he never said you had to use the lock to release it, only put it on. Maybe they stopped doing things by hand and started using robots for the soldering? Who knows… It seems the faults are usually because of a soldering issue though. Makes me wonder, since these are often made in low wage factories if a competitor managed to hire workers, who are now being paid by DeWalt and by the competition to purposely do a lousy job. That said, this seems to be happening to DeWalt batteries by the ten/s of thousands each year since 2019 if not further back, I don’t have time to look at reviews further back then 2019 but on multiple sites, the 1 star reviews all say that the batteries either are dead out of the box, show lights but won’t charge, or the led Guage is broken, or they take a charge and never work again or they’re draining ridiculously fast. Meaning it doesn’t matter how well he seats it, it’s not gonna change because it’s already full… While there are easier ways to say that, like “My battery charges fine, but the LED indicator is always stuck on 1 bar.’ He literally said it shows one bar but won’t take a charge because the battery is already full. Except you couldn’t blame him even if you wanted to, because you misread what he wrote, silly rabbit!
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