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DeWalt FLEXVOLT: How Voltage Changes Between Tools

Updated · Standard formula, shown below

DeWalt FLEXVOLT batteries change how their cells are connected when you attach them to a compatible tool: the same battery can supply a higher voltage for certain 60V MAX tools or operate at 20V MAX in compatible 20V MAX tools. You do not select a voltage with a switch; the battery and tool’s compatible contacts determine the configuration automatically. Before you start, check the battery and tool labels, and remove the battery before inspecting or cleaning either one.

What You’ll Need

  • A DeWalt FLEXVOLT battery in good condition.
  • A tool explicitly marked as compatible with that battery’s voltage platform, such as a compatible 20V MAX or 60V MAX tool.
  • The tool and battery manuals if you need to confirm compatibility, charging instructions, or contact-cleaning guidance.

Step-by-Step

  1. Identify the battery and tool ratings. Read the labels on the battery and tool, rather than relying on color, appearance, or a retailer listing. FLEXVOLT batteries are designed to work with compatible 20V MAX tools and certain 60V MAX tools. Do not assume that every DeWalt battery fits every tool, or that a FLEXVOLT battery makes an incompatible tool compatible.
  2. Confirm the exact combination. Check the tool manual or manufacturer’s compatibility information for the battery type and voltage platform. Also check that the battery is within its permitted temperature range and shows no cracks, swelling, leakage, damaged contacts, or other signs of damage. Do not use a damaged battery.
  3. Make the tool safe to handle. Switch the tool off. For a tool with a trigger or other control that could be pressed accidentally, keep your finger clear and use its lock or safety feature as directed in the manual. Remove any accessory that could move unexpectedly if the manual recommends doing so. Never insert or remove a battery while the tool is running.
  4. Inspect the battery bay and contacts. Remove the battery if it is already installed. Look for dirt, metal debris, moisture, or damage on the battery contacts and inside the tool’s battery slot. Do not bridge contacts with metal objects, probe them, or use liquid cleaners. If cleaning is needed, follow the manuals; use only a dry, nonconductive method that they permit.
  5. Align the battery correctly. Hold the battery so its guide rails and contacts line up with the tool’s matching rails and contacts. Slide it into the battery bay in the direction shown by the tool. Do not force, twist, or hammer it into place. If it does not slide in smoothly, stop and recheck the battery type, alignment, and tool compatibility.
  6. Seat the battery until it latches. Push it fully into the bay until the retaining latch engages. Give it a gentle tug to verify it is secure; do not pull it hard or use the tool if the battery is loose. A battery that appears to fit but does not latch may be incompatible, misaligned, or damaged.
  7. Let the battery-tool combination set the voltage. There is no user-operated voltage selector on a FLEXVOLT battery. When fitted to a compatible tool, the battery’s internal cell configuration and the tool’s contacts provide the appropriate platform connection. Use the tool only as labeled and described in its manual. Do not try to alter the battery’s contacts or force a particular voltage.
  8. Test the tool safely. Keep the tool pointed away from yourself and others, with the accessory clear of people and objects. Follow the tool’s operating instructions and use its normal trigger or switch. If it does not start, behaves abnormally, or displays a warning, release the control, switch it off, and remove the battery before checking anything.
  9. Remove the battery when finished. Switch the tool off, wait for moving parts to stop, and press the battery release as directed. Slide the battery out without pulling on the tool’s cable or striking the battery. Store and charge it according to the battery manual, using a charger specified as compatible.

Common Mistakes

  • Looking for a voltage button. FLEXVOLT changes configuration automatically with compatible tools; you do not switch the battery between 20V and 60V by hand.
  • Assuming voltage alone proves compatibility. The tool must be designed for the battery’s platform and physical connection. Check the exact model’s manual.
  • Forcing a battery that will not fit. Resistance can indicate wrong alignment, debris, damage, or an incompatible model. Stop rather than modifying the battery or tool.
  • Confusing the label with a selectable output. A FLEXVOLT battery’s stated voltage relates to its designed configurations; it does not mean every tool receives that same voltage.
  • Using a damaged battery or cleaning contacts while installed. Remove the battery before inspection, and do not use or charge it if it is visibly damaged, unusually hot, or has been exposed to liquid.

Tips

  • Use the model number, platform marking, and manual to confirm a match; product names and battery appearance are not enough.
  • Keep the battery and tool contacts clean and dry, and store the battery as its manual specifies.
  • Allow a hot battery or tool to cool as directed before charging or continued use. Do not try to cool it with water or place it near a heat source.
  • Use only a charger listed as compatible with the battery. A battery’s ability to fit a tool does not establish that a particular charger is suitable.
  • If a battery has been dropped, crushed, punctured, or otherwise damaged, stop using it and follow the manufacturer’s guidance for service or disposal.

Troubleshooting

  • Battery will not slide into the tool: Switch the tool off and remove the battery. Confirm the platform and model compatibility, check alignment, and look for debris or visible damage. Never shave, bend, or modify rails or contacts to make a fit.
  • Battery slides in but will not latch: Remove it and inspect the latch area for obstruction or damage. Reinsert it straight along the rails. If it still will not lock securely, do not operate the tool; consult the manual or an authorized service provider.
  • Tool does not start: Check that the battery is fully seated, the tool control is in its normal operating position, and the battery has charge. If the battery has a charge indicator, use it according to its instructions. Test only with a known-compatible battery if one is available, and stop if the tool or battery becomes unusually hot or acts abnormally.
  • Tool works briefly, then stops: A low charge, excessive load, overheating, or a tool fault may be involved. Release the trigger, switch off, remove the battery, and let the equipment cool in a safe, dry place. Check the manuals for indicator meanings and operating limits; do not bypass a thermal or overload protection feature.
  • Charger does not charge the battery: Verify the charger is specified for the battery, check its indicators using the charger manual, and allow a hot or cold battery to reach the permitted charging temperature. Do not open the battery or charger. If the charger reports a fault or charging still fails, contact the manufacturer or service provider.

Frequently Asked Questions

Do I have to switch a FLEXVOLT battery from 20V to 60V?
No. There is no manual voltage switch. The battery works with the compatible tool’s connection and intended platform.

Can every FLEXVOLT battery fit every 20V MAX tool?
FLEXVOLT batteries are designed for compatible 20V MAX tools, but check the specific battery and tool manuals. Do not assume compatibility across every model or accessory.

Can I use a FLEXVOLT battery in a 60V MAX tool?
Use it only if the battery is specified as compatible with that tool. Confirm the exact model’s requirements in its manual.

Does the battery always deliver 60V?
No. Its configuration depends on a compatible tool platform. The voltage marking is not a setting that the user selects or a promise that every connected tool receives the same voltage.

Why does the battery fit but the tool not run?
It may be discharged, not fully latched, too hot or cold, incompatible, or affected by a tool fault. Switch off, remove it, and check the labels, charge, indicators, and manuals.

Can I make an older tool work by adapting the battery contacts?
No. Do not alter contacts, add improvised adapters, or bypass tool protections. Use only combinations approved for the specific tool and battery.

Related

Method: the standard formula for this calculation, rounded as each result states. See how the calculators work or report an error.